MLCC Internal Electrode Porosity Layout for Crack Suppression
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Solution Overview
Problem
Multilayer ceramic capacitors are prone to cracking during mounting and use due to the brittleness of ceramics, and cracks can also be generated or propagated during the sintering process.
Innovation Solution
A multilayer electronic component design that includes a body with dielectric layers and internal electrodes, where the internal electrodes have disconnection portions with controlled porosity, specifically with a porosity ratio at the end of the internal electrode being 40% or less compared to the central portion, to suppress crack generation and propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the internal electrode is made continuous without disconnection portions, then the electrical conductivity is improved, but cracks are more likely to generate and propagate during mounting and sintering
Solution Approach 1:
The internal electrode is divided into multiple electrode portions separated by disconnection portions. This segmentation allows the electrode structure to accommodate thermal expansion and contraction during sintering and mounting processes, preventing crack generation and propagation while maintaining electrical conductivity through the remaining continuous paths.
Solution Approach 2:
The disconnection portions are strategically positioned at specific locations within the internal electrode structure. These localized discontinuities create stress relief zones that prevent crack propagation, while the rest of the electrode maintains its continuous conductive path. The porosity within disconnection portions is controlled to optimize both crack resistance and electrical performance.
2Reliability
If disconnection portions with high porosity are introduced to suppress cracks, then crack resistance is improved, but the electrical conductivity may be degraded
Solution Approach 1:
The porosity within disconnection portions is precisely controlled within specific ranges (5-50% or 10-40%). This parameter optimization ensures that the disconnection portions provide sufficient stress relief to prevent cracks while maintaining adequate electrical conductivity. The controlled porosity creates a balance between mechanical reliability and electrical performance.
3Reliability
If the porosity ratio Dm/Dc is increased to reduce stress concentration, then crack propagation is suppressed, but the electrical performance at electrode ends deteriorates
Solution Approach 1:
The disconnection portions exhibit asymmetric porosity distribution along the electrode length, with different porosity levels at different positions. The porosity ratio Dm/Dc is controlled to be within 0.1-0.8, creating asymmetric stress distribution that prevents crack propagation while maintaining electrical performance. This asymmetric design allows different regions of the electrode to have optimized properties for their specific functional requirements.
Data Source
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AI summary
A multilayer electronic component may include: a body including a dielectric layer and internal electrodes alternately disposed in a first direction; and an external electrode disposed on the body and connected to the internal electrode, wherein the internal electrode may include a plurality of electrode portions and disconnection portions, and the disconnection portion may include at least one of a dielectric and a pore.