MLCC Dielectric Grain Control via Ionic Core-Shell Pre-Diffusion
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Solution Overview
Problem
Existing methods for forming dielectric crystal grains with uniform size in multilayer ceramic capacitors face challenges in achieving uniform dispersion and reliability due to limitations in dispersibility and coating uniformity, leading to high size dispersion and reduced electrical characteristics.
Innovation Solution
The method involves coating dielectric particles with additive elements in an ionic state, using a liquid-phase pre-diffusion process to achieve a core-shell structure with uniform size distribution and controlled grain growth, enhancing the reliability and electrical characteristics of multilayer electronic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If organic dispersant in organic solvent is used to disperse dielectric powder and additive particles, then dispersion is improved, but manufacturing complexity and environmental concerns increase
Solution Approach 1:
The patent changes the physical-chemical parameters of the additive by converting it from molecular form to ionic form. This parameter change enables the additive to disperse uniformly in water-based slurry without requiring organic dispersants, thereby simplifying the manufacturing process while achieving stable uniform dispersion of dielectric powder and additive particles
Solution Approach 2:
The patent substitutes the chemical dispersion mechanism (using organic dispersants) with a physical-chemical mechanism (ionic dissolution and diffusion). The ionic additive dissolves and diffuses into the dielectric particles through liquid-phase pre-diffusion, replacing the need for complex organic dispersant systems and reducing manufacturing complexity
2Manufacturing precision
If coating dielectric powder with additive is performed to achieve uniform size, then crystal grain uniformity is improved, but coating uniformity and dispersion quality deteriorate due to high size dispersion
Solution Approach 1:
The patent performs preliminary dissolution of the ionic additive into the dielectric particles before the main sintering process. This preliminary action ensures that the additive is already uniformly distributed within the particles, eliminating the need for subsequent coating operations and achieving both uniform size and high coating uniformity
Solution Approach 2:
The patent uses liquid-phase pre-diffusion as an intermediary process between particle mixing and sintering. During this intermediary stage, the ionic additive diffuses into the dielectric particles through the liquid phase, ensuring uniform distribution and preventing aggregation, thereby achieving both uniform crystal grain size and high dispersion quality
3Volume of moving object
If miniaturization of multilayer ceramic capacitors is pursued to meet smaller device requirements, then device size is reduced, but reliability deteriorates due to difficulties in maintaining uniform crystal grain size at smaller scales
Solution Approach 1:
The patent changes the state of the additive to ionic form, which enables precise control of crystal grain growth parameters during sintering. This parameter change allows uniform crystal grain size to be maintained even in miniaturized capacitors, thereby achieving both small device size and high reliability
Solution Approach 2:
The patent achieves local quality control by ensuring uniform distribution of ionic additive at the particle level. This local uniformity in additive distribution controls crystal grain growth locally, preventing size variation even when the overall device size is reduced, thus maintaining reliability in miniaturized capacitors
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 results in dielectric crystal grains with a uniform size distribution, improved reliability, and enhanced electrical characteristics, as demonstrated by the reduced size deviation and increased mean time to failure in experimental examples.
Implementation Method 1
coating dielectric particles with additive elements in an ionic state, using a liquid-phase pre-diffusion process
Implementation Method 2
liquid-phase pre-diffusion process to achieve a core-shell structure with uniform size distribution
Implementation Method 3
firing the additives, forming dielectric crystal grains with a uniform size distribution
Data Source
AI summary
A multilayer electronic component includes: a body including a dielectric layer and an internal electrode; and an external electrode disposed outside the body and connected to the internal electrode, in which the dielectric layer includes a plurality of dielectric crystal grains, and at least one of the plurality of dielectric crystal grains includes a core-shell structure including an inner core area and a shell area covering at least a portion of the core area, and 90% or more of the plurality of dielectric crystal grains satisfy an average size of 170.0 nm to 190.0 nm, and a maximum deviation of sizes of the dielectric crystal grains satisfies ±60.0 nm compared to an average size of the dielectric crystal grains.