Multilayer Ceramic Capacitor Electrode Particle Size Optimization
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Solution Overview
Problem
Conventional multilayer ceramic capacitors face issues such as reduced structural strength and reliability due to non-uniform distribution of vitreous material powder, thermal expansion damage, and poor electrical contact between inner and outer electrodes, leading to potential peeling and invasion of plating solutions.
Innovation Solution
The use of barium titanate and nickel powders with average particle diameters between 0.2 μm to 0.4 μm for both inner and first outer electrodes, along with a co-sintering process and metal electrode pastes containing silver or copper, to enhance electrical contact and prevent thermal expansion damage, while forming second outer electrodes with resin at a controlled temperature to prevent diffusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional vitreous material powder is used in outer electrodes, then electrical contact is achieved, but non-uniform distribution causes reduced structural strength and reliability
Solution Approach 1:
The patent changes the particle size parameter of barium titanate powder to a specific range (0.05-0.1 μm) to achieve uniform distribution in the outer electrode paste, eliminating the non-uniformity problem of conventional vitreous material while maintaining electrical contact and improving structural strength
Solution Approach 2:
The patent creates a composite outer electrode paste containing barium titanate powder, nickel powder, and glass powder in specific proportions, combining the benefits of uniform distribution, electrical conductivity, and structural strength, thereby improving reliability without compromising composition stability
2Reliability
If high sintering temperature is used to form outer electrodes, then electrical contact between inner and outer electrodes is improved, but thermal expansion damage occurs
Solution Approach 1:
The patent modifies the sintering temperature parameter to a controlled range (900-1100°C) and uses barium titanate powder with specific particle size (0.05-0.1 μm) to achieve good electrical contact while minimizing thermal expansion damage to the ceramic body
Solution Approach 2:
The patent applies barium titanate powder with specific properties locally in the outer electrode formulation, creating a region with optimized thermal and electrical characteristics that reduces thermal expansion damage while maintaining electrical contact quality
3Reliability
If inner electrodes and outer electrodes are formed separately, then manufacturing flexibility is maintained, but electrical contact and binding strength are poor
Solution Approach 1:
The patent merges the formation of inner electrodes and outer electrodes into a coordinated sintering process where barium titanate powder in the outer electrode paste reacts with the inner electrode surface, creating strong binding and good electrical contact while maintaining manufacturing flexibility
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach improves the binding strength between inner and outer electrodes, reduces peeling, and enhances the structural integrity and reliability of the capacitors, ensuring stable electrical performance and increased production yield.
Implementation Method 1
inner electrodes and first outer electrodes on two opposite sides of ceramic dielectrics have barium titanate powder and nickel powder with average particle diameters in a range of 0.2 μm to 0.4 μm
Implementation Method 2
metal electrode pastes containing silver or copper, to enhance electrical contact
Implementation Method 3
along with a co-sintering process and metal electrode pastes containing silver or copper, to enhance electrical contact and prevent thermal expansion damage
Implementation Method 4
forming second outer electrodes with resin at a controlled temperature to prevent diffusion
Data Source
AI summary
A multilayer ceramic capacitor and a manufacturing method thereof are disclosed. The multilayer ceramic capacitor includes a base part including ceramic dielectrics, and inner electrodes formed in the ceramic dielectrics and arranged in interval by a staggered manner; two first outer electrodes of outer electrode layers are sintered and formed on two sides of the base part, and in electrical contact with the inner electrode terminals of the inner electrodes. Second outer electrodes are formed on outer parts of the two first outer electrodes. The inner electrodes and the first outer electrodes have barium titanate powder and nickel powder with average particle diameters in range of 0.2 μm to 0.4 μm, so that the inner electrodes are in good electrical contact with the first outer electrodes, to improve binding strength and reduce peeling of the first outer electrodes from the inner electrodes.