Multilayer Ceramic Component Using Conductive Oxide Electrodes
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Solution Overview
Problem
The manufacturing of multilayer ceramic electronic components faces challenges such as increased costs due to the need for reducing atmospheres during firing to prevent oxidation of internal electrodes, and thermal expansion mismatches between metal and ceramic materials, leading to defects like cracking.
Innovation Solution
The use of conductive oxides like indium-tin oxide or ruthenium oxide for both internal and external electrodes, along with conductive metal and organic polymer layers, allows for firing in air without the need for a reducing atmosphere, and forms stable connections between electrodes and ceramic bodies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a base metal such as nickel is used for internal electrodes, then manufacturing costs are reduced, but the internal electrode is oxidized when fired in air
Solution Approach 1:
The invention changes the chemical state of the electrode material from metallic (prone to oxidation) to oxide form (oxidation-resistant). By using conductive oxide materials like nickel oxide, ruthenium oxide, or indium tin oxide, the electrodes maintain their conductivity while being inherently resistant to oxidation during firing in air, eliminating the need for costly reducing atmosphere control
Solution Approach 2:
The invention replaces expensive noble metals (silver, palladium) with cheaper base metal oxides that provide similar functionality. Materials like nickel oxide, ruthenium oxide, and indium tin oxide offer cost-effective alternatives that maintain electrical conductivity while resisting oxidation, making the manufacturing process more economical
2Reliability
If a reducing atmosphere is maintained during firing, then electrode oxidation is prevented, but technology and manufacturing costs increase
Solution Approach 1:
The conductive oxide materials inherently protect themselves from oxidation during the firing process. Since the electrodes are already in oxide form, they do not require external protection through reducing atmospheres. The material itself provides the necessary oxidation resistance, simplifying the manufacturing process to standard atmospheric firing
Solution Approach 2:
The invention changes the chemical composition of the electrode material from reactive metal to stable oxide, fundamentally altering the firing requirements. This parameter change allows the use of simple atmospheric firing instead of complex reducing atmosphere control, reducing manufacturing complexity while maintaining electrode integrity
3Manufacturing precision
If metal and ceramic are subjected to repeated thermal history, then electrodes are formed, but cracks are generated at interfaces due to thermal expansion mismatch
Solution Approach 1:
The invention uses oxide materials for both the internal electrodes and the ceramic body, creating material homogeneity at the interface. Since both materials are in oxide form, their thermal expansion coefficients are more compatible, reducing stress concentration and preventing crack formation during repeated thermal cycling
Solution Approach 2:
The invention creates a composite structure where conductive oxide particles are embedded in the ceramic matrix. This composite approach allows for better thermal matching between electrode and ceramic materials, as the oxide-based composite has thermal properties intermediate between pure metal and ceramic, reducing thermal stress and interface cracking
Data Source
AI summary
There are provided a multilayer ceramic electronic component that does not require a heat treatment under a reduction atmosphere, and a manufacturing method thereof, wherein a conductive oxide is used as a material of internal and external electrodes and conductive layers having elasticity are formed on the external electrodes. In the case of the multilayer ceramic electronic component, a firing process may be performed under an air atmosphere, such that a manufacturing process may be simplified and manufacturing costs may be reduced.