Multilayer Ceramic Dielectric Structure for Longer Component Life
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Solution Overview
Problem
There is a demand for further improvement in the life characteristics of multilayer ceramic electronic components, particularly in dielectric layers, as they have become thinner and stacked in greater numbers, while maintaining high dielectric constants.
Innovation Solution
The multilayer ceramic electronic component incorporates core-shell grains with specific concentrations of donor elements in the first and second shell layers and a grain boundary containing an Mn element, along with a manufacturing process involving multiple stages of synthesis and firing to enhance the dielectric layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the thickness of dielectric layers is reduced and the number of dielectric layers is increased, then the capacitance increases and the size is reduced, but the life characteristics deteriorate
Solution Approach 1:
The patent applies local quality by creating core-shell grains with non-uniform donor element distribution. The shell layer has a higher concentration of donor elements (5-20 at%) compared to the core (1-5 at%), providing localized enhancement at the grain boundary region where oxide ion vacancies typically form. This localized modification improves life characteristics without requiring uniform thickening of the entire dielectric layer, thus maintaining high capacitance density while enhancing reliability.
Solution Approach 2:
The patent employs composite materials by combining barium titanate (BaTiO3) base material with shell layers containing specific donor elements (Nb, Ta, W, Mo). This composite structure creates a core-shell grain configuration where the shell layer with enhanced donor element concentration provides improved resistance to oxide ion vacancy formation, while the core maintains the high dielectric constant properties, achieving both high capacitance and improved life characteristics.
2Reliability
If the concentration of donor elements is increased to improve life characteristics, then the reliability improves, but the dielectric constant may be affected
Solution Approach 1:
The patent uses local quality by concentrating donor elements in the shell layer (5-20 at%) rather than uniformly distributing them throughout the entire grain. This localized concentration at the grain boundary region specifically addresses oxide ion vacancy formation without significantly altering the bulk dielectric properties, thus improving life characteristics while maintaining stable dielectric constant.
Solution Approach 2:
The patent applies parameter changes by precisely controlling the donor element concentration in different regions: 1-5 at% in the core and 5-20 at% in the shell layer. This graded parameter distribution allows optimization of both reliability (through higher shell concentration) and dielectric stability (through controlled core concentration), demonstrating how parameter variation can simultaneously address multiple performance requirements.
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 and manufacturing method improve the life characteristics of the dielectric layers by reducing oxide ion vacancies, leading to enhanced reliability and performance.
Implementation Method 1
This configuration and manufacturing method improve the life characteristics of the dielectric layers by reducing oxide ion vacancies
Implementation Method 2
a grain boundary containing an Mn element
Implementation Method 3
subjecting the element body to firing
Data Source
AI summary
A multilayer ceramic electronic component includes an element body including internal electrode layers and dielectric layers stacked alternately. Each of the dielectric layers includes core-shell grains each including a core portion, a first shell layer provided around the core portion, and a second shell layer provided around the first shell layer. The dielectric layer further includes a grain boundary between adjacent ones of the core-shell grains. Each of a concentration of a donor element in the first shell layer and a concentration of a donor element in the second shell layer is higher than a concentration of a donor element in the core portion.