Multilayer Ceramic Capacitor Insulating Layer Composite

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Solution Overview

Problem

Multilayer ceramic capacitors face challenges with low withstand voltage due to exposed internal electrodes and the risk of cracks in glass-based insulating layers, which can lead to moisture resistance issues and infiltration during the plating process.

Innovation Solution

A multilayer electronic component with insulating layers containing a glass composition and a ceramic composition, where the ceramic composition includes oxides such as Al, Zr, Ti, Ce, Fe, Mn, Cu, Co, and Zn, and the glass composition includes SiO2, alkali metals, BaO, and Al2O3, providing enhanced moisture resistance and preventing crack extension.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If glass is used as the insulating layer material, then the insulating performance is improved, but cracks may emerge due to external shock and extend to the ceramic green body, reducing moisture resistance

Engineering Contradiction:

Improveinsulating performanceVSAvoidcrack susceptibility

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The insulating layer is formed as a composite material containing both glass composition (35-75 wt% SiO2, 10-35 wt% alkali metals, 10-50 wt% BaO) and ceramic composition (10-70 wt% when whole insulating layer is 100 wt%). The glass phase provides insulating performance while the ceramic phase (oxides of Al, Zr, Ti, Ce, Fe, Mn, Cu, Co, Zn) enhances mechanical strength and crack resistance, preventing crack propagation to the ceramic green body during external shocks.

Inventive Principle:

Principle #40Composite materials

2Productivity

If internal electrodes are exposed from side surface to improve electrode utilization efficiency, then the electrostatic capacitance increases, but the withstand voltage decreases

Engineering Contradiction:

Improveelectrode utilization efficiencyVSAvoidwithstand voltage

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The insulating layer uses a composite of glass and ceramic compositions that provides both high insulating performance and mechanical strength. This allows the internal electrodes to be exposed from the side surface for improved electrode utilization and capacitance, while the robust composite insulating layer maintains adequate withstand voltage by preventing crack formation and providing electrical isolation.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If cracks reach the ceramic sintered body, then plating liquid infiltration occurs and moisture resistance decreases

Engineering Contradiction:

Improveplating processVSAvoidmoisture resistance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The insulating layer is designed with a composite structure where the ceramic composition phase acts as a reinforcement that prevents crack propagation before cracks can reach the ceramic green body. The specific composition ratios (glass 25-65 wt%, ceramic 35-75 wt%) create a material that absorbs and distributes stress, cushioning against external shocks and preventing crack initiation and propagation that would lead to plating liquid infiltration and moisture resistance degradation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS10446321B2Multilayer electronic component

Publication Date: 2019.10.15 TDK CORP

AI summary

The present invention relates to a multilayer electronic component which includes an element body where a plurality of internal electrode layers and dielectric layers are alternately laminated. Insulating layers are disposed on a pair of side surfaces of the element body, facing each other. The insulating layers contain a glass composition and a ceramic composition.