Multilayer Ceramic Component Protective Layer Design

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Solution Overview

Problem

Multilayer ceramic electronic components face issues with moisture penetration and ion migration in harsh environments, leading to mechanical stress, cracks, and reliability concerns such as short circuits due to hydrophilic oxide layers and high humidity exposure.

Innovation Solution

A multilayer ceramic electronic component design featuring a ceramic body with dielectric layers and internal electrodes, along with a protective layer comprising an adhesion assisting layer and a coating layer to enhance moisture resistance and bonding strength, preventing ion migration and improving reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a plating layer is formed on the external electrode after sintering, then the electrical conductivity is improved, but the reliability deteriorates due to moisture penetration through pores at the interface

Engineering Contradiction:

ImprovereliabilityVSAvoidmoisture penetration

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a protective layer as an intermediary substance between the external electrode and the environment. This protective layer fills pores at the interface and prevents moisture from penetrating into the component, thereby resolving the contradiction between maintaining electrical conductivity and preventing moisture-induced reliability degradation

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent uses a composite structure consisting of the plating layer and the protective layer. The plating layer provides electrical conductivity while the protective layer provides moisture barrier functionality. This composite approach allows both electrical performance and reliability to be maintained simultaneously

Inventive Principle:

Principle #40Composite materials

2Strength

If the oxide layer with high surface energy is formed on the ceramic body surface, then the bonding strength is improved, but ion migration increases due to moisture adhesion

Engineering Contradiction:

Improvebonding strengthVSAvoidion migration

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The protective layer serves as an intermediary between the hydrophilic oxide layer and the environment. It maintains the bonding strength provided by the oxide layer while blocking moisture from adhering to the high-energy surface, thereby preventing ion migration without sacrificing bonding strength

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent extracts the harmful moisture-adhesion property from the system by introducing the protective layer. The protective layer removes the moisture affinity from the oxide layer surface, allowing the oxide layer to maintain its bonding strength while the protective layer prevents moisture interaction

Inventive Principle:

Principle #2Taking out (Extraction)

3Adaptability or versatility

If the multilayer ceramic electronic component is used in harsh environments, then the adaptability is improved, but the reliability deteriorates due to thermal stress and vibration

Engineering Contradiction:

ImproveadaptabilityVSAvoidreliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The protective layer provides beforehand cushioning against environmental damage. It pre-provides a barrier against moisture and corrosion before harsh conditions can cause damage, and also cushions against thermal stress and vibration by providing a protective envelope that reduces the impact of these environmental factors on the internal structure

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 proposed design effectively suppresses ion migration, enhances bonding strength, and reduces defects like short circuits, ensuring improved reliability and performance in harsh environments.

Implementation Method 1

deterioration of characteristics due to penetration of moisture may be prevented

Methodology Applied

Scientific EffectMoisture penetration prevention: Physical Containment

Implementation Method 2

ion migration may be suppressed

Methodology Applied

Scientific EffectIon migration suppression: Diffusion Barrier

Implementation Method 3

a protective layer disposed on the ceramic body, the first external electrode, and the second external electrode, wherein the protective layer includes an adhesion assisting layer

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS11594374B2Multilayer ceramic electronic component

Publication Date: 2023.02.28 SAMSUNG ELECTRO MECHANICS CO LTD

AI summary

A multilayer ceramic electronic component includes: a ceramic body including dielectric layers and first internal electrodes and second internal electrodes disposed to face each other and alternately stacked with the respective dielectric layers interposed therebetween; a first external electrode connected to the first internal electrodes; a second external electrode connected to the second internal electrodes; and a protective layer disposed on the ceramic body, the first external electrode, and the second external electrode, wherein the protective layer includes an adhesion assisting layer and a coating layer.