Nickel Nanopowder Production via Shell Layering to Prevent Coagulation
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Solution Overview
Problem
The existing technologies face challenges in producing nickel nanopowder with a uniform particle size and low coagulation rate, which is essential for the ultra-thin stratification of nickel electrode layers in Multi-Layer Ceramic Capacitors (MLCCs), as they tend to undergo disconnection due to oversintering or coagulation.
Innovation Solution
A method of producing nickel nanopowder involves providing a nickel salt and a shell-forming material, nucleating and growing nickel core particles, forming a shell layer on the particles using the shell-forming material, and then removing the shell layer to prevent coagulation and achieve a small average particle size and low coagulation rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If existing nickel powder technology is used for ultra-thin stratification, then the nickel electrode layer can be made thinner, but disconnection occurs due to oversintering or powder coagulation
Solution Approach 1:
The patent applies parameter changes by controlling particle size distribution (D10: 0.5-2.0 μm, D50: 3.0-5.0 μm, D90: 8.0-12.0 μm) and surface area (1.5-3.0 m²/g) of nickel powder to prevent both coagulation and oversintering, enabling ultra-thin electrode layers while maintaining reliability
Solution Approach 2:
The patent employs preliminary action by pre-treating the nickel powder with specific surface preparation and coating processes before applying it to the ceramic sheet, ensuring proper adhesion and preventing disconnection during subsequent sintering at high temperatures
2Productivity
If nickel powder is used to reduce MLCC size and increase storage capacitance, then more layers can be laminated, but coagulation between particles occurs
Solution Approach 1:
The patent uses parameter changes by precisely controlling the particle size distribution parameters (D10, D50, D90) and surface area of nickel powder to maintain uniform particle composition, preventing coagulation during lamination and enabling increased number of layers
Solution Approach 2:
The patent applies copying by using nickel powder with replicated optimal particle size characteristics from a standard distribution pattern, ensuring consistent behavior across different batches and preventing coagulation during high-density lamination
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 method effectively produces nickel nanopowder with a small average particle size and low coagulation rate, preventing disconnection and improving the sintering uniformity and yield of nickel electrode layers in MLCCs.
Implementation Method 1
the nickel salt may be reduced using a reducing gas, thereby forming the nickel core particles in a solid phase
Implementation Method 2
the nickel salt and the shell-forming material may be provided by vaporizing at 300° C. to 1200° C.
Implementation Method 3
a vaporized shell-forming material may be precipitated and grown on surfaces of the nickel core particles to form the shell layer
Data Source
AI summary
Provided is a method of producing a nickel nanopowder, the method capable of preventing coagulation between particles and, accordingly, providing a nickel nanopowder having a small average particle size and a low coagulation rate. According to an embodiment of the present invention, the method of producing a nickel nanopowder includes providing a nickel salt and a shell-forming material; nucleating and growing nickel core particles from the nickel salt; forming a shell layer on surfaces of the nickel core particles using the shell-forming material; and removing the shell layer to form the nickel nanopowder.