Multilayer Ceramic Capacitor Electrode Thickness Uniformity
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Solution Overview
Problem
The miniaturization of electronic products has led to a demand for multilayer ceramic electronic components with small size and large capacitance, resulting in non-uniform inner electrode layers that can cause disconnection and deteriorate breakdown voltage characteristics, thereby reducing the reliability of these components.
Innovation Solution
The solution involves ensuring that the thickness of the dielectric layer is 0.6 μm or less and that the ratio of the maximum to minimum inner electrode layer thickness is less than 0.30, with the average thickness of the inner electrode layers also being 0.6 μm or less, using specific ratios of ceramic and metal powder particle diameters to maintain uniformity and prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the dielectric layer and inner electrode layer are thinned to increase the number of lamination layers, then the capacitance increases and the component size decreases, but the inner electrode layers become non-uniform and may disconnect, deteriorating breakdown voltage characteristics and reliability
Solution Approach 1:
The patent applies parameter changes by precisely controlling the thickness of the dielectric layer (td) and inner electrode layer (te) within specific ranges, and by controlling the ratio (tmax-tmin)/td to be 0.30 or less. This quantitative parameter control ensures uniformity of the inner electrode layers even when thinned, preventing disconnection and maintaining breakdown voltage characteristics while achieving high capacitance.
Solution Approach 2:
The patent employs preliminary action by pre-controlling the thickness uniformity of inner electrode layers before assembly and by selecting ceramic powder particles with specific diameter ranges (0.5-2.0 μm) before lamination. This preliminary control of material properties and layer uniformity prevents connectivity issues and breakdown voltage deterioration that would occur after thinning to increase capacitance.
2Quantity of substance
If the inner electrode layers are thinned to increase capacitance, then the component achieves larger capacitance in smaller size, but the thickness uniformity deteriorates causing partial disconnection
Solution Approach 1:
The patent controls the thickness of the inner electrode layer (te) to be 0.5-2.0 μm and maintains the ratio (tmax-tmin)/td at 0.30 or less, where td is the dielectric layer thickness. This precise parameter control ensures that even when layers are thinned to increase capacitance, the thickness uniformity is maintained within acceptable limits, preventing partial disconnection.
Solution Approach 2:
The patent applies local quality by ensuring that the inner electrode layers maintain consistent thickness characteristics across different locations. By controlling the thickness ratio (tmax-tmin)/td and using ceramic powder with specific diameter ranges, the patent ensures uniform local thickness throughout the component, preventing disconnection even when overall layer thickness is reduced for higher capacitance.
3Volume of moving object
If non-uniform inner electrode layers are used to increase capacitance density, then the component size decreases, but thick portions of adjacent inner electrode layers come close together, deteriorating breakdown voltage characteristics
Solution Approach 1:
The patent controls the thickness of the dielectric layer (td) and inner electrode layer (te) within specific ranges, and crucially controls the ratio (tmax-tmin)/td to be 0.30 or less. This parameter control ensures that even when component size is reduced and layers are thinned to increase capacitance density, the thickness uniformity prevents thick portions of adjacent inner electrode layers from coming too close, thereby maintaining breakdown voltage characteristics.
4Quantity of substance
If the dielectric layer thickness is reduced to increase the number of lamination layers, then the capacitance increases, but the insulating properties deteriorate, reducing reliability
Solution Approach 1:
The patent controls the dielectric layer thickness (td) within specific ranges and maintains the ratio (tmax-tmin)/td at 0.30 or less. This parameter control ensures that even when the dielectric layer is thinned to increase the number of lamination layers and capacitance, the uniformity of thickness prevents insulation deterioration, maintaining reliability.
Data Source
AI summary
There is provided a multilayer ceramic electronic component including: a ceramic body including a dielectric layer; and first and second inner electrode layers formed within the ceramic body, wherein, when a thickness of the dielectric layer is defined as td and a maximum thickness and a minimum thickness of the first or second inner electrode layer are defined as tmax and tmin, respectively, td≦0.6 μm and (tmax−tmin)/td<0.30 are satisfied. According to the present invention, a large-capacity multilayer ceramic electronic component capable of improving withstand voltage characteristics and having excellent reliability can be realized by improving uniformity in the thickness of the inner electrode layers.