Multilayer Ceramic Capacitor Oxidized Electrodes Flexural Strength
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Solution Overview
Problem
Multilayer ceramic capacitors with thin dielectric and internal electrode layers and small-size components exhibit inferior flexural strength, leading to chipping or cracking when mounted on substrates or subjected to stress.
Innovation Solution
The outermost and/or innermost internal electrode layers are substantially oxidized, which enhances the flexural strength of the multilayer ceramic capacitor, while the unoxidized layers maintain capacitance, allowing for high flexural strength without compromising capacitance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If thin dielectric layers and thin internal electrode layers are used to achieve small-size components and high capacitance, then capacitance is enhanced and size is reduced, but flexural strength deteriorates leading to chipping or cracking
Solution Approach 1:
The patent applies local quality by differentiating the properties of internal electrode layers at different positions. The outermost internal electrode layers are oxidized to have high flexural strength, while inner internal electrode layers remain unoxidized to maintain electrical conductivity and capacitance function. This spatial differentiation of material properties resolves the contradiction between strength and capacitance.
Solution Approach 2:
The patent changes the oxidation state parameter of internal electrode layers to achieve different functional properties. By controlling the oxidation degree (from fully oxidized to unoxidized states), the patent creates a gradient of mechanical and electrical properties throughout the capacitor structure, enabling thin layers to achieve both high strength and high capacitance.
2Quantity of substance
If thin dielectric layers and thin internal electrode layers are used for capacitance enhancement, then high capacitance is achieved, but the component becomes fragile and prone to damage during mounting and stress application
Solution Approach 1:
The patent applies local quality by differentiating the properties of internal electrode layers at different positions. The outermost internal electrode layers are oxidized to have high flexural strength, while inner internal electrode layers remain unoxidized to maintain electrical conductivity and capacitance function. This spatial differentiation of material properties resolves the contradiction between strength and capacitance.
Solution Approach 2:
The patent applies beforehand cushioning by pre-oxidizing the outermost internal electrode layers to create a protective structural framework before the capacitor is subjected to mounting stresses or operational loads. This pre-established strong skeleton prevents chipping and cracking during subsequent handling and use.
3Volume of moving object
If small-size components (0603-size or 0402-size) are used for size reduction, then component dimensions are reduced, but flexural strength deteriorates making the component susceptible to damage
Solution Approach 1:
The patent applies local quality by differentiating the properties of internal electrode layers at different positions. The outermost internal electrode layers are oxidized to have high flexural strength, while inner internal electrode layers remain unoxidized to maintain electrical conductivity and capacitance function. This spatial differentiation of material properties resolves the contradiction between strength and capacitance.
Solution Approach 2:
The patent applies composite materials by combining oxidized and unoxidized internal electrode layers within the same capacitor structure. The oxidized layers provide mechanical strength while the unoxidized layers provide electrical functionality, creating a composite structure that achieves both small size and high strength.
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 approach results in a multilayer ceramic capacitor with improved flexural strength, preventing chipping or cracking during mounting and stress application, even with thin layers and small components.
Implementation Method 1
two of the internal electrode layers that are located outermost and/or at least one of the internal electrode layers that is located inside each outermost internal electrode layer are substantially oxidized
Implementation Method 2
the fired ceramic chip is further subjected to a heat-treating process referred to as a reoxidizing process
Data Source
AI summary
A multilayer ceramic capacitor and a method of manufacturing the same is provided. The capacitor comprises dielectric layers and internal electrode layers alternately stacked. Two of the internal electrode layers that are located outermost and/or at least one of the internal electrode layers that is located inside each outermost internal electrode layer are substantially oxidized and do not function as electrodes. The capacitance of the multilayer ceramic capacitor depends on the unoxidized internal electrode layers other tan the oxidized ones. The method of manufacturing a multilayer ceramic capacitor comprises forming green dielectric layers, forming green internal electrode layers, preparing a green ceramic chip, forming green external electrodes, and firing the green ceramic chip.