Multilayer Ceramic Capacitor Grain Growth Suppression
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Solution Overview
Problem
The miniaturization of multilayer ceramic capacitors is hindered by the growth of dielectric powder grains during the manufacturing process, making it difficult to achieve thinner dielectric layers and increase capacitance.
Innovation Solution
Incorporating dielectric grains with Ca, Zr, Ti, and a rare earth element, where P is present between the grains and at least a portion of the rare earth element is in a solid solution, to suppress grain growth during the heating step, allowing for thinner dielectric layers and increased capacitance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If dielectric powder is made finer to enable miniaturization, then the dielectric layer thickness can be reduced, but grain growth during heating prevents achieving sufficiently fine powder
Solution Approach 1:
The patent changes the chemical composition parameters of the dielectric powder by incorporating specific rare earth elements (La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Y) along with Ca, Zr, and Ti. This compositional parameter change suppresses grain growth during heating, enabling the production of finer dielectric powder with controlled grain size, which in turn allows for thinner dielectric layers while maintaining manufacturing precision
Solution Approach 2:
The patent creates a composite dielectric material system combining multiple elements (Ca, Zr, Ti, and rare earth elements). This composite material approach leverages the grain growth suppression effect of rare earth elements to achieve fine powder characteristics that enable miniaturization and thinner dielectric layers
2Productivity
If the dielectric layer is made thinner to increase capacitance, then more layers can be stacked for a given size, but grain growth limits how thin the layer can be made
Solution Approach 1:
By modifying the chemical composition to include rare earth elements, the patent changes the thermal behavior parameters of the dielectric material. This enables the production of ultra-fine dielectric layers with controlled thickness while suppressing grain growth, thereby increasing the number of stackable layers and improving capacitance density
3Ease of manufacture
If heating is applied to form the capacitor, then the dielectric layer is sintered and formed, but grain growth occurs making finer powder difficult to achieve
Solution Approach 1:
The patent modifies the chemical composition parameters to include rare earth elements that fundamentally change the sintering behavior of the dielectric material. This enables the sintering process to proceed while suppressing grain growth, achieving both ease of manufacture through standard heating processes and precise grain size control for finer powder production
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 formation of thin dielectric layers with multiple layers for a given size, enhancing capacitance while maintaining reliability and reducing insulation resistance deterioration at high temperatures.
Implementation Method 1
the dielectric layer includes a plurality of dielectric grains including Ca, Zr, Ti and a rare earth element, P is present between the plurality of dielectric grains, and where at least a portion of the rare earth element is in a solid solution in the dielectric grains
Implementation Method 2
at least a portion of the rare earth element is in a solid solution in the dielectric grains
Data Source
AI summary
A multilayer ceramic capacitor that includes a ceramic body including a stack of a plurality of dielectric layers and a plurality of internal electrodes; a first external electrode on a first end surface of the ceramic body and electrically connected to a first set of the plurality of internal electrodes; and a second external electrode on a second end surface of the ceramic body and electrically connected to a second set of the plurality of internal electrodes. The dielectric layer includes a plurality of dielectric grains including Ca, Zr, Ti and a rare earth element, P is present between the plurality of dielectric grains, and where at least a portion of the rare earth element is in a solid solution in the dielectric grains.