Multilayer Capacitor Electrodes With Heterogeneous Nickel Layers

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Solution Overview

Problem

Existing multilayer ceramic capacitors face limitations in miniaturization and high-capacity realization due to the thickness of internal electrodes, as conventional screen-printing and gravure printing processes struggle to produce ultra-thin electrodes with functional materials.

Innovation Solution

A multilayer electronic component is developed using a vacuum deposition process to form internal electrodes with multiple nickel layers and a heterogeneous material layer, enabling the creation of ultra-thin, high-capacity electrodes with improved electrical and physical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If screen-printing or gravure printing process is used to form internal electrode, then manufacturing process is simple and easy to implement, but internal electrode thickness cannot be reduced below certain limit

Engineering Contradiction:

Improveinternal electrode thicknessVSAvoidmanufacturing process complexity

Core Design Contradiction:

Length of moving objectVSEase of manufacture

Solution Approach 1:

The patent replaces the mechanical screen-printing or gravure printing process with a vacuum deposition process. This substitution enables the formation of ultra-thin internal electrodes (10-100 nm thickness) that cannot be achieved with conventional printing methods, while maintaining manufacturing feasibility through established vacuum deposition technology.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the fundamental parameter of electrode formation from paste-based printing to atomic/molecular layer deposition. This parameter change allows precise control of electrode thickness at the nanometer scale and enables the incorporation of functional materials in controlled layers, resolving the thickness limitation of conventional methods.

Inventive Principle:

Principle #35Parameter changes

2Volume of moving object

If internal electrode thickness is reduced for miniaturization, then component size decreases and capacity increases, but electrical and physical properties deteriorate

Engineering Contradiction:

Improvecomponent volumeVSAvoidelectrical and physical properties

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent employs composite material structures within the internal electrode, combining nickel layers with functional material layers. This composite approach maintains electrical conductivity through the nickel while the functional materials provide enhanced physical properties and connectivity, allowing ultra-thin electrodes to retain necessary performance characteristics despite reduced thickness.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies different material properties to different regions of the internal electrode structure. Nickel layers provide conductivity where needed, while functional material layers provide specific local functions such as connectivity enhancement or interface optimization. This local differentiation allows the overall electrode to maintain performance despite ultra-thin dimensions.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If conventional printing processes are used, then manufacturing is straightforward, but functional materials cannot be effectively incorporated into internal electrode

Engineering Contradiction:

Improvefunctional material incorporationVSAvoidmanufacturing process simplicity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent segments the internal electrode into multiple distinct layers: nickel layers for conductivity and separate functional material layers for specific functions. This segmentation allows each layer to be optimized independently and incorporated through the vacuum deposition process, enabling functional material integration that is impossible with conventional printing methods.

Inventive Principle:

Principle #1Segmentation

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 approach allows for the miniaturization and integration of multilayer ceramic capacitors by achieving internal electrode thicknesses of 10-100 nm, enhancing connectivity and capacity while incorporating functional materials not feasible with traditional direct printing processes.

Implementation Method 1

performing vacuum deposition to form: (i) a first layer including nickel, (ii) a layer including a heterogeneous material on the first layer, and (iii) a second layer including nickel on the layer including the heterogeneous material

Methodology Applied

Scientific EffectVacuum deposition: Physical Vapour Deposition

Data Source

PatentUS11837406B2Multilayer electronic component

Publication Date: 2023.12.05 SAMSUNG ELECTRO MECHANICS CO LTD

AI summary

A multilayer electronic component includes a body including a plurality of internal electrodes and a dielectric layer disposed between the plurality of internal electrodes; and an external electrode disposed on the body and connected to the plurality of internal electrodes, wherein each of the plurality of internal electrodes includes a plurality of nickel layers, and a heterogeneous material layer provided between the plurality of nickel layers.