Multilayer Electronic Component Electrode Composition for Thermal Stability
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Solution Overview
Problem
The challenge in developing multilayer ceramic capacitors is the degradation of internal electrode connectivity and reliability due to increased thermal contraction initiation temperature differences between dielectric layers and internal electrodes, exacerbated by material atomization, which reduces capacitance and thermal stability, and existing solutions like adding BaTiO3 lead to decreased film density and capacitance.
Innovation Solution
Incorporating nickel (Ni) and dysprosium (Dy) in internal electrodes within specific atomic percentage ranges (0.02 at% to 5 at%) to reduce thermal contraction initiation temperature differences and enhance thermal stability without compromising dielectric constant, thereby improving reliability and capacitance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If internal electrodes and dielectric layers are made thinner to reduce size and increase capacitance, then the component size is reduced and capacitance is increased, but the materials become atomized which decreases melting point and thermal stability, increases thermal contraction initiation temperature difference, and degrades reliability
Solution Approach 1:
The patent changes the chemical composition parameters of the internal electrode paste by incorporating specific ceramic additives (BaTiO3 in amounts of 1-10 wt% based on internal electrode paste weight) to modify the thermal properties. This parameter change allows the electrode material to maintain thermal stability and reduce thermal contraction initiation temperature differences even when the electrode thickness is reduced to achieve miniaturization.
Solution Approach 2:
The patent creates a composite material system by combining metal powder (Ni, Cu, or their alloys) with ceramic additives (BaTiO3) in the internal electrode paste. This composite structure allows the electrode to simultaneously achieve electrical conductivity from the metal component and thermal stability from the ceramic component, resolving the contradiction between thinning the electrode for miniaturization and maintaining reliability.
2Reliability
If BaTiO3 is added to internal electrode paste as a ceramic additive to reduce thermal contraction initiation temperature difference, then thermal stability is improved, but film density of the internal electrode decreases and BaTiO3 moves to the dielectric layer during firing, increasing dielectric layer thickness and decreasing capacitance
Solution Approach 1:
The patent optimizes the amount of BaTiO3 additive within a specific range (1-10 wt% of internal electrode paste weight) to balance thermal stability improvement with capacitance maintenance. By controlling this parameter, the patent achieves sufficient thermal stability while minimizing BaTiO3 migration to the dielectric layer and maintaining film density.
Solution Approach 2:
The patent ensures that BaTiO3 is uniformly distributed within the internal electrode paste matrix, creating local regions with enhanced thermal stability without causing excessive migration to the dielectric layer. This localized quality improvement maintains the electrode's functional properties while achieving thermal stability.
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 improves the mean time to failure (MTTF), breakdown voltage (BDV), and reliability of multilayer electronic components while maintaining high capacitance and miniaturization, by controlling the concentration of Dy in relation to Ni to stabilize the internal electrodes and dielectric layers.
Implementation Method 1
the internal electrodes include nickel (Ni) and dysprosium (Dy) in amounts which satisfies the following formula: 0.02 at %≤C0≤5 at %
Data Source
AI summary
A multilayer electronic component includes a body including a dielectric layer and internal electrodes having the dielectric layer interposed therebetween in a first direction and external electrodes disposed on the body and connected to the internal electrodes, wherein the internal electrodes include nickel (Ni) and dysprosium (Dy) and 0.02 at %≤C0≤5 at % in which C0 is an atomic percentage (at %) calculated by dividing a number of atoms of Dy by a sum of a number of atoms of Ni and Dy included in the internal electrode.