Porous Outer Electrodes in Multilayer Ceramic Components for Hydrogen Blocking
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Solution Overview
Problem
The use of base metals like nickel in inner electrodes of multilayer ceramic electronic components leads to incomplete prevention of hydrogen ion absorption, resulting in deterioration of insulation resistance due to hydrogen ions generated during the plating of outer electrodes.
Innovation Solution
The structure of outer electrodes is improved by incorporating electroconductive metal and glass including silicon, with uniformly distributed pores in the range of 20-600 nm, formed through a specific firing process, to gasify and prevent hydrogen ion diffusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If base metal such as Ni is used as inner electrode material to reduce cost, then material cost is reduced, but hydrogen ions generated during plating still cause deterioration of insulation resistance
Solution Approach 1:
The outer electrode is designed with a porous structure containing numerous pores (20-600 nm in diameter) that act as hydrogen ion traps. These pores capture hydrogen ions generated during the plating process, preventing them from diffusing into the ceramic layers and deteriorating insulation resistance, while maintaining the cost advantage of using base metal inner electrodes
Solution Approach 2:
The porous outer electrode structure serves as an intermediary barrier between the plating process and the ceramic layers. It intercepts hydrogen ions in the plating solution before they can reach and damage the ceramic layers, thus protecting the insulation resistance while allowing the use of economical base metal inner electrodes
2Reliability
If Ni is added to inner electrodes to inactivate hydrogen absorption, then hydrogen influence is reduced, but insulation resistance deterioration cannot be completely prevented
Solution Approach 1:
Instead of merely trying to block hydrogen ions, the invention converts the harmful hydrogen ions into a beneficial trapping mechanism. The porous structure of the outer electrode actively captures hydrogen ions, transforming the plating process from a harmful source of hydrogen into a controlled process where hydrogen is contained and prevented from reaching ceramic layers
3Reliability
If outer electrode structure is improved with porous structure, then hydrogen ion diffusion is prevented, but manufacturing complexity increases
Solution Approach 1:
The porous structure of the outer electrode is achieved by controlling firing parameters (temperature, atmosphere, time) rather than introducing complex manufacturing steps. By optimizing firing conditions, the desired pore structure (20-600 nm diameter) is formed naturally, maintaining manufacturing simplicity while achieving the hydrogen ion trapping function
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 effectively reduces the influence of hydrogen ions on ceramic layers, ensuring adhesion and preventing insulation resistance deterioration while maintaining electrostatic capacitance.
Implementation Method 1
the influence on the ceramic layers of hydrogen ions generated by a chemical reaction during the step of plating the outer electrodes is reduced or prevented
Implementation Method 2
gasify and prevent hydrogen ion diffusion
Implementation Method 3
heat-drying the electroconductive material to gelate the electroconductive material
Implementation Method 4
performing firing at a temperature higher than or equal to a softening point of the glass raw material, lower than or equal to a melting point of the glass raw material
Implementation Method 5
performing firing at a temperature higher than or equal to a softening point of the glass raw material, lower than or equal to a melting point of the glass raw material
Data Source
AI summary
A multilayer ceramic electronic component includes a ceramic body including laminated ceramic layers and inner electrodes located along interfaces between the ceramic layers, an outer electrode on a surface of the ceramic body and electrically connected to the inner electrodes, and a plating film on the outer electrode. The outer electrode includes an electroconductive metal and glass including silicon. In a cross section along a thickness direction of the outer electrode, twenty or more pores with a major axis of about 20 nm or more and about 600 nm or less are present in a region located in a central portion with respect to the thickness direction and with a dimension of about 1 μm in the thickness direction and a dimension of about 5 μm in a width direction orthogonal to the thickness direction. Hydrogen ions are gasified in the pores so that diffusion of hydrogen ions into the ceramic body is reduced.