Multi-layer Ceramic Capacitor Side Margin Porosity Control

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Solution Overview

Problem

Multi-layer ceramic capacitors face challenges in maintaining moisture resistance when the thickness of their side margins is reduced, leading to potential infiltration of moisture and reduced insulation properties.

Innovation Solution

The capacitors incorporate a side margin with a porosity of 1% or less, ensuring high compactness and effective moisture resistance, even with thinner margins, by using a method that includes sintering and optimizing the dimensions of the side margin and oxidized areas to prevent short circuits and insulation failures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the thickness of the side margin is reduced to increase the intersectional area of internal electrodes, then the capacitance increases, but the moisture resistance deteriorates

Engineering Contradiction:

ImprovecapacitanceVSAvoidmoisture resistance

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent changes the porosity parameter of the side margin material to 1% or less, transforming it from a conventional porous structure to a highly dense structure. This parameter change allows the side margin to maintain effective moisture barrier properties even at reduced thickness, thereby resolving the contradiction between increasing capacitance (by reducing side margin thickness) and maintaining moisture resistance.

Inventive Principle:

Principle #35Parameter changes

2Area of stationary object

If the thickness of the side margin is reduced, then the intersectional area of internal electrodes increases, but moisture infiltration increases

Engineering Contradiction:

Improveintersectional area of internal electrodesVSAvoidmoisture infiltration

Core Design Contradiction:

Area of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The patent applies parameter change by controlling the porosity of the side margin to be 1% or less, fundamentally altering the material's barrier properties. This enables the side margin to effectively prevent moisture infiltration even when its thickness is reduced to maximize the intersectional area of internal electrodes.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite material design by combining the side margin made of insulating ceramics with specific porosity characteristics (1% or less) with the multi-layer ceramic structure. This composite approach ensures that the side margin provides both electrical insulation and effective moisture barrier functions at reduced thickness.

Inventive Principle:

Principle #40Composite materials

3Productivity

If the side margin thickness is reduced, then the productivity increases, but the moisture resistance decreases

Engineering Contradiction:

Improveproduction efficiencyVSAvoidmoisture resistance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent changes the porosity parameter of the side margin to 1% or less, which enables the use of thinner side margins without compromising moisture resistance. This parameter change directly supports productivity improvement by allowing reduced material usage and faster production cycles while maintaining reliable moisture protection.

Inventive Principle:

Principle #35Parameter changes

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

This configuration ensures reliable moisture resistance and prevents short circuits, allowing for the reduction of side margin thickness while maintaining the capacitors' performance and integrity.

Implementation Method 1

The side margin covers the multi-layer unit from a second direction orthogonal to the first direction and has a porosity of 1% or less. With this configuration, because of high compactness of the side margin, moisture or the like is difficult to infiltrate into the multi-layer chip from the outside via the side margin

Methodology Applied

Scientific EffectPorosity control: Porosity

Implementation Method 2

Each of the internal electrodes may include an oxidized area, the oxidized area being adjacent to the side margin and having a dimension in the second direction that is 0.4 μm or more. Setting the dimension of the oxidized area in the second direction to 0.4 μm or more can suppress a short circuit failure or an insulation resistance (IR) failure between the internal electrodes

Methodology Applied

Scientific EffectOxidation: Oxidation

Data Source

PatentUS10622152B2Multi-layer ceramic capacitor and method of producing the same

Publication Date: 2020.04.14 TAIYO YUDEN KK

AI summary

A multi-layer ceramic capacitor includes a multi-layer unit and a side margin. The multi-layer unit includes ceramic layers laminated in a first direction and internal electrodes disposed between the ceramic layers. The side margin covers the multi-layer unit from a second direction orthogonal to the first direction and has a porosity of 1% or less.