Multilayer Ceramic Capacitor Local Porosity Margin Design
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Solution Overview
Problem
Existing multilayer ceramic capacitors face limitations in miniaturization and capacitance enhancement due to thick margin parts and porosity issues, which affect mechanical strength and reliability.
Innovation Solution
A multilayer ceramic capacitor design with side margin parts of 18 μm or less thickness, formed using ceramic slurry, and controlled porosity to increase the overlapped area of internal electrodes, improving capacitance and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the margin part region is reduced to increase internal electrode overlapped area, then capacitance is improved, but mechanical strength deteriorates due to thicker edge margin parts
Solution Approach 1:
The patent applies local quality by creating different porosity levels in different regions of the margin part. The first region (adjacent to internal electrodes) has porosity P1 in range of 5-30%, while the second region (adjacent to side surfaces) has porosity P2 in range of 1-20%. This spatial variation in porosity allows the margin part to simultaneously provide mechanical support and accommodate electrode geometry, resolving the contradiction between reducing margin thickness for capacitance and maintaining mechanical strength.
2Quantity of substance
If the margin part thickness is decreased to increase internal electrode overlapped area, then capacitance is improved, but carbon removal difficulty increases
Solution Approach 1:
The patent implements local quality by controlling porosity distribution within the margin part. The first region has higher porosity (P1: 5-30%) to facilitate carbon removal during sintering, while the second region has lower porosity (P2: 1-20%) to maintain structural integrity. This differentiated porosity control enables effective carbon removal without requiring excessive margin thickness, thus maintaining high capacitance.
3Ease of manufacture
If porosity is increased to improve carbon removal, then manufacturing ease is improved, but mechanical strength deteriorates
Solution Approach 1:
The patent resolves this contradiction by applying local quality through spatially differentiated porosity control. The first region (P1: 5-30%) has higher porosity to facilitate carbon removal during manufacturing, while the second region (P2: 1-20%) has lower porosity to maintain mechanical strength. This localized porosity optimization allows both easy carbon removal and adequate mechanical strength without compromising overall component performance.
4Quantity of substance
If the margin part thickness is reduced to increase internal electrode overlapped area, then capacitance is improved, but reliability deteriorates due to porosity-related vulnerabilities
Solution Approach 1:
The patent applies local quality by creating distinct porosity zones within the margin part. The first region adjacent to internal electrodes has porosity P1 (5-30%) to facilitate manufacturing, while the second region adjacent to side surfaces has lower porosity P2 (1-20%) to enhance mechanical strength and reliability. This differentiated structure maintains high capacitance through reduced overall margin thickness while preventing reliability issues through localized porosity control in critical regions.
Data Source
AI summary
There is provided a multilayer ceramic capacitor including a ceramic body having first and second side surfaces and third and fourth end surfaces, a plurality of internal electrodes and having one ends exposed to the third or fourth end surface, and first and second side margin parts formed so that an average thickness from the first and second side surfaces to edges of the internal electrodes is 18 μm or less, wherein when the first or second side margin part is divided into two regions by a virtual line obtained by connecting mid points of distances between the edges of the internal electrodes and points at which lines extended from the internal electrodes contact the first or second side surface, when a region adjacent to the internal electrodes is defined as S1 and a porosity of S1 is defined as P1, P1 is in a range of 1 to 20 (1≦P1≦20).