Multilayer Capacitor Segmented Stacked Units for Thickness Deviation Control
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Solution Overview
Problem
Highly-stacked multilayer capacitors are vulnerable to dielectric breakdown due to nonuniform thickness and shape irregularities between dielectric layers and internal electrodes, particularly in high-capacity server products, leading to potential failures in advanced technologies like 5G systems.
Innovation Solution
The multilayer capacitor design includes alternating stacked units with varying dielectric layer densities and internal electrode widths, where surfaces of higher and lower density portions face each other, and a buffer layer may be used to reduce thickness deviations and end bending, ensuring uniform electrode thickness and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of stacked layers is increased to achieve high capacity, then the capacitance increases, but the thickness deviation between dielectric layer and internal electrode increases causing dielectric breakdown
Solution Approach 1:
The capacitor body is divided into multiple stacked units, each with a controlled number of layers (e.g., 400-600 layers per unit). By segmenting the total stack into multiple units rather than creating one large stack, the thickness deviation and level differences are controlled within each smaller unit, preventing dielectric breakdown while achieving high total capacitance through the combination of multiple units.
Solution Approach 2:
The patent transitions from a single-stack configuration to a multi-unit stacked configuration, adding a new dimensional aspect to the structure. Each stacked unit is arranged in a specific pattern (e.g., alternating high-density and low-density portions) to distribute stress and reduce cumulative thickness deviation, thereby maintaining manufacturing precision across the entire capacitor body.
2Manufacturing precision
If the stacked units are arranged with alternating density portions, then the thickness deviation is reduced, but the device complexity increases
Solution Approach 1:
Different regions of the capacitor body are designed with different dielectric layer densities. Specifically, adjacent stacked units have alternating patterns where one unit has higher density portions and the next has lower density portions. This local variation in quality compensates for thickness deviations by creating a self-balancing structure, reducing overall nonuniformity without requiring complex external adjustments.
Data Source
AI summary
A multilayer capacitor includes: a capacitor body formed by placing two or more stacked units in a row in a stacking direction of dielectric layers, each stacked unit including a plurality of dielectric layers, and a plurality of first and second internal electrodes alternately disposed with the dielectric layers interposed therebetween; and first and second external electrodes disposed on the capacitor body to be electrically connected to the first and second internal electrodes, respectively, and, in the capacitor body, adjacent stacked units are disposed to allow surfaces with similar density to be adjacent to each other.