Multilayer Ceramic Capacitor Marginless Design

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Solution Overview

Problem

Miniaturized multilayer ceramic capacitors face reliability issues due to voids at the interface between the ceramic body and side margin portions, leading to reduced breakdown voltage and waterproof reliability, as existing methods to enhance breakdown voltage through oxide layers have insufficient effects.

Innovation Solution

A method of manufacturing multilayer ceramic capacitors where the oxide region on the internal electrode's end portion is minimized to less than 10% of the overall area, with conductive metal filling to enhance breakdown voltage and reliability, and side margin portions are formed with controlled magnesium content to prevent void generation and electric field concentration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If side margin portions are attached to maximize internal electrode area, then capacity is increased, but voids are generated at the interface between ceramic body and side margin portion

Engineering Contradiction:

Improveinternal electrode areaVSAvoidinterface quality

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent removes the side margin portions entirely, transitioning from a design with margins to a marginless design where internal electrodes are directly exposed on the lateral surfaces of the ceramic body, thereby eliminating the interface where voids form

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of attaching side margin portions to the lateral surfaces, the patent inverts the approach by having the ceramic body itself provide the lateral surfaces with exposed internal electrodes, reversing the traditional structure

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If oxide layer is formed in voids to enhance breakdown voltage, then reliability is improved, but the effect is insufficient

Engineering Contradiction:

Improvebreakdown voltageVSAvoidmanufacturing effectiveness

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent converts the harmful voids into beneficial exposed internal electrode surfaces by eliminating the side margin portions, transforming the problem of void-induced electric field concentration into an opportunity for direct electrode exposure that enhances breakdown voltage without requiring oxide layer formation

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The marginless design is implemented during the green sheet stacking and cutting stages before sintering, preliminarily establishing the exposed internal electrode structure that prevents void formation from occurring in the first place

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11387042B2Multilayer ceramic capacitor and method of manufacturing the same

Publication Date: 2022.07.12 SAMSUNG ELECTRO MECHANICS CO LTD

AI summary

A multilayer ceramic capacitor includes a ceramic body including a dielectric layer and having first and second surfaces opposing each other in a width direction, third and fourth surfaces connecting the first and second surfaces in a length direction, and fifth and sixth surfaces opposing each other in a thickness direction, internal electrodes disposed inside the ceramic body, exposed through the first and second surfaces, and having one end portion exposed through the third or fourth surface, and first and second side margin portions disposed on edges of the internal electrodes, exposed through the first and second surfaces. In a cross-section cut along a width-thickness plane of the ceramic body, an area of an oxide region disposed on the edges of the internal electrodes is less than 10% of an overall area of the internal electrodes exposed through the first and second surfaces.