Multilayer Ceramic Capacitor Step Portion Absorbing Layers
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Solution Overview
Problem
The miniaturization of multilayer ceramic electronic components has led to reduced product reliability due to intensified step portions between internal electrode forming and non-forming parts, resulting in deteriorated withstand voltage characteristics, which existing methods fail to effectively address through precise alignment and ceramic material addition.
Innovation Solution
The introduction of step portion absorbing layers in the width-direction margin parts and the use of dummy electrodes in the length-direction margin parts, along with gap parts formed of insulating material, to alleviate the step portion issue and enhance capacitance and withstand voltage characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of ceramic green sheets is increased to achieve high capacitance, then capacitance is improved, but step portion intensity increases and deteriorates withstand voltage characteristics
Solution Approach 1:
The patent applies local quality by forming a margin part in the ceramic green sheet with different properties from the internal electrode forming part. The margin part has reduced ceramic material density or different composition to minimize step portion formation during stacking and compressing, while the internal electrode forming part maintains normal density for capacitance function. This localized differentiation resolves the contradiction by allowing high capacitance through multiple sheets without the step portion reliability penalty.
Solution Approach 2:
The patent implements preliminary action by pre-forming the margin part structure in the ceramic green sheet before the stacking and compressing processes. The margin part is prepared in advance with appropriate material distribution to prevent step portion intensification during subsequent manufacturing steps. This preliminary structural preparation ensures that when multiple sheets are stacked for high capacitance, the withstand voltage characteristics are preserved from the outset.
2Reliability
If a separate ceramic material is added to the margin part by negative printing process, then step portion problems are reduced, but manufacturing complexity and precision requirements increase
Solution Approach 1:
The patent merges the margin part formation with the existing ceramic green sheet manufacturing process. Instead of adding a separate negative printing process for ceramic material, the margin part is formed during the standard slurry coating and drying process by controlling material deposition. This integration eliminates the need for additional manufacturing steps while achieving the same step portion reduction effect, thereby reducing manufacturing complexity.
Solution Approach 2:
The patent uses the same ceramic slurry material for forming both the internal electrode forming part and the margin part, eliminating the need for separate ceramic materials. The margin part is created by controlling the distribution and density of the standard ceramic slurry during the coating process, rather than requiring a different material composition. This approach simplifies material handling and manufacturing while effectively reducing step portion issues.
Data Source
AI summary
A multilayer ceramic electronic component includes a ceramic body and first and second external electrodes. The ceramic body includes an active region including a plurality of dielectric layers and first and second internal electrodes alternately disposed on surfaces of the plurality of dielectric layers to contribute to capacitance formation, and a protective layer provided on at least one of upper and lower surfaces of the active region. The first and second external electrodes are electrically connected to the first and second internal electrodes, respectively, and formed on both end surfaces of the ceramic body. The ceramic body includes a plurality of first and second dummy electrodes respectively extended from the second and first external electrodes into length-direction margin parts of the active region so as to face the first and second internal electrodes, respectively. Further, step portion absorbing layers are disposed in width-direction margin parts of the active region.