Multilayer Ceramic Component Nickel Cover Carbon Removal
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Solution Overview
Problem
Multilayer ceramic electronic components face challenges in achieving high reliability due to issues like crack generation, delamination, and residual carbon, which affect their voltage withstand characteristics and overall performance.
Innovation Solution
The use of nickel metal in cover parts formed by reducing nickel oxide particles in the second green sheets during sintering, along with specific weight percentages and particle sizes, helps in efficiently removing residual carbon and improving the ceramic body's density and strength, while maintaining target capacitance and reducing acoustic noise differences based on mounting direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manufacturing methods are used, then production process is simple, but residual carbon remains in the ceramic body affecting reliability
Solution Approach 1:
Nickel oxide particles are incorporated into the green sheets before sintering, so that during the sintering process the nickel oxide reduces to nickel metal which then reacts with and removes residual carbon from the ceramic body. This preliminary incorporation of the carbon removal mechanism into the manufacturing process itself eliminates the need for separate post-processing steps.
Solution Approach 2:
The residual carbon, which is normally a harmful impurity that reduces reliability, is converted into a beneficial outcome by using nickel oxide as a carbon trap. The nickel oxide reduces to nickel metal during sintering and reacts with the carbon to form nickel carbide or other compounds, thereby removing the harmful carbon from the ceramic body and improving reliability.
2Reliability
If nickel oxide particles are added to green sheets, then residual carbon is removed effectively, but manufacturing process becomes more complex
Solution Approach 1:
The composition of the green sheets is modified by incorporating nickel oxide particles at controlled concentrations (typically 0.1-5 wt%). The particle size is also controlled within specific ranges (e.g., 1-10 μm). These parameter changes enable effective carbon removal while maintaining manageable manufacturing complexity through standardized material specifications.
3Strength
If cover parts with nickel metal are used, then ceramic body strength is improved, but manufacturing precision requirements increase
Solution Approach 1:
The cover parts are designed with specific thickness ranges (e.g., 10-50 μm) and nickel metal content ranges (0.18-19 wt%) to optimize the balance between strength improvement and manufacturing feasibility. These controlled parameter ranges ensure that the strength enhancement from nickel metal incorporation does not come at the cost of excessive manufacturing precision 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 approach effectively decreases residual carbon content, enhances the ceramic body's strength and sintering density, ensures target capacitance, and minimizes acoustic noise variations regardless of mounting direction, thereby improving the reliability and performance of multilayer ceramic electronic components.
Implementation Method 1
The cover parts may contain a nickel metal formed by reduction of the nickel oxide particles contained in the second green sheets during the sintering of the green sheet multilayer body
Implementation Method 2
sintering the green sheet multilayer body to prepare a ceramic body including an inner layer part in which first dielectric layers and internal electrodes are alternately disposed, and cover parts disposed on upper and lower surfaces of the inner layer part
Data Source
AI summary
A multilayer ceramic electronic component includes an inner layer part comprising dielectric layers and internal electrodes that are alternately disposed; and cover parts disposed on upper and lower surfaces of the inner layer part. The cover parts contain a nickel metal.