MLCC Internal Electrode Composition for Thermal Contraction Matching
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Solution Overview
Problem
The challenge in developing multilayer ceramic capacitors is the degradation of internal electrode connectivity and reliability due to increased thermal contraction initiation temperature differences between dielectric layers and internal electrodes, which is exacerbated by material atomization, and the limitations of using BaTiO3 as a ceramic additive, leading to reduced capacitance and thermal stability.
Innovation Solution
Incorporating nickel (Ni) and dysprosium (Dy) into the internal electrodes in specific atomic percentages to reduce the thermal contraction initiation temperature difference and improve thermal stability without compromising dielectric constant, thereby enhancing the reliability and capacitance of multilayer electronic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If internal electrodes and dielectric layers are made thinner to reduce size and increase capacitance, then miniaturization and high capacitance are achieved, but material atomization occurs which decreases melting point and thermal contraction initiation temperature, leading to degradation of internal electrode connectivity and reliability
Solution Approach 1:
The patent changes the chemical composition parameters of the internal electrode paste by incorporating specific ceramic additives (BaTiO3 in amounts of 1-10 wt% based on internal electrode paste weight) to adjust the thermal contraction initiation temperature. This parameter modification allows thinner internal electrodes to maintain adequate thermal stability and connectivity during the firing process, resolving the contradiction between miniaturization and reliability.
Solution Approach 2:
The patent creates a composite material system by combining metal particles (Ni, Cu, or their alloys) with ceramic additives (BaTiO3) in the internal electrode paste. This composite structure leverages the high conductivity of metals and the high melting point/thermal stability of ceramics, enabling thinner internal electrodes to withstand thermal processing without degradation, thus achieving both size reduction and maintained reliability.
2Stability of the object's composition
If BaTiO3 is added to internal electrode paste as a ceramic additive to reduce thermal contraction initiation temperature difference, then thermal stability is improved, but film density of the internal electrode decreases and BaTiO3 moves to the dielectric layer during firing, increasing dielectric layer thickness and decreasing capacitance
Solution Approach 1:
The patent optimizes the amount of BaTiO3 additive within a specific range (1-10 wt% of internal electrode paste weight) to balance thermal stability improvement with capacitance maintenance. By controlling this parameter, the patent achieves adequate thermal contraction initiation temperature reduction without excessive BaTiO3 migration to the dielectric layer, thus maintaining film density and capacitance.
Solution Approach 2:
The patent applies a controlled amount of BaTiO3 additive that is sufficient to improve thermal stability but limited to prevent excessive migration and capacitance loss. This partial action approach ensures that enough BaTiO3 is present to raise the thermal contraction initiation temperature, while the amount remains controlled to minimize dielectric layer thickening and capacitance reduction.
3Volume of moving object
If internal electrodes are made thinner to achieve miniaturization, then component size is reduced, but the difference in thermal contraction initiation temperature between dielectric layer and internal electrode increases, degrading reliability
Solution Approach 1:
The patent modifies the thermal contraction initiation temperature parameter of the internal electrode material by adding BaTiO3, bringing it closer to that of the dielectric layer. This parameter adjustment reduces thermal stress during firing, preventing degradation of internal electrode connectivity and smoothness, even when internal electrodes are made thinner for miniaturization.
Solution Approach 2:
The patent utilizes the thermal expansion and contraction properties of ceramic additives (BaTiO3) to match the thermal behavior of the dielectric layer. By incorporating materials with similar thermal contraction initiation temperatures, the patent reduces differential thermal stress during processing, maintaining internal electrode integrity and connectivity in miniaturized components.
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
The use of Ni and Dy in the internal electrodes improves the mean time to failure (MTTF), breakdown voltage (BDV), and overall reliability of multilayer electronic components, allowing for thinner dielectric and internal electrode layers while maintaining high capacitance and thermal stability, facilitating miniaturization and performance.
Implementation Method 1
as materials are atomized, a melting point thereof decreases, to lower a thermal contraction initiation temperature
Data Source
AI summary
A multilayer electronic component includes a body including a dielectric layer and internal electrodes having the dielectric layer interposed therebetween in a first direction and external electrodes disposed on the body and connected to the internal electrodes, wherein the internal electrodes include nickel (Ni) and dysprosium (Dy) and 0.02 at %≤C0≤5 at % in which C0 is an atomic percentage (at %) calculated by dividing a number of atoms of Dy by a sum of a number of atoms of Ni and Dy included in the internal electrode.