MLCC Internal Electrodes with Variable Oxidized Areas
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Solution Overview
Problem
Multi-layer ceramic capacitors face challenges in balancing capacitance and preventing short circuit failures due to non-uniform shrinkage and deformation of internal electrodes during sintering, which can lead to electrical conduction and capacitance loss.
Innovation Solution
A multi-layer ceramic capacitor design with oxidized areas of varying dimensions adjacent to side margins, where larger oxidized areas are formed near easily deformed regions to prevent short circuits and smaller areas near stable regions to maintain capacitance, using nickel and metal elements like magnesium or manganese to control oxide formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large oxidized areas are formed at the ends of internal electrodes to prevent short circuit failures, then reliability is improved, but the area contributing to capacitance formation is reduced
Solution Approach 1:
The patent applies local quality by forming oxidized areas with different dimensions at different locations. Specifically, first oxidized areas are formed at ends of internal electrodes in a first region, while second oxidized areas are formed at ends in a second region, with the second oxidized areas having smaller dimensions than the first oxidized areas. This localized differentiation allows prevention of short circuits where most needed while preserving capacitance area where less critical.
Solution Approach 2:
The patent segments the internal electrodes into different regions along the stacking direction, dividing them into a first region and a second region. This segmentation allows different oxidized area dimensions to be applied to different segments, optimizing both short circuit prevention and capacitance preservation in respective regions.
2Productivity
If internal electrodes are enlarged to increase capacitance, then productivity is improved, but manufacturing precision deteriorates due to non-uniform shrinkage and deformation
Solution Approach 1:
The patent applies preliminary action by forming oxidized areas at the ends of internal electrodes before final sintering and deformation occurs. These pre-formed oxidized areas serve as protective barriers that prevent short circuits even after non-uniform shrinkage and deformation during the sintering process, anticipating and preventing potential failure modes in advance.
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 effectively suppresses short circuit failures while ensuring capacitance by controlling oxide formation and electrical conduction, achieving a balance between preventing shorts and maintaining capacitance.
Implementation Method 1
The internal electrodes each include an oxidized area, the oxidized area being adjacent to the side margin and intensively including a metal element that forms an oxide together with nickel
Data Source
AI summary
A multi-layer ceramic capacitor includes a multi-layer unit and a side margin. The multi-layer unit includes a capacitance forming unit and a cover. The capacitance forming unit includes ceramic layers laminated in a first direction and internal electrodes disposed between the ceramic layers and mainly containing nickel. The cover covers the capacitance forming unit from the first direction. The side margin covers the multi-layer unit from a second direction orthogonal to the first direction. The internal electrodes each include an oxidized area adjacent to the side margin and intensively including a metal element that forms an oxide together with nickel. The capacitance forming unit includes a first portion adjacent to the cover and a second portion adjacent to the first portion in the first direction and including the oxidized area having a smaller dimension in the second direction than that of the oxidized area of the first portion.