Multilayer Ceramic Capacitor Dielectric Layer Particle Size Gradient
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Solution Overview
Problem
Multilayer ceramic electronic devices face insufficient binding strength between dielectric and internal electrode layers, leading to reduced mechanical strength and accelerated life time due to inadequate lamination methods.
Innovation Solution
The solution involves alternately laminating internal electrode layers with dielectric layers, where the first dielectric particles have a larger particle size and thickness than the second dielectric particles, and a method of forming a green chip by coating pastes for internal and dielectric layers on a support body, ensuring a higher density of first ceramic particles near the internal electrode pattern layer not contacting the green sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a green sheet is applied to a base material and sheet units are formed by sequential lamination, then the dielectric layer and internal electrode layer within one sheet unit have sufficient binding strength, but the binding strength between the internal electrode layer and dielectric layer of another sheet unit formed on said sheet unit becomes insufficient
Solution Approach 1:
The patent applies local quality by using dielectric layers with different average particle diameters at different locations. Specifically, a first dielectric layer with a larger average particle diameter (α1) is used at the interface with the internal electrode layer, while a second dielectric layer with a smaller average particle diameter (α2) is used in other regions. This local variation in particle size optimizes the binding strength between the dielectric layer and internal electrode layer at the critical interface, thereby improving overall mechanical strength and reliability of the element body.
2Strength
If the thickness of the first ceramic layer with smaller particle diameter is reduced to improve binding strength, then binding strength is enhanced, but highly accelerated life time is reduced
Solution Approach 1:
The patent resolves this contradiction by applying local quality through spatial differentiation of dielectric layers. A first dielectric layer with larger average particle diameter (α1) is positioned at the critical interface with the internal electrode layer to maximize binding strength. A second dielectric layer with smaller average particle diameter (α2) is positioned in other regions, including areas where mechanical strength and durability are critical. This localized optimization allows the interface binding strength to be enhanced while maintaining sufficient thickness in other regions to preserve highly accelerated life time.
Solution Approach 2:
The patent applies composite materials by creating a composite dielectric structure consisting of two distinct dielectric layers with different average particle diameters. The first dielectric layer (α1) and second dielectric layer (α2) form a composite structure where each layer contributes its unique properties: the first layer optimizes interface binding strength while the second layer maintains overall mechanical strength and durability. This composite approach enables simultaneous optimization of both binding strength and highly accelerated life time.
Data Source
AI summary
An electronic device includes a plurality of internal electrode layers and dielectric layers alternately laminated. The particle size of the first dielectric particles contacting one laminating direction end face of the internal electrode layer is larger than the particle size of second dielectric particles contacting another laminating direction end face of the internal electrode layer. A thickness of a first ceramic layer formed by the first dielectric particles is smaller than a thickness of a second ceramic layer formed by the second dielectric particles.