Multilayer Ceramic Capacitor Electrode Sintering Control
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Solution Overview
Problem
The challenge in manufacturing high-capacitance multilayer ceramic capacitors is the increased risk of electrode disconnection and aggregation due to thin internal electrodes, which affects the reliability and capacitance of the components.
Innovation Solution
A method involving the use of a ceramic green sheet with a conductive paste containing conductive metal particles and additives, where the average number of conductive metal particles in the internal electrode pattern's thickness direction is controlled to be between 2 and 5, to suppress electrode disconnection and aggregation during sintering, ensuring high connectivity and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the thickness of internal electrode is decreased to increase capacitance, then the capacitance per unit volume increases, but the sintering driving force increases causing electrode disconnection and aggregation
Solution Approach 1:
The patent changes the chemical composition parameters of the conductive paste by controlling the ratio of metal powder to glass powder (3:7 to 7:3), and adjusting the particle size distribution (D10, D50, D90 values) to optimize sintering behavior and prevent electrode disconnection while maintaining thin electrode geometry
Solution Approach 2:
The patent uses a composite conductive paste material consisting of metal powder (Ni, Pd, Pt, or their alloys) combined with glass powder (borosilicate or aluminosilicate glass), where the glass component provides binding and sintering control to prevent electrode aggregation and disconnection during the sintering process
2Quantity of substance
If the number of stacked internal electrodes is increased to achieve high capacitance, then the capacitance increases, but the complexity of manufacturing increases
Solution Approach 1:
The patent divides the capacitor structure into multiple stacked layers with alternating internal electrodes, where each layer can be manufactured using the same conductive paste formulation and sintering process, enabling scalable production of high-capacitance components through repetitive stacking rather than complex single-layer structures
3Quantity of substance
If the area of internal electrode is increased while maintaining thin thickness, then the capacitance increases, but the electrode becomes more prone to disconnection and aggregation during sintering
Solution Approach 1:
The patent optimizes the particle size distribution parameters (D10, D50, D90) of both metal powder and glass powder, and controls the metal-to-glass powder ratio to ensure proper flow and bonding characteristics during sintering, preventing aggregation and disconnection even when electrodes have large area-to-thickness ratios
Solution Approach 2:
The glass powder acts as an intermediary material that facilitates controlled sintering between metal particles, providing a binding matrix that maintains electrode integrity during the sintering process and prevents both aggregation and disconnection of thin, large-area electrodes
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 enables the production of multilayer ceramic capacitors with high capacitance and excellent reliability by maintaining electrode connectivity and preventing disconnection and aggregation issues, even with thin internal electrodes.
Implementation Method 1
forming a ceramic body including dielectric layers and internal electrodes by sintering the ceramic laminate
Data Source
AI summary
A method of manufacturing a multilayer ceramic electronic component includes preparing a ceramic green sheet containing a ceramic powder and forming an internal electrode pattern on the ceramic green sheet using a conductive paste containing conductive metal particles and an additive. A ceramic laminate is formed by stacking the ceramic green sheets on which the internal electrode pattern is formed. A ceramic body including dielectric layers and internal electrodes is formed by sintering the ceramic laminate. An average number of conductive metal particles in the internal electrode pattern in a thickness direction is more than 2 and 5 or less.