Boosting ultra-wide temperature dielectric stability of multilayer ceramic capacitor through tailoring the combination types of polar nanoregions

With the rapid development of space exploration and new energy vehicles,it is urgent to build ultra-wide temperature multilayer ceramic capacitors(UWT MLCCs)to match electronic circuits that can withstand harsh environmental conditions.Relaxor ferroelectrics with diffuse phase transition feature are potential dielectrics for the construction of UWT MLCCs.However,how to ensure high dielectric constant together with low dielectric loss in the wide temperature region is still a big challenge.Here,the above difficulties are addressed by tailoring the combination types of polar nanoregions(PNRs)in the(1-x)(0.8Na_(0.5)Bi_(0.5)TiO_(3)-0.2K_(0.5)Bi_(0.5)TiO_(3))-xNaTaO3(NBT-KBT-xNT)system.Compared with PNRS types of P4bm+R3c and P4bm+Pbnm,the combination type of P4bm+Pbnm+R3c PNRs in NBT-KBT-0.31NT is the most beneficial to obtain comprehensive excellent dielectric performance because it can balance the relationship between high dielectric constant and temperature stability over a wide temperature region.Further,by optimizing the laminating pressure and co-firing temperature to realize a tight interfacial structure between the dielectric layer and the Pt inner electrode,a record-high dielectric constant(er=(907%±15%))together with low dielectric loss(tan δ≤0.025)is achieved over an ultra-wide range from-61℃ to 306℃ for NBT-KBT-0.31 NT MLCC,demonstrating that tailoring the combination types of PNRs is a powerful strategy in designing UWT MLCC dielectrics.

Unusual local electric field concentration in multilayer ceramic capacitors

Local electric-field around multitype pores(dielectric pore,interface pore,electrode pore)in multilayer ceramic capacitors(MLCCs)was investigated using Kelvin probe force microscopy combined with the finite element simulation to understand the effect of pores on the electric reliability of MLCCs.Electricfield is found to be concentrated significantly in the vicinity of these pores and the strength of the local electric-field is 1.5e5.0 times of the nominal strength.Unexpectedly,the concentration degree of the pores in the inner electrode is much higher than that in the dielectrics and dielectric-electrode interfaces.Meanwhile,geometry orientations are found to have a remarkable influence on the local electric field strength.The pores act as an insulation degradation precursor via local electric,thermal center,and oxygen vacancies accumulation center.Such unusual local electric field concentration of multitype pores can provide new insights into the understanding of insulation degradation evolution,processing tailoring and design optimization for MLCCs.

BaTiO_(3)基超薄层BME MLCC的可靠性机理

多层陶瓷电容器(Multilayer ceramic capacitors,MLCC)作为市场占有率最高的无源电子元器件,是基础电子元件产业中需要突破关键技术的重点产品之一,在汽车电子、5G通讯、电网调频、航空航天等领域有广泛的应用。在小型化、薄层化发展趋势下,MLCC的介质层厚度不断降低,单层介质在相同电压下的电场显著增大,尤其是中高压超薄层MLCC。因此,MLCC的可靠性愈发成为一项关键的产品质量指标。本文结合加速老化测试、高温阻抗谱、漏电流测试,系统研究超薄层MLCC的劣化机理,揭示抑制氧空位的迁移与富集是保证超薄层MLCC可靠性的重中之重。为此,应减小介质层内部的氧空位浓度,增大其迁移所需的激活能,提高界面肖特基势垒,从而提升超薄层MLCC的可靠性。本文的研究成果为超薄层MLCC介质材料的设计提供了有力指导。

用于MLCC叠层工艺的设备设计与实现

简述了MLCC发展背景、制备流程,并基于叠层工序进行工艺需求分析,为满足这些需求设计了一种MLCC叠层机,包括收\放卷传输机构、剥离工作台、膜片搬运机械手、加压机构和收/放料机械手,探讨了叠层机的控制原理和主要逻辑动作,完成设备的电气控制与人机交互系统的设计实现,设备已取得了良好的实际应用效果。

Application of response surface method for optimal transfer conditions of multi-layer ceramic capacitor alignment system

The multi-layer ceramic capacitor (MLCC) alignment system aims at the inter-process automation between the first and the second plastic processes.As a result of testing performance verification of MLCC alignment system,the average alignment rates are 95% for 3216 chip,88.5% for 2012 chip and 90.8% for 3818 chip.The MLCC alignment system can be accepted for practical use because the average manual alignment is just 80%.In other words,the developed MLCC alignment system has been upgraded to a great extent,compared with manual alignment.Based on the successfully developed MLCC alignment system,the optimal transfer conditions have been explored by using RSM.The simulations using ADAMS has been performed according to the cube model of CCD.By using MiniTAB,the model of response surface has been established based on the simulation results.The optimal conditions resulted from the response optimization tool of MiniTAB has been verified by being assigned to the prototype of MLCC alignment system.

基于机器学习的小容值MLCC容量模型的研究

小容值多层瓷介电容器(MLCC)容易出现容量命中率低的问题,本文通过机器学习算法建立小容值MLCC容量模型,采用MSE、R2、拟合精度和预测精度评估各模型的准确度。最后选择采用线性回归模型表达小容值MLCC的印刷层数和电容量之间的关系,并通过实际投产验证,证明该模型可以用于指导小容值MLCC的实际生产,提高小容值MLCC容量命中率。

MLCC电容环境失效案例解析

MLCC电容的全称为多层片式陶瓷电容器(Multi-layer Ceramic Capacitor,英文缩写MLCC),是由陶瓷介质薄膜与内电极以层层错位的方法交替叠合,经过高温一次性烧结制成陶瓷芯片,最后在陶瓷芯片的两端涂覆外电极浆料而制成的电容器。因此,MLCC的内应力复杂,耐环境应力的能力有限。在实际的复杂使用环境中,MLCC往往会由于经受机械应力、电应力以及温度应力的综合作用导致MLCC出现裂纹或金属电极错位而失效。本文通过对MLCC电容典型失效案例的解析,总结了常见MLCC的失效原因,对复杂工况下PCBA的可靠性设计有一定参考意义。

MLCC手工焊接质量控制研究

针对多层瓷介电容器(MLCC)在手工焊接过程中可能引入的裂纹损伤从而降低其使用可靠性的问题开展了研究。探索了手工焊接过程中MLCC外形尺寸、印制电路板(PCB)是否预热、焊盘散热速率和焊接温度对MLCC裂纹的影响程度,摸索最优焊接工艺参数,尽可能消除MLCC应用过程中可能引入裂纹损伤的质量隐患,进一步确保MLCC的使用可靠性。

Enhanced breakdown strength of BaTiO_(3)-based multilayer ceramic capacitor by structural optimization

0.5 wt%Nb_(2)O_(5)doped 0.12BiAlO_(3)-0.88BaTiO_(3)(12BA5N)multilayer ceramic capacitor(MLCC-1)was prepared,which satisfied EIA X7R specification(where X is the minimum temperature,R is the percentage of capacitance variation limit)at 1 kHZ.The distribution of internal electric field under breakdown voltage was simulated by finite element method(FEM),indicating that the electric field strength increased significantly at the terminal of internal electrode.These areas may become the headstream of breakdown for MLCC-1 due to the shape mutation.In order to improve the breakdown performance of MLCC-1,it was optimized by 12BA5N+2G green sheets(prepared by 12BA5N ceramic powder with 2 wt%B-Al-Si glass additive),then MLCC-2 was obtained which satisfied EIA X8R specification.Its BDS rose from 20 to29.4 kV·mm^(-1),and the electric field distribution of dielectric layer was also analyzed by FEM.Besides,it was also found that the grain size and the dielectric constants of"core"and"shell"parts for the 12BA5N+2G dielectric layer both contributed to the enhanced BDS of MLCC-2according to the simulation results from FEM.

Perspectives and challenges for lead-free energy-storage multilayer ceramic capacitors

The growing demand for high-power-density electric and electronic systems has encouraged the development of energy-storage capacitors with attributes such as high energy density,high capacitance density,high voltage and frequency,low weight,high-temperature operability,and environmental friendliness.Compared with their electrolytic and film counterparts,energy-storage multilayer ceramic capacitors(MLCCs)stand out for their extremely low equivalent series resistance and equivalent series inductance,high current handling capability,and high-temperature stability.These characteristics are important for applications including fast-switching third-generation wide-bandgap semiconductors in electric vehicles,5G base stations,clean energy generation,and smart grids.There have been numerous reports on state-of-the-art MLCC energy-storage solutions.However,lead-free capacitors generally have a low-energy density,and high-energy density capacitors frequently contain lead,which is a key issue that hinders their broad application.In this review,we present perspectives and challenges for lead-free energy-storage MLCCs.Initially,the energy-storage mechanism and device characterization are introduced;then,dielectric ceramics for energy-storage applications with aspects of composition and structural optimization are summarized.Progress on state-of-the-art energy-storage MLCCs is discussed after elaboration of the fabrication process and structural design of the electrode.Emerging applications of energy-storage MLCCs are then discussed in terms of advanced pulsed power sources and high-density power converters from a theoretical and technological point of view.Finally,the challenges and future prospects for industrialization of lab-scale lead-free energy-storage MLCCs are discussed.

Energy storage properties of 0.87BaTiO3-0.i3Bi(Zn2/3(Nb0.85Ta0.15)1/3)O3 multilayer ceramic capacitors with thin dielectric layers

Multilayer ceramic capacitors(MLCCs)for energy storage applications require a large discharge energy density and high discharge/charge efficiency under high electric fields.Here,0.87BaTiO3--0.13Bi(Zn23(Nbog8sTao.1s)u3)O3(BTBZNT)MLCCs with double active dielectric layers were fabricated,and the effects of inner electrode and sintering method on the energy storage properties of BTBZNT MLCCs were investigated.By using the pure Pt as inner electrode instead of Ago.6Pdo4 aloys,an alternating current(AC)breakdown strength(BDS)enhancement from 1047 to 1500 kV/cm was achieved.By investigating the leakage current behavior of BTBZNT MLCCs,the Pt inner electrode and two-step sintering method(TSS)were confirmed to enhance the Schottky barrier and minimize the leakage current density.With relatively high permitivity,dielectric sublinearity,and ultra-high BDS,the Pt TSS BTBZNT MLCCs exhibited a surprisingly discharge energy density(Udis)of 14.08 J/cm2.Moreover,under an operating electric field of 400 kV/cm,the MLCCs also exhibited thermal stability with Udis variation<±8%over a wide temperature (t) range from-50 to 175℃ and cycling reliability with Uais reduction<0.3%after 3000 charge-discharge cycles.These remarkable performances make Pt TSS BTBZNT MLCCs promising for energy storage applications.

Effect of SiO_2 addition on the dielectric properties and microstructure of BaTiO_3-based ceramics in reducing sintering

The effect of SiO2 doping on the sintering behavior, microstructure, and dielectric properties of BaTiO3-based ceramics has been investigated. Silica was added to the BaTiO3-based powder prepared by the solid state method with 0.075mol%, 0.15mol%, and 0.3mol%, respectively. The SiO2-doped BaTiO3-based ceramic with high density and uniform grain size were obtained, which were sintered in reducing atmosphere. A scanning electron microscope, X-ray diffraction, and LCR meter were used to determine the microstructure as well as the dielectric properties. SiO2 can form a liquid phase belonging to the ternary system of BaO-TiO2-SiO2, leading to the formation of BaTiO3 ceramics with high density at a lower sintering temperature. The SiO2-doped BaTiO3-based ceramics can be sintered to a theoretical density higher than 95% at 1220℃ with a soaking time of 2 h. The dielectric constants of the sample with 0.15mol% SiO2 addition sintered at 1220℃ is about 9000. Doping with a small amount of silica can improve the sintering and dielectric properties of BaTiO3-based ceramics.

Large electrocaloric effect in BaTiO_3 based multilayer ceramic capacitors

The electrocaloric effect(ECE) of multilayer ceramic capacitor(MLCC) of Y5 V type was directly measured via a differential scanning calorimetry(DSC) method and a reference resistor was used to calibrate the heat flow due to the heat dissipation. The results are compared with those calculated from Maxwell relations by using the polarization data obtained from the polarization–electric field hysteresis loops. The direct method shows a larger ECE temperature change, which is accounted for the situation approaches an ideal condition. For the indirect method using Maxwell relations, only the polarization projection along the electric field was taken into account, which will be less than the randomly distributed real polarizations that contribute to the ECE. The MLCCs exhibit a broad peak of ECE around 80 C, which will be favorite for the practical ECE cooling devices.

Energy storage properties of surface-modified BaTiO_(3)ceramic films for multilayer capacitors applications

Surface-modified BaTiO_(3)of 230 nm average grain size were synthesized by coating BaTiO_(3)particles with 3 wt.%Al2O_(3)and 1 wt.%SiO2.Ceramic films of different thicknesses were prepared via tape casting and laminating processes followed by two-steps sintering method.After sintering,the average grain size of Surface-modified BaTiO_(3)ceramic slightly increased to 275 nm,and great enhancement of AC breakdown strength(BDS)from 184 kV/cm to 665 kV/cm was obtained as the thickness of ceramic films decreased from 63μm to 12μm,resulting in improvement of discharge energy density from 1.14 J/cm3to 4.06 J/cm3.Because of their low-cost,easily fabrication,lead-free,improved AC BDS and discharge energy density,surface-modified BaTiO_(3)ceramic films appeared promising for applications in multilayer energy storage capacitors.

Series multilayer internal electrodes for high energy density glass-ceramic capacitors

The glass-ceramic dielectrics and internal electrode structures are investigated for improving the general energy storage density of capacitors. Calculation indicates that glass-ceramics acquired from glass matrix annealing at 850℃ for 3 hours can be approximately up to 17 J/cm3 in energy storage density. They are appropriately chosen as the dielectrics for preparing high energy storage density capacitors (HESDCs). A series multilayer structure of internal electrode is developed for the HESDCs, in which each layer is a combination of gold film and silver paste. This electrode structure promises the capacitor immune from the residual porosity defects inevitably brought by electrode paste sintering process, and specifically improves the electrical breakdown strength of the capacitor. Based on this new electrode structure, the energy storage densities of capacitors are increased by more than one order of magnitude compared with those traditional ones with only single layer of internal electrode. Thus, HESDCs based on the optimized glass-ceramic dielectrics can potentially achieve 7.5 J/cm3 in energy storage density, even taking into consideration the enlargement of total capacitor volumes while encapsulating practicable capacitors from dielectrics media.

基于MLCC电子陶瓷的片式电子元件高速智能切割机的设计和实现

电子产品的不断发展,对电子元件的尺寸、质量和生产效率提出了更高的要求。为了满足这些要求,设计了一种创新的高速智能切割机,旨在提高生产效率、降低制造成本和保证产品质量。从机体结构和框架设计、载台和真空吸盘系统及DD直驱伺服转动机构等方面探讨高速智能切割机的设计,然后结合高速智能切割机的特点,探讨切割机工作流程和控制系统的实现,进而推动电子元件制造业向智能化和高效化方向迈进。

贱金属内电极多层陶瓷电容器(BME-MLCCs)研究进展

贱金属内电极多层陶瓷电容器(BME-MLCCs)经过40年的发展,目前已成为多层陶瓷电容器的主流。钛酸钡的缺陷化学是发展BME-MLCCs的理论基础,利用该理论研发抗还原的钛酸钡基介质陶瓷组成,使钛酸钡基介质陶瓷与镍内电极能够在还原性气氛中共烧。BME-MLCCs工业化的一个关键问题是降低由带电荷的氧空位移动所造成的老化。

微波MLCC绝缘电阻的工艺影响因素研究

在即定原材料和多层电容器整体结构设计基础上,立足于微波片式多层陶瓷电容器的规模化生产工艺,对各种影响绝缘电阻的生产工艺因素进行了系统研究。结果表明,工艺因素对微波片式多层陶瓷电容器(MLCC)绝缘电阻的影响较大;在实际生产过程中,优化流延工艺改善陶瓷膜片性能,在印刷中采用合适的内电极烘干温度,叠层后采用合适的干燥工艺、合理的排胶烧结制度和电镀工艺均能有效提高微波MLCC的绝缘电阻。

面向方案设计的BME MLCC宇航鉴定关键技术

近年来,随着技术逐渐成熟,在欧美等国,BME MLCC已经逐渐进入宇航应用领域。相对传统的PME MLCC,BM E M LCC具有缓慢老化失效模式、介质减薄等特性,也存在可靠性风险。从"初步评估、详细评估、鉴定检验"宇航鉴定思路出发,结合电容器失效模式和失效机理,分析AEC-Q200、MIL-PRF-32535、NASA S-311-P-838等标准试验项目,对比PME MLCC与BME MLCC通用规范要求。在鉴定范围和材料结构要求、结构分析和生产一致性、长寿命可靠性、环境适应性等方面,提出了面向方案设计的BME MLCC宇航鉴定关键技术。

Ni–MgO核–壳纳米粉体的制备

采用包覆热分解烧结法,制备了多层陶瓷电容器内部电极用MgO包覆Ni纳米粉体,讨论了反应物浓度和分散剂含量对包覆纳米镍盐前驱体颗粒大小和均匀性的影响,分析了还原烧结温度对包覆纳米Ni粉球形度和分散性的影响,并利用X射线衍射仪、扫描电镜、透射电镜、热机械分析仪对MgO包覆纳米Ni粉进行了表征分析。结果表明:反应物浓度达到足以引起反应爆炸成核时,能够获得纳米镍盐颗粒;添加适量的分散剂,可以得到分散良好的纳米镍盐前驱体颗粒;还原烧结温度700℃时,可以获得球形度和分散性良好的MgO包覆纳米Ni粉;MgO包覆在纳米Ni粉表面,形成了核壳结构,该纳米Ni粉具有良好的收缩延迟效果。