Multilayered Ceramic Component Electrode Connectivity
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Solution Overview
Problem
Multilayered ceramic capacitors (MLCCs) face challenges in achieving high reliability and capacity due to electrode disconnection issues caused by low sintering temperatures and the use of particulate metal powders, which are exacerbated by miniaturization trends.
Innovation Solution
A multilayered ceramic component structure is developed where internal electrode layers and dielectric layers are alternately layered, with 0.01 to 12 wt% common material based on metal powders, and an average particle size of the common material is 30 to 50% of the dielectric base material, using barium titanate and metal oxides to control sintering and improve connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the thickness of dielectric layers is decreased to achieve miniaturization and high capacity, then capacity increases, but reliability deteriorates due to electrode disconnection
Solution Approach 1:
The patent changes the particle size parameter of the common material to 30-50% of the dielectric base material, which modifies the sintering behavior and shrinkage characteristics. This parameter change allows the electrode layers to maintain connectivity even when dielectric layer thickness is reduced, thus resolving the contradiction between capacity improvement and reliability maintenance.
Solution Approach 2:
The patent uses a composite material system consisting of metal powders (Ni or Cu) combined with a specific common material having controlled particle size and composition. This composite structure enables the electrode layers to undergo coordinated shrinkage during sintering, preventing electrode disconnection while allowing thinner dielectric layers for higher capacity.
2Reliability
If sintering temperature is increased to improve electrode connectivity, then connectivity improves, but common material is excessively absorbed into dielectric layers affecting dielectric characteristics
Solution Approach 1:
The patent optimizes the particle size parameter of the common material to 30-50% of the dielectric base material, which controls the absorption rate during sintering. This parameter adjustment allows sufficient common material to remain in the electrode layers to maintain connectivity while preventing excessive absorption that would degrade dielectric characteristics.
Solution Approach 2:
The patent creates a local quality difference by having the common material distributed specifically in the electrode layers with controlled concentration. This local presence ensures connectivity at the electrode level while the overall dielectric layer composition remains stable and maintains its electrical characteristics.
3Volume of moving object
If particulate metal powders are used in thinned MLCC for miniaturization, then device size decreases, but electrode disconnection increases
Solution Approach 1:
The patent creates a composite electrode material system combining metal powders with a specifically sized common material. This composite structure provides a matrix that holds the metal particles together during shrinkage, preventing disconnection even in miniaturized devices with thinned construction.
Solution Approach 2:
The patent changes the particle size parameter of the common material to 30-50% of the dielectric base material, which optimizes the shrinkage behavior during sintering. This parameter adjustment ensures that the electrode layers shrink uniformly without breaking, maintaining connectivity in miniaturized devices.
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 structure enhances the connectivity and reliability of the internal electrode layers, maintaining high capacity and preventing electrode disconnection, while controlling the thickness of dielectric and internal electrode layers to ensure effective sintering and capacity characteristics.
Implementation Method 1
The process includes (1) squeezing out the common material while shrinking the metal powders at 800 to 1000° C., (2) connecting the internal electrode layers with each other while shrinking the dielectric layers at 1000 to 1100° C.
Implementation Method 2
squeezing out the common material while shrinking the metal powders at 800 to 1000° C.
Data Source
AI summary
Disclosed herein is a multilayered ceramic component having a structure in which internal electrode layers and dielectric layers are alternately multilayered, wherein the internal electrode layer includes 0.01 to 12 wt % of common material based on weight of metal powders, and an average particle size of the common material is 30 to 50% of an average particle size of a dielectric base material included in the dielectric layer. According to the first exemplary embodiment of the present invention, the particle size and the added amount of the common material squeezed out from the internal electrode layers at the time of firing thereof at a high temperature are controlled, thereby making it possible to improve the capacity and the reliability of the internal electrode.