Multilayer Ceramic Capacitor Nickel Diffusion Control
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Solution Overview
Problem
In multilayer ceramic capacitors, the uneven distribution of base metal concentration in dielectric layers leads to decreased permittivity and capacitance variability, causing capacitance anomalies that fall below acceptable limits.
Innovation Solution
A multilayer ceramic capacitor design with a uniform base metal concentration across five regions between internal electrodes, ensuring the concentration is within ±20% of the average, inhibiting the decrease in permittivity and stabilizing capacitance by diffusing nickel into the dielectric layer through controlled calcination processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If base metal is diffused into 3 to 30% of the distance between internal electrodes to improve temperature characteristic of capacitance, then temperature characteristic is improved, but base metal concentration becomes uneven in the stacking direction causing decreased permittivity
Solution Approach 1:
The patent applies local quality by introducing a specific additive layer containing base metal between the internal electrode and dielectric layer. This additive layer creates a localized region of base metal concentration that diffuses controllably into the dielectric layer, ensuring uniform distribution in the stacking direction while maintaining improved temperature characteristics. The additive layer acts as a controlled source that compensates for non-uniform diffusion from the internal electrode alone.
2Quantity of substance
If dielectric layers are thinned and number of stacked dielectric layers is increased to achieve small-sized large-capacity, then capacitance capacity increases, but base metal diffusion control becomes more difficult causing concentration non-uniformity
Solution Approach 1:
The patent introduces an additive layer as an intermediary between the internal electrode and dielectric layer. This intermediary layer contains base metal that diffuses into the dielectric layer in a controlled manner, mediating the concentration distribution. By using this intermediate layer, the patent achieves uniform base metal concentration even in thin dielectric layers with increased stacking numbers, thereby maintaining capacitance capacity while improving concentration uniformity.
3Quantity of substance
If base metal concentration is increased to improve capacitance, then capacitance increases, but permittivity decreases due to high concentration regions
Solution Approach 1:
The patent applies parameter changes by controlling the base metal concentration distribution through the additive layer. Instead of simply increasing overall base metal concentration, the patent modifies the spatial distribution parameters by introducing the additive layer with specific thickness and composition. This allows achieving desired capacitance while maintaining permittivity through controlled concentration gradients and uniform distribution in the stacking direction.
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
The uniform nickel concentration stabilizes capacitance, reducing variability and capacitance anomalies, ensuring the capacitance remains within the normal distribution range, thereby enhancing the reliability and performance of multilayer ceramic capacitors.
Implementation Method 1
a concentration of the base metal in each of five regions is within ±20% of an average of the concentrations of the base metal in the five regions, the five regions being obtained by dividing a region of the dielectric layer equally into five in a stacking direction
Implementation Method 2
stabilizing capacitance by diffusing nickel into the dielectric layer through controlled calcination processes
Data Source
AI summary
A multilayer ceramic capacitor includes: a pair of external electrodes; a first internal electrode containing a base metal and coupled to one of the external electrodes; a dielectric layer stacked on the first internal electrode and containing a ceramic material and the base metal; and a second internal electrode stacked on the dielectric layer, containing the base metal, and coupled to another one of the external electrodes, wherein a concentration of the base metal in each of five regions is within ±20% of an average of the concentrations of the base metal in the five regions, the five regions being obtained by dividing a region from a location 50 nm away from the first internal electrode of the dielectric layer to a location 50 nm away from the second internal electrode of the dielectric layer in a stacking direction between the first and second internal electrodes equally into five.