Multilayer Ceramic Capacitor with Segregated Manganese Phase
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Multilayer ceramic capacitors face challenges in achieving high Q value, short charging time, and high moisture resistance, as existing designs often compromise on these parameters.
Innovation Solution
A multilayer ceramic capacitor design featuring a dielectric ceramic layer with a perovskite-type compound containing Zr and Mn, along with a secondary phase of segregated Mn, and specific molar ratios, and a layered structure with distinct regions optimizing the distribution of the secondary phase, which enhances Q value, reduces charging time, and maintains high moisture resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a segregation layer containing Mg and Si is formed in the dielectric layer, then moisture resistance is improved, but Q value deteriorates
Solution Approach 1:
The patent applies local quality by creating distinct regions within the dielectric layer with different compositions. The first region contains the segregation layer with Mg and Si for moisture resistance, while the second region has main phase grains with optimized perovskite composition for high Q value. This spatial differentiation allows each region to perform its specific function without compromising the other.
Solution Approach 2:
The patent uses composite materials by combining multiple phases within the dielectric layer. The dielectric layer comprises main phase grains containing perovskite-type compound with specific ratios of Ba, Sr, Ca, Ti, and Zr, along with a segregation layer containing Mg and Si. This composite structure achieves both high Q value through the perovskite phase and moisture resistance through the segregation layer.
2Reliability
If the dielectric layer contains barium titanate and Mg oxide with Si oxide, then moisture resistance is improved, but charging time increases
Solution Approach 1:
The patent applies parameter changes by optimizing the chemical composition parameters of the perovskite-type compound. By controlling the molar ratios of Ba, Sr, Ca, Ti, and Zr within specific ranges, and by controlling the content of Mg and Si, the patent achieves fast charging capability while maintaining moisture resistance. The specific composition parameters enable both rapid charge acceptance and protection against moisture ingress.
3Loss of energy
If the perovskite-type compound contains high Zr and Mn content, then Q value is improved, but manufacturing precision becomes difficult to control
Solution Approach 1:
The patent applies parameter changes by defining specific ranges for compositional parameters that balance Q value and manufacturability. The perovskite-type compound contains Zr in the range of 2-10 atomic% and Mn in the range of 2-10 atomic%, with additional constraints on the ratios of other elements. These parameter ranges ensure high Q value while maintaining control over the sintering process and final product consistency.
Data Source
AI summary
A dielectric ceramic layer includes main phase grains and a secondary phase. The main phase grains include a perovskite-type compound. The perovskite-type compound includes Zr, Mn and at least one element selected from the group consisting of Ti, Ca, Sr, and Ba. In the perovskite-type compound, a molar ratio z between Ti/(Zr+Ti) satisfies 0≦z≦0.2, a molar ratio between Zr/(Zr+Ti) is equal to 1−z, a molar ratio x between Sr/(Ca+Sr+Ba) satisfies 0≦x≦1.0, a molar ratio y between Ba/(Ca+Sr+Ba) satisfies 0≦y≦0.3, a molar ratio between Ca/(Ca+Sr+Ba) is equal to 1−x−y, and a molar ratio m between (Ca+Sr+Ba)/(Zr+Ti) satisfies 0.95≦m<1.03. The secondary phase contains segregated Mn. In a body including the dielectric ceramic layer and an internal electrode alternately stacked, the secondary phase is located inside of a second region and not located inside of a third region.