Multilayer Ceramic Capacitor Shock-Absorbing Regions
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Solution Overview
Problem
Multilayer ceramic capacitors are prone to cracks due to mechanical and thermal shocks, which can lead to electrical failures by propagating through the active zone, causing defects and altering electrical properties.
Innovation Solution
Incorporating shock-absorbing regions at the top and bottom surfaces of the ceramic capacitor, made with higher porosity and brittleness, to absorb mechanical stress and prevent crack propagation into the active zone, utilizing a higher concentration of organic binder agent and glass powder in the ceramic green parts or tapes before sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shock-absorbing regions with higher porosity and brittleness are incorporated at the top and bottom surfaces, then crack propagation is reduced and reliability is improved, but device complexity and manufacturing formulation complexity increase
Solution Approach 1:
The capacitor body is segmented into functionally distinct regions: an active zone with standard ceramic properties and shock-absorbing regions with modified properties (higher porosity and brittleness). This segmentation allows cracks to be contained within the shock-absorbing regions while preserving the integrity of the active zone, thereby improving reliability without requiring a complete redesign of the entire device structure.
Solution Approach 2:
Different regions of the capacitor body are assigned different material qualities tailored to their specific functions. The shock-absorbing regions incorporate higher concentrations of organic binder agent and glass powder to create a more brittle, porous structure that preferentially absorbs mechanical shocks and stops crack propagation, while the active zone maintains its standard ceramic composition for optimal electrical performance.
2Reliability
If shock-absorbing regions are incorporated to prevent crack propagation, then reliability is improved, but manufacturing process complexity increases
Solution Approach 1:
The shock-absorbing regions are prepared in advance by modifying the ceramic green part formulation before sintering. By incorporating higher concentrations of organic binder agent and glass powder into the green tape or green part at the formulation stage, the desired porous and brittle structure is pre-established, which then naturally forms the shock-absorbing regions after sintering without requiring additional post-processing steps.
Solution Approach 2:
The manufacturing approach leverages parameter changes in the ceramic formulation - specifically increasing the concentration of organic binder agent and glass powder in the shock-absorbing regions. These parameter changes alter the sintering behavior and final microstructure of the ceramic, creating the desired porous and brittle characteristics that provide shock absorption and crack propagation resistance.
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 solution effectively reduces crack propagation, enhancing the reliability and shock tolerance of ceramic capacitors without significant changes to manufacturing processes, reducing failures and rework costs, and ensuring correct orientation during automated assembly.
Implementation Method 1
the shock-absorbing region is configured to absorb mechanical stress and prevent crack propagation into the active zone
Implementation Method 2
cracks occur in the underneath brittle ceramic capacitor layers
Data Source
AI summary
An electrical ceramic capacitor, in particular a multilayer ceramic capacitor, comprising a ceramic body including a stack of parallel metallic layers of opposing polarity separated by a dielectric material arranged in an active zone of the ceramic body enclosed between outer surfaces, wherein at one or more surfaces a shock-absorbing region is arranged.