Multilayer ceramic capacitor

Abstract

To provide a multilayer ceramic capacitor in which ESR can be reduced.SOLUTION: A multilayer ceramic capacitor 1 includes a multilayer body 10 including a stack of dielectric layers 20 and a stack of internal electrode layers 30, and an external electrode 40 connected to the internal electrode layer 30. The external electrode 40 includes a conductive resin layer 60 and a plating layer 70 disposed on the conductive resin layer 60. The conductive resin layer 60 includes a resin part 61, conductive fillers 62 dispersed in the resin part 61, and metal particles 63 existing in the conductive resin layer 60 with bias in distribution different from the conductive fillers 62. An abundance ratio of the metal particles 63 to the resin part 61 is higher on the plating layer 70 side in the conductive resin layer 60 than on the multilayer body 10 side in the conductive resin layer 60.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to a multilayer ceramic capacitor. [Background technology]

[0002] Conventionally, multilayer ceramic capacitors have been known that include external electrodes containing conductive resin layers to absorb stresses generated by sudden thermal changes, etc. Patent Document 1 discloses external electrodes in which a conductive resin layer is formed on the surface of a baked electrode layer, and a plating layer is further formed on the surface of that conductive resin layer. The conductive resin layer is made of a thermosetting resin blended with a conductive filler. This conductive filler ensures the conductivity of the conductive resin layer. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 11-162771 Summary of the Invention [Problem to be solved by the invention]

[0004] In the configuration of Patent Document 1, the conductivity within the conductive resin layer and the conductivity between the conductive resin layer and the plating layer depend on the contact probability of the conductive filler. Therefore, if the contact probability of the conductive filler is low, the equivalent series resistance (ESR) will be high. Furthermore, if the conductive filler present near the interface between the conductive resin layer and the plating layer is covered with a thermosetting resin, plating is less likely to deposit in this covered area. Furthermore, this area can also cause a decrease in conductivity between the conductive resin layer and the plating layer.

[0005] An object of the present invention is to provide a multilayer ceramic capacitor capable of reducing ESR. [Means for solving the problem]

[0006] The multilayer ceramic capacitor according to the present invention comprises a laminate including a plurality of laminated dielectric layers and a plurality of laminated internal electrode layers, and external electrodes connected to the internal electrode layers, wherein the external electrodes have a conductive resin layer and a plating layer disposed on the conductive resin layer, and the conductive resin layer has a resin portion, a conductive filler dispersed within the resin portion, and metal particles that are unevenly distributed in the conductive resin layer and have a different distribution from the conductive filler, and the abundance ratio of the metal particles to the resin portion is higher on the plating layer side of the conductive resin layer than on the laminate side of the conductive resin layer. [Effects of the Invention]

[0007] According to the present invention, it is possible to provide a multilayer ceramic capacitor capable of reducing ESR. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is an external perspective view of a multilayer ceramic capacitor according to an embodiment; [Figure 2] 2 is a cross-sectional view taken along line II-II of the multilayer ceramic capacitor shown in FIG. [Figure 3] 3 is a cross-sectional view taken along line III-III of the multilayer ceramic capacitor shown in FIG. 2. [Figure 4] 4 is a cross-sectional view taken along line IV-IV of the multilayer ceramic capacitor shown in FIG. 2. [Figure 5] 3 is an enlarged view of a V portion of the multilayer ceramic capacitor shown in FIG. 2, showing an outline of a conductive resin layer. [Figure 6A] FIG. 1 is a diagram showing a multilayer ceramic capacitor with a double structure. [Figure 6B] FIG. 1 is a diagram showing a multilayer ceramic capacitor with a triple structure. [Figure 6C] FIG. 1 is a diagram showing a multilayer ceramic capacitor with a four-element structure. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, a multilayer ceramic capacitor 1 according to an embodiment of the present invention will be described. Fig. 1 is an external perspective view of the multilayer ceramic capacitor 1 according to the embodiment. Fig. 2 is a cross-sectional view taken along line II-II of the multilayer ceramic capacitor 1 of Fig. 1. Fig. 3 is a cross-sectional view taken along line III-III of the multilayer ceramic capacitor 1 of Fig. 2. Fig. 4 is a cross-sectional view taken along line IV-IV of the multilayer ceramic capacitor 1 of Fig. 2. Fig. 5 is an enlarged view of part V of the multilayer ceramic capacitor 1 shown in Fig. 2, illustrating an outline of the conductive resin layer 60.

[0010] The multilayer ceramic capacitor 1 has a laminate 10 and external electrodes 40 .

[0011] 1 to 4 show an XYZ Cartesian coordinate system. The length direction L of the multilayer ceramic capacitor 1 and the laminate 10 corresponds to the X direction. The width direction W of the multilayer ceramic capacitor 1 and the laminate 10 corresponds to the Y direction. The stacking direction T of the multilayer ceramic capacitor 1 and the laminate 10 corresponds to the Z direction. Here, the cross section shown in FIG. 2 is also referred to as the LT cross section. The cross section shown in FIG. 3 is also referred to as the WT cross section. The cross section shown in FIG. 4 is also referred to as the LW cross section.

[0012] As shown in Figures 1 to 4, the laminate 10 includes a first main surface TS1 and a second main surface TS2 that face each other in a stacking direction T, a first side surface WS1 and a second side surface WS2 that face each other in a width direction W that is perpendicular to the stacking direction T, and a first end surface LS1 and a second end surface LS2 that face each other in a length direction L that is perpendicular to the stacking direction T and the width direction W.

[0013] As shown in FIG. 1, the laminate 10 has a substantially rectangular parallelepiped shape. The dimension of the laminate 10 in the length direction L is not necessarily longer than the dimension in the width direction W. The corners and ridges of the laminate 10 are preferably rounded. A corner is a portion where three surfaces of the laminate intersect, and a ridge is a portion where two surfaces of the laminate intersect. Incidentally, unevenness may be formed on part or all of the surfaces constituting the laminate 10.

[0014] The dimensions of the laminate 10 are not particularly limited.

[0015] As shown in Figures 2 and 3, the laminate 10 has an inner layer portion 11, and a first main surface side outer layer portion 12 and a second main surface side outer layer portion 13 arranged to sandwich the inner layer portion 11 in the stacking direction T.

[0016] The inner layer portion 11 includes a plurality of dielectric layers 20 and a plurality of internal electrode layers 30. The inner layer portion 11 includes the internal electrode layer 30 located closest to the first principal surface TS1 in the stacking direction T to the internal electrode layer 30 located closest to the second principal surface TS2. In the inner layer portion 11, the multiple internal electrode layers 30 are arranged opposite each other with the dielectric layer 20 interposed therebetween. The inner layer portion 11 is a portion that generates electrostatic capacitance and essentially functions as a capacitor.

[0017] The plurality of dielectric layers 20 are made of a dielectric material. The dielectric material may be, for example, a dielectric ceramic containing components such as BaTiO3, CaTiO3, SrTiO3, or CaZrO3. The dielectric material may also be one in which a secondary component such as a Mn compound, an Fe compound, a Cr compound, a Co compound, or a Ni compound is added to the above main component.

[0018] The thickness of the dielectric layer 20 is preferably 0.5 μm or more and 10 μm or less. The number of laminated dielectric layers 20 is preferably 15 to 700. Note that this number of dielectric layers 20 is the total number of the dielectric layers in the inner layer portion 11 and the dielectric layers in the first main surface side outer layer portion 12 and the second main surface side outer layer portion 13.

[0019] The multiple internal electrode layers 30 include multiple first internal electrode layers 31 and multiple second internal electrode layers 32. The multiple first internal electrode layers 31 and the multiple second internal electrode layers 32 are embedded so as to be alternately arranged in the stacking direction T of the laminate 10.

[0020] The first internal electrode layer 31 has a first opposing portion 31A opposing the second internal electrode layer 32, and a first lead portion 31B led from the first opposing portion 31A to the first end face LS1. The first lead portion 31B is exposed at the first end face LS1.

[0021] The second internal electrode layer 32 has a second opposing portion 32A opposing the first internal electrode layer 31, and a second lead portion 32B led from the second opposing portion 32A to the second end face LS2. The second lead portion 32B is exposed at the second end face LS2.

[0022] In this embodiment, the first opposing portion 31A and the second opposing portion 32A face each other via the dielectric layer 20, thereby forming capacitance and exhibiting the characteristics of a capacitor.

[0023] The shapes of the first opposing portion 31A and the second opposing portion 32A are not particularly limited, but are preferably rectangular. However, the corners of the rectangular shape may be rounded or may be angled. The shapes of the first drawer portion 31B and the second drawer portion 32B are not particularly limited, but are preferably rectangular. However, the corners of the rectangular shape may be rounded or may be angled.

[0024] The width direction W dimension of the first facing portion 31A and the width direction W dimension of the first lead portion 31B may be the same dimension, or one of the dimensions may be smaller. The width direction W dimension of the second facing portion 32A and the width direction W dimension of the second lead portion 32B may be the same dimension, or one of the dimensions may be smaller.

[0025] The first internal electrode layer 31 and the second internal electrode layer 32 are made of an appropriate conductive material, such as a metal such as Ni, Cu, Ag, Pd, or Au, or an alloy containing at least one of these metals. When an alloy is used, the first internal electrode layer 31 and the second internal electrode layer 32 may be made of, for example, an Ag-Pd alloy.

[0026] The thickness of each of the first internal electrode layers 31 and the second internal electrode layers 32 is preferably, for example, about 0.2 μm or more and 2.0 μm or less. The total number of the first internal electrode layers 31 and the second internal electrode layers 32 is preferably 15 or more and 200 or less.

[0027] The first main surface side outer layer portion 12 is located on the first main surface TS1 side of the laminate 10. The first main surface side outer layer portion 12 is an assembly of multiple dielectric layers 20 located between the first main surface TS1 and the internal electrode layer 30 closest to the first main surface TS1. The dielectric layers 20 used in the first main surface side outer layer portion 12 may be the same as the dielectric layers 20 used in the internal layer portion 11.

[0028] The second main surface side outer layer portion 13 is located on the second main surface TS2 side of the laminate 10. The second main surface side outer layer portion 13 is an assembly of multiple dielectric layers 20 located between the second main surface TS2 and the internal electrode layer 30 closest to the second main surface TS2. The dielectric layers 20 used in the second main surface side outer layer portion 13 may be the same as the dielectric layers 20 used in the internal layer portion 11.

[0029] The laminate 10 has a counter electrode portion 11E. The counter electrode portion 11E is a portion where the first counter portion 31A of the first internal electrode layer 31 and the second counter portion 32A of the second internal electrode layer 32 face each other. The counter electrode portion 11E is configured as a part of the inner layer portion 11. FIG. 4 shows the range of the counter electrode portion 11E in the width direction W and the length direction L. The counter electrode portion 11E is also called the effective portion of the capacitor.

[0030] The laminate 10 has a side surface outer layer portion WG. The side surface outer layer portion WG has a first side surface outer layer portion WG1 and a second side surface outer layer portion WG2. The first side surface outer layer portion WG1 is a portion including the dielectric layer 20 located between the counter electrode portion 11E and the first side surface WS1. The second side surface outer layer portion WG2 is a portion including the dielectric layer 20 located between the counter electrode portion 11E and the second side surface WS2. Figures 3 and 4 show the ranges in the width direction W of the first side surface outer layer portion WG1 and the second side surface outer layer portion WG2. The side surface outer layer portion WG is also referred to as a W gap or a side gap.

[0031] The laminate 10 has an end surface side outer layer portion LG. The end surface side outer layer portion LG has a first end surface side outer layer portion LG1 and a second end surface side outer layer portion LG2. The first end surface side outer layer portion LG1 is a portion including the dielectric layer 20 located between the counter electrode portion 11E and the first end surface LS1. The second end surface side outer layer portion LG2 is a portion including the dielectric layer 20 located between the counter electrode portion 11E and the second end surface LS2. Figures 2 and 4 show the ranges in the length direction L of the first end surface side outer layer portion LG1 and the second end surface side outer layer portion LG2. The end surface side outer layer portion LG is also referred to as an L gap or end gap.

[0032] The external electrode 40 has a first external electrode 40A arranged on the first end face LS1 side and a second external electrode 40B arranged on the second end face LS2 side.

[0033] The first external electrode 40A is disposed on the first end face LS1. The first external electrode 40A is connected to the first internal electrode layer 31. The first external electrode 40A may also be disposed on a portion of the first main surface TS1 and a portion of the second main surface TS2, as well as a portion of the first side surface WS1 and a portion of the second side surface WS2. In this embodiment, the first external electrode 40A is formed to extend from the first end face LS1 to a portion of the first main surface TS1 and a portion of the second main surface TS2, as well as a portion of the first side surface WS1 and a portion of the second side surface WS2.

[0034] The second external electrode 40B is disposed on the second end face LS2. The second external electrode 40B is connected to the second internal electrode layer 32. The second external electrode 40B may also be disposed on a portion of the first main surface TS1 and a portion of the second main surface TS2, as well as a portion of the first side surface WS1 and a portion of the second side surface WS2. In this embodiment, the second external electrode 40B is formed to extend from the second end face LS2 to a portion of the first main surface TS1 and a portion of the second main surface TS2, as well as a portion of the first side surface WS1 and a portion of the second side surface WS2.

[0035] As described above, in the laminate 10, the first opposing portion 31A of the first internal electrode layer 31 and the second opposing portion 32A of the second internal electrode layer 32 face each other via the dielectric layer 20, thereby forming a capacitance. Therefore, the characteristics of a capacitor are exhibited between the first external electrode 40A connected to the first internal electrode layer 31 and the second external electrode 40B connected to the second internal electrode layer 32.

[0036] The first external electrode 40A is composed of multiple layers including a first conductive resin layer 60A and a first plating layer 70A disposed on the first conductive resin layer 60A. In this embodiment, the first external electrode 40A has a first base electrode layer 50A, a first conductive resin layer 60A disposed on the first base electrode layer 50A, and a first plating layer 70A disposed on the first conductive resin layer 60A. The first plating layer 70A has a first Ni plating layer 71A as a lower plating layer and a first Sn plating layer 72A as an upper plating layer.

[0037] The second external electrode 40B is composed of multiple layers including a second conductive resin layer 60B and a second plating layer 70B disposed on the second conductive resin layer 60B. In this embodiment, the second external electrode 40B has a second base electrode layer 50B, a second conductive resin layer 60B disposed on the second base electrode layer 50B, and a second plating layer 70B disposed on the second conductive resin layer 60B. The second plating layer 70B has a second Ni plating layer 71B as a lower plating layer and a second Sn plating layer 72B as an upper plating layer.

[0038] The layers constituting the first external electrode 40A and the second external electrode 40B have the same basic configuration. The first external electrode 40A and the second external electrode 40B are generally symmetrical with respect to a WT cross section at the center of the longitudinal direction L of the multilayer ceramic capacitor 1. Therefore, when there is no need to distinguish between the first external electrode 40A and the second external electrode 40B, they may be collectively referred to as the external electrode 40. When there is no need to distinguish between the first base electrode layer 50A and the second base electrode layer 50B, they may be collectively referred to as the base electrode layer 50. When there is no need to distinguish between the first conductive resin layer 60A and the second conductive resin layer 60B, they may be collectively referred to as the conductive resin layer 60. When there is no need to distinguish between the first plating layer 70A and the second plating layer 70B, they may be collectively referred to as the plating layer 70. Furthermore, when there is no need to particularly distinguish between the first Ni plating layer 71A and the second Ni plating layer 71B, they may be collectively referred to as the Ni plating layer 71. Furthermore, when there is no need to particularly distinguish between the first Sn plating layer 72A and the second Sn plating layer 72B, they may be collectively referred to as the Sn plating layer 72.

[0039] The base electrode layer 50 includes a first base electrode layer 50A and a second base electrode layer 50B.

[0040] The first base electrode layer 50A is disposed on the first end face LS1. The first base electrode layer 50A is connected to the first internal electrode layer 31. In this embodiment, the first base electrode layer 50A is formed to extend from the first end face LS1 to a portion of the first main surface TS1, a portion of the second main surface TS2, and a portion of the first side surface WS1 and a portion of the second side surface WS2.

[0041] The second base electrode layer 50B is disposed on the second end face LS2. The second base electrode layer 50B is connected to the second internal electrode layer 32. In this embodiment, the second base electrode layer 50B is formed to extend from the second end face LS2 to a part of the first main surface TS1, a part of the second main surface TS2, a part of the first side surface WS1, and a part of the second side surface WS2.

[0042] In this embodiment, the base electrode layer 50 is a baking layer. The baking layer contains a glass component and a metal. The glass component of the baking layer contains at least one selected from B, Si, Ba, Mg, Al, Li, etc. The metal of the baking layer contains at least one selected from Cu, Ni, Ag, Pd, Ag-Pd alloy, Au, etc. The baking layer is formed by applying a conductive paste containing glass and a metal to a laminate and baking it. The baking layer may be formed by simultaneously firing a laminated chip having internal electrode layers and dielectric layers with a conductive paste applied to the laminated chip, or by firing a laminated chip having internal electrode layers and dielectric layers to obtain a laminate, and then applying a conductive paste to the laminate and baking it. Note that when a laminated chip having internal electrode layers 30 and dielectric layers 20 is simultaneously fired with a conductive paste applied to the laminated chip, it is preferable to form the baking layer by adding a dielectric material instead of the glass component and baking it. The baking layer may be multi-layered.

[0043] The thickness in the longitudinal direction of the first base electrode layer 50A located on the first end surface LS1 is preferably, for example, approximately 3 μm or more and 160 μm or less at the center in the stacking direction T and width direction W of the first base electrode layer 50A.

[0044] The thickness in the longitudinal direction of the second base electrode layer 50B located on the second end surface LS2 is preferably, for example, approximately 3 μm or more and 160 μm or less at the center in the stacking direction T and width direction W of the second base electrode layer 50B.

[0045] When the first base electrode layer 50A is provided on a portion of the first main surface TS1 and a portion of the second main surface TS2, the thickness in the stacking direction of the first base electrode layer 50A provided on this portion is preferably, for example, approximately 3 μm or more and 40 μm or less at the center in the length direction L and width direction W of the first base electrode layer 50A provided on this portion.

[0046] When the first base electrode layer 50A is provided on a portion of the first side surface WS1 and a portion of the second side surface WS2, the widthwise thickness of the first base electrode layer 50A provided on this portion is preferably, for example, approximately 3 μm or more and 40 μm or less at the center in the length direction L and stacking direction T of the first base electrode layer 50A provided on this portion.

[0047] When the second base electrode layer 50B is provided on a portion of the first main surface TS1 and a portion of the second main surface TS2, the thickness in the stacking direction of the second base electrode layer 50B provided on this portion is preferably, for example, approximately 3 μm or more and 40 μm or less at the center in the length direction L and width direction W of the second base electrode layer 50B provided on this portion.

[0048] When the second base electrode layer 50B is provided on a portion of the first side surface WS1 and a portion of the second side surface WS2, the widthwise thickness of the second base electrode layer 50B provided on this portion is preferably, for example, approximately 3 μm or more and 40 μm or less at the center in the length direction L and stacking direction T of the second base electrode layer 50B provided on this portion.

[0049] The base electrode layer 50 is not limited to a baked layer, but may be a thin film layer. The thin film layer is a layer of 1 μm or less in thickness formed by a thin film formation method such as sputtering or vapor deposition, and is formed by depositing metal particles. The base electrode layer 50 may be omitted, and a conductive resin layer 60 (described below) may be disposed directly on the laminate 10.

[0050] The conductive resin layer 60 has a first conductive resin layer 60A and a second conductive resin layer 60B.

[0051] The first conductive resin layer 60A is disposed so as to cover the first base electrode layer 50A. The second conductive resin layer 60B is disposed so as to cover the second base electrode layer 50B.

[0052] The longitudinal thickness of the first conductive resin layer 60A located on the first end face LS1 side is preferably, for example, approximately 50 μm or more and 150 μm or less at the center of the first conductive resin layer 60A in the stacking direction T and width direction W.

[0053] The longitudinal thickness of the second conductive resin layer 60B located on the second end face LS2 side is preferably, for example, approximately 50 μm or more and 150 μm or less at the center of the second conductive resin layer 60B in the stacking direction T and width direction W.

[0054] When the first conductive resin layer 60A is provided on a portion of the first main surface TS1 side and a portion of the second main surface TS2 side, the thickness in the stacking direction of the first conductive resin layer 60A provided on this portion is preferably, for example, approximately 15 μm or more and 60 μm or less at the center in the length direction L and width direction W of the first conductive resin layer 60A provided on this portion.

[0055] When the first conductive resin layer 60A is provided on a portion of the first side surface WS1 side and a portion of the second side surface WS2 side, the widthwise thickness of the first conductive resin layer 60A provided on this portion is preferably, for example, approximately 15 μm or more and 60 μm or less at the center in the length direction L and stacking direction T of the first conductive resin layer 60A provided on this portion.

[0056] When the second conductive resin layer 60B is provided on a portion of the first main surface TS1 side and a portion of the second main surface TS2 side, the thickness in the stacking direction of the second conductive resin layer 60B provided on this portion is preferably, for example, approximately 15 μm or more and 60 μm or less at the center in the length direction L and width direction W of the second conductive resin layer 60B provided on this portion.

[0057] When the second conductive resin layer 60B is provided on a portion of the first side surface WS1 side and a portion of the second side surface WS2 side, the widthwise thickness of the second conductive resin layer 60B provided on this portion is preferably, for example, approximately 15 μm or more and 60 μm or less at the center in the length direction L and stacking direction T of the second conductive resin layer 60B provided on this portion.

[0058] FIG. 5 is an enlarged view of portion V of the multilayer ceramic capacitor shown in FIG. 2, illustrating an outline of the conductive resin layer 60. As described above, the first conductive resin layer 60A and the second conductive resin layer 60B have the same basic configuration, and therefore will be collectively described as the conductive resin layer 60 using FIG. 5. The same applies to the other layers constituting the first external electrode 40A and the second external electrode 40B. As shown in FIG. 5, the conductive resin layer 60 is disposed on the base electrode layer 50. A plating layer 70, which will be described later, is disposed so as to cover the conductive resin layer 60. The plating layer 70 includes a Ni plating layer 71 and a Sn plating layer 72.

[0059] The conductive resin layer 60 has a resin portion 61, conductive filler 62 dispersed within the resin portion 61, and metal particles 63 that are unevenly distributed in the conductive resin layer 60 in a different manner from the conductive filler 62.

[0060] The resin portion 61 of the conductive resin layer 60 may contain at least one selected from various known thermosetting resins, such as epoxy resin, phenoxy resin, phenolic resin, urethane resin, silicone resin, and polyimide resin. Among these, epoxy resin is one of the most suitable resins, due to its excellent heat resistance, moisture resistance, and adhesion. Furthermore, the resin portion 61 of the conductive resin layer 60 preferably contains a curing agent in addition to the thermosetting resin. When an epoxy resin is used as the base resin, the curing agent for the epoxy resin may be any of various known compounds, such as phenolic, amine, acid anhydride, imidazole, active ester, and amide-imide compounds.

[0061] The resin portion 61 contained in the conductive resin layer 60 is preferably contained in an amount of 25 vol % or more and 65 vol % or less with respect to the entire volume of the conductive resin layer 60 .

[0062] Because the conductive resin layer 60 includes the resin portion 61, it is more flexible than a conductive layer made of, for example, a plating film or a fired conductive paste. Therefore, even when the multilayer ceramic capacitor 1 is subjected to a physical shock or a shock due to a thermal cycle, the conductive resin layer 60 functions as a buffer layer. Therefore, the conductive resin layer 60 suppresses the occurrence of cracks in the multilayer ceramic capacitor 1.

[0063] The conductive fillers 62 are dispersed in a substantially uniform distribution within the resin portion 61. The conductive fillers 62 are mainly responsible for the electrical conductivity of the conductive resin layer 60. Specifically, when the plurality of conductive fillers 62 come into contact with each other, a conductive path is formed within the conductive resin layer 60, and electrical continuity is established between the base electrode layer 50 and the plating layer 70. The plurality of conductive fillers 62 also come into contact with each other in the depth direction of FIG. 5 .

[0064] The metal constituting the conductive filler 62 may be Au, Ag, Cu, Ni, Sn, Bi, Zn, or an alloy containing any of these. The conductive filler 62 preferably contains Ag. The conductive filler 62 is, for example, Ag metal powder. Ag has the lowest resistivity of all metals and is therefore suitable as an electrode material. Furthermore, Ag is a noble metal, so it is resistant to oxidation and has high weather resistance. Therefore, Ag metal powder is suitable as the conductive filler 62.

[0065] The conductive filler 62 may also be a metal powder whose surface is coated with Ag. When using a metal powder whose surface is coated with Ag, the metal powder is preferably a powder of Cu, Ni, Sn, Bi, or an alloy thereof. To maintain the properties of Ag while using a cheaper base metal, it is preferable to use an Ag-coated metal powder.

[0066] Furthermore, the conductive filler 62 may be Cu or Ni that has been subjected to an anti-oxidation treatment. Alternatively, the conductive filler 62 may be a metal powder whose surface is coated with Sn, Ni, or Cu. When using metal powder whose surface is coated with Sn, Ni, or Cu, the metal powder is preferably Ag, Cu, Ni, Sn, Bi, or an alloy powder thereof.

[0067] There is no particular limitation on the shape of the conductive filler 62. The conductive filler 62 may be spherical, flat, or the like, but it is preferable to use a mixture of spherical metal powder and flat metal powder.

[0068] The average particle diameter of the conductive filler 62 may be, for example, 0.2 μm or more. The average particle diameter of the conductive filler 62 is preferably 0.5 μm or more and 20 μm or less, and more preferably 1 μm or more and 10 μm or less.

[0069] The conductive filler 62 contained in the conductive resin layer 60 is preferably contained in an amount of 35 vol % or more and 75 vol % or less with respect to the total volume of the conductive resin layer 60. More preferably, it is 40 vol % or more and 60 vol % or less.

[0070] Here, the ratio of the conductive filler 62 to the resin portion 61 is approximately the same on the laminate 10 side of the conductive resin layer 60 and on the plating layer 70 side of the conductive resin layer 60. As will be described later, the conductive resin paste for forming the conductive resin layer 60 is produced by stirring and mixing a thermosetting resin and the conductive filler 62. Therefore, the conductive filler 62 is uniformly dispersed and present in the conductive resin paste. Therefore, even in the conductive resin layer 60 after application and heat treatment, the conductive filler 62 is uniformly dispersed and present in the resin portion 61.

[0071] The metal particles 63 are unevenly distributed in the conductive resin layer 60, with a distribution different from that of the conductive filler 62. The metal particles 63 have the function of improving electrical contact within the conductive resin layer 60 and electrical contact between the conductive resin layer 60 and the plating layer 70.

[0072] Specifically, the plurality of metal particles 63 come into contact with each other, and also come into contact with the conductive fillers 62, thereby increasing the electrical contact between the conductive fillers 62. In other words, the conductive fillers 62 are electrically connected to each other via the metal particles 63, thereby increasing the probability of electrical contact within the conductive resin layer 60. In this way, the metal particles 63 are present between the plurality of conductive fillers 62 in the resin part 61, and form electrical paths between the plurality of conductive fillers 62.

[0073] The ratio of the metal particles 63 to the resin portion 61 is higher on the plating layer 70 side of the conductive resin layer 60 than on the laminate 10 side of the conductive resin layer 60. Specifically, the metal particles 63 are present at a higher density on the surface layer side of the conductive resin layer 60 than on the laminate 10 side. This allows the plating to be well deposited on the surface of the conductive resin layer 60. Therefore, the metal particles 63 in the surface layer of the conductive resin layer 60 and the plating layer 70 are in good contact with each other, thereby increasing the conductivity between the conductive resin layer 60 and the plating layer 70.

[0074] In this way, since the conductive resin layer 60 contains, in addition to the conductive filler 62, metal particles 63 that are unevenly distributed differently from the conductive filler 62, the electrical conductivity in the external electrode 40 is improved, and as a result, the ESR of the multilayer ceramic capacitor 1 is reduced.

[0075] The metal particles 63 are metal particles converted from organometallic complexes or metal ions impregnated in the impregnation step described below, and are in the state of primary metal particles 63 A. When the primary metal particles 63 A are aggregated or otherwise formed into secondary metal particles 63 B, the metal particles 63 refer to these secondary metal particles 63 B or the primary metal particles 63 A that make up these secondary metal particles 63 B.

[0076] Primary metal particles, as defined in JIS H7008:2002 "Terminology for Metallic Particles," refer to particles generated by the growth of a single crystal nucleus. Secondary metal particles, as defined in JIS H7008:2002 "Terminology for Metallic Particles," refer to particles generated by the coalescence, growth, aggregation, solidification, etc. of primary particles.

[0077] The metal particles 63 may contain at least one selected from Au, Pt, Pd, Ag, Cu, etc. The metal particles 63 preferably have low resistivity and are easily reduced and precipitated as a metal after the impregnation step described below. The metal particles 63 preferably contain Pd.

[0078] The metal particles 63 may be made of the same metal as the metal constituting the conductive filler 62. For example, if the metal particles 63 are made of the same metal as the metal constituting the conductive filler 62, potential corrosion due to contact between dissimilar metals can be prevented.

[0079] On the other hand, the metal particles 63 may be a metal different from the metal constituting the conductive filler 62. For example, the metal particles 63 may be a metal having a lower ionization tendency than the metal constituting the conductive filler 62. For example, when the conductive filler 62 contains Ag, the metal particles 63 may be Au, Pt, or Pd. When the conductive filler 62 is Cu, the metal particles 63 may be Au, Pt, Pd, or Ag. Metals with a low ionization tendency are easily reduced after being impregnated in the form of an organometallic complex or metal ions, and are therefore easily precipitated as metals.

[0080] The conductive resin layer 60 may contain a precursor before it becomes the metal particles 63. For example, the conductive resin layer 60 contains an organic metal complex or a metal ion. For example, when Pd is used as the metal particles 63, the conductive resin layer 60 may contain an organic Pd complex (organic palladium complex) or Pd ions (palladium ions).

[0081] As described above, the metal particles 63 include primary metal particles 63A and secondary metal particles 63B composed of the primary metal particles 63A. The primary metal particles 63A are fine metal particles having an average particle diameter smaller than that of the conductive filler 62. The average particle diameter of the primary metal particles 63A is preferably not more than one-tenth of the average particle diameter of the conductive filler 62. The average particle diameter of the primary metal particles 63A may be not more than one-hundredth of the average particle diameter of the conductive filler 62. For example, when the average particle diameter of the conductive filler 62 is 1 μm or more and 10 μm or less, the average particle diameter of the primary metal particles 63A may be 100 nm or less (0.1 μm or less). The average particle diameter of the primary metal particles 63A is preferably 5 nm or more and 50 nm or less (0.005 μm or more and 0.05 μm or less).

[0082] The metal particles 63, in the state of primary metal particles 63A, are sufficiently smaller than the conductive filler 62 and therefore easily enter the gaps between the plurality of conductive fillers 62. Therefore, the metal particles 63 effectively form electrical paths between the plurality of conductive fillers 62. In other words, by using metal particles 63 that are sufficiently smaller than the conductive filler 62, it is possible to improve electrical contact within the conductive resin layer 60 and easily obtain the effect of reducing ESR.

[0083] The metal particles 63 contained in the conductive resin layer 60 are preferably contained in an amount of 0.5 vol % to 20 vol % with respect to the entire volume of the conductive resin layer 60 .

[0084] The abundance ratio of the metal particles 63 to the resin portion 61 is higher on the plating layer 70 side of the conductive resin layer 60 than on the laminate 10 side of the conductive resin layer 60.

[0085] Furthermore, as mentioned above, the conductive filler 62 is dispersed in a substantially uniform distribution within the resin part 61, and therefore the ratio of the metal particles 63 to the conductive filler 62 is higher on the plating layer 70 side of the conductive resin layer 60 than on the laminate 10 side of the conductive resin layer 60.

[0086] As will be described later, the metal particles 63 are disposed in the conductive resin layer 60 by impregnating their precursor into the surface of the resin portion 61 after thermal curing. Therefore, the metal particles 63 are present from the boundary between the conductive resin layer 60 and the plating layer 70 to the laminate 10 side of the conductive resin layer 60. The metal particles 63 are present at a higher density in the conductive resin layer 60 near the boundary between the conductive resin layer 60 and the plating layer 70.

[0087] Hereinafter, a method for measuring various parameters relating to the conductive resin layer 60 in this embodiment will be described.

[0088] A method for measuring the average particle diameter of the conductive filler 62 will be described. Here, the average particle diameter refers to the number-based arithmetic mean area diameter. First, the multilayer ceramic capacitor 1 including the external electrodes 40 is processed into a thin piece by focused ion beam (FIB) processing. Next, this thin piece sample is imaged using a transmission electron microscope (TEM) or a scanning electron microscope (SEM). The captured TEM or SEM image is then analyzed to detect the boundaries of the conductive filler 62 in the conductive resin layer 60 of the external electrodes 40. Note that the transmission electron microscope (TEM) or scanning electron microscope (SEM) appropriate for the sample is used. Next, the area-equivalent diameter based on the cross-sectional area of ​​the conductive filler 62 whose boundaries have been detected is calculated as the particle diameter of the conductive filler 62. Then, the particle diameters of the multiple conductive fillers 62 present in the measurement area are calculated, and the number-based arithmetic mean is calculated as the average particle diameter. The measurement area can be appropriately set so that the number of conductive fillers 62 in the measurement area is approximately 30 to 300. Then, the average particle size is calculated based on the particle sizes of 30 or more conductive fillers 62.

[0089] A method for measuring the average particle diameter of the metal primary particles 63A will be described. First, the multilayer ceramic capacitor 1 including the external electrodes 40 is processed into a thin piece by FIB processing. Next, this thin piece sample is imaged using a TEM or SEM. The captured TEM or SEM image is then analyzed to detect the boundaries of the metal primary particles 63A in the conductive resin layer 60 of the external electrodes 40. TEM or SEM is used, whichever is appropriate for the sample. Next, the area-equivalent diameter based on the cross-sectional area of ​​the metal primary particles 63A whose boundaries have been detected is calculated as the particle diameter of the metal primary particles 63A. Then, the particle diameters of the metal primary particles 63A present within a measurement region within the imaging range are calculated, and the number-based arithmetic mean is calculated as the average particle diameter. The measurement region can be appropriately set so that the number of metal primary particles 63A within the measurement region is approximately 30 to 300. The average particle diameter is then calculated based on the particle diameters of 30 or more metal primary particles 63A. The metal particles 63 to be measured for particle diameter are those that can be identified as primary metal particles 63 A. When the primary metal particles 63 A that make up the secondary metal particles 63 B can be identified, the particle diameter of the identified primary metal particles 63 A is measured.

[0090] The method for measuring the abundance ratio of the conductive filler 62 and the abundance ratio of the metal particles 63 will be described. First, the multilayer ceramic capacitor 1 including the external electrodes 40 is processed into a thin film by FIB processing. Next, this thin film sample is imaged using a TEM. The captured TEM image is then analyzed to distinguish the resin portion 61, the conductive filler 62, and the metal particles 63. Here, since the conductive filler 62 and the metal particles 63 have different average particle diameters, the conductive filler 62 and the metal particles 63 are distinguished based on size information on the TEM image, etc. The distinguishing process may be automatic or manual. Note that if the shapes of the conductive filler 62 and the metal particles 63 are different, the conductive filler 62 and the metal particles 63 may be distinguished using a shape coefficient. Furthermore, if the materials of the conductive filler 62 and the metal particles 63 are different, the conductive filler 62 and the metal particles 63 may be distinguished using mapping by an electron microprobe analyzer (EPMA). These determination methods can also be used when measuring the conductive filler 62 or the average particle diameter described above.

[0091] Then, by taking the ratio of the area of ​​the portion showing the conductive filler 62 to the area of ​​the portion showing the resin portion 61 in the TEM image, the abundance ratio of the metal particles 63 to the resin portion 61 is calculated. Also, by taking the ratio of the area of ​​the portion showing the metal particles 63 to the area of ​​the portion showing the resin portion 61 in the TEM image, the abundance ratio of the metal particles 63 to the resin portion 61 is calculated. Also, by taking the ratio of the area of ​​the portion showing the metal particles 63 to the area of ​​the portion showing the conductive filler in the TEM image, the abundance ratio of the metal particles 63 to the conductive filler 62 is calculated.

[0092] These abundance ratios can be calculated, for example, by dividing the conductive resin layer 60 equally into two parts in the thickness direction and calculating them for each divided area. This allows, for example, the abundance ratio of the metal particles 63 to the resin portion 61 in the area on the side of the arrow J in FIG. 5 , i.e., the laminate 10 side of the conductive resin layer 60, to be calculated, and the abundance ratio of the metal particles 63 to the resin portion 61 in the area on the side of the arrow K in FIG. 5 , i.e., the plating layer 70 side of the conductive resin layer 60, to be calculated, and these abundance ratios can be compared. Note that in this embodiment, when the conductive resin layer 60 is divided equally into thirds or fourths in the thickness direction, the abundance ratio of the metal particles 63 to the resin portion 61 increases toward the plating layer 70 side of the conductive resin layer 60. Note that when calculating each abundance ratio, the TEM measurement area in each divided area is set to the same size. For example, when calculating the abundance ratio of the metal particles 63 to the resin portion 61, the measurement area is set to, for example, 0.5 μm × 0.5 μm regardless of which divided area is used for measurement.

[0093] The plating layer 70 includes a first plating layer 70A and a second plating layer 70B.

[0094] The first plating layer 70A is disposed so as to cover the first conductive resin layer 60A. The second plating layer 70B is disposed so as to cover the second conductive resin layer 60B.

[0095] The plating layer 70 may contain at least one selected from, for example, Cu, Ni, Sn, Ag, Pd, an Ag-Pd alloy, Au, etc. The plating layer 70 may be formed of multiple layers. The plating layer 70 preferably has a two-layer structure consisting of a Ni plating layer 71 and a Sn plating layer 72. The Ni plating layer 71 prevents the base electrode layer 50 and the conductive resin layer 60 from being eroded by solder when mounting the multilayer ceramic capacitor 1. The Sn plating layer 72 improves the wettability of the solder when mounting the multilayer ceramic capacitor 1. This makes it easier to mount the multilayer ceramic capacitor 1.

[0096] In this embodiment, the first plating layer 70A has a two-layer structure consisting of a Ni plating layer 71A as a lower plating layer and a Sn plating layer 72A as an upper plating layer, while the second plating layer 70B has a two-layer structure consisting of a Ni plating layer 71B as a lower plating layer and a Sn plating layer 72B as an upper plating layer.

[0097] The thickness of each of the Ni plating layer 71A and the Sn plating layer 72A is preferably 1 μm or more and 15 μm or less.

[0098] In this embodiment, the conductive resin layer 60, which is the layer below the plating layer 70, contains the aforementioned conductive filler 62 and metal particles 63, so that the plating layer 70 adheres well to the conductive resin layer 60.

[0099] As described above, the multilayer ceramic capacitor 1 of this embodiment has a laminate 10 including a plurality of laminated dielectric layers 20 and a plurality of laminated internal electrode layers 30, and an external electrode 40 connected to the internal electrode layer 30, and the external electrode 40 has a conductive resin layer 60 and a plating layer 70 arranged on the conductive resin layer 60, and the conductive resin layer 60 has a resin portion 61, conductive filler 62 dispersed within the resin portion 61, and metal particles 63 that are unevenly distributed in the conductive resin layer 60 and different from the conductive filler 62, and the abundance ratio of the metal particles 63 to the resin portion 61 is higher on the plating layer 70 side of the conductive resin layer 60 than on the laminate 10 side of the conductive resin layer 60.

[0100] More specifically, the multilayer ceramic capacitor 1 of this embodiment includes a laminate 10 including a plurality of laminated dielectric layers 20 and a plurality of laminated internal electrode layers 30, and including a first main surface TS1 and a second main surface TS2 facing in the stacking direction T, a first side surface WS1 and a second side surface WS2 facing in the width direction W perpendicular to the stacking direction T, and a first end face LS1 and a second end face LS2 facing in the length direction L perpendicular to the stacking direction T and the width direction W, a first external electrode 40A arranged on the first end face LS1, and a second external electrode 40B arranged on the second end face LS2, and the plurality of internal electrode layers 30 include a first internal electrode layer 31 exposed at the first end face LS1 of the laminate 10 and connected to the first external electrode 40A, and a second internal electrode layer 32 exposed at the second end face of the laminate 10 and connected to the second external electrode 40B, The electrode 40A has a first conductive resin layer 60A and a first plating layer 70A disposed on the first conductive resin layer 60A, and the second external electrode 40B has a second conductive resin layer 60B and a second plating layer 70B disposed on the second conductive resin layer 60B. The first conductive resin layer 60A and the second conductive resin layer 60B each have a resin portion 61, conductive fillers 62 dispersed in the resin portion 61, and a first conductive layer 70A. and metal particles 63 which are unevenly distributed in the conductive resin layer 60A and the second conductive resin layer 60B, different from the conductive filler 62, and the abundance ratio of the metal particles 63 to the resin portion 61 is higher on the plating layer 70 side of the first conductive resin layer 60A than on the laminate 10 side of the first conductive resin layer 60A, and is higher on the plating layer 70 side of the second conductive resin layer 60B than on the laminate 10 side of the second conductive resin layer 60B.

[0101] If the lengthwise dimension of the multilayer ceramic capacitor 1 including the laminate 10 and the external electrodes 40 is defined as L, then the L dimension is preferably 0.2 mm or more and 10 mm or less. If the lengthwise dimension of the multilayer ceramic capacitor 1 in the stacking direction is defined as T, then the T dimension is preferably 0.1 mm or more and 10 mm or less. The widthwise dimension of the multilayer ceramic capacitor 1 is defined as W. The W dimension is preferably 0.1 mm or more and 10 mm or less.

[0102] Next, a method for manufacturing the multilayer ceramic capacitor 1 of this embodiment will be described.

[0103] A dielectric sheet for the dielectric layer 20 and a conductive paste for the internal electrode layer 30 are prepared. The dielectric sheet and the conductive paste for the internal electrode contain a binder and a solvent. The binder and the solvent may be known.

[0104] On the dielectric sheets, a conductive paste for the internal electrode layers 30 is printed in a predetermined pattern by, for example, screen printing or gravure printing. In this way, a dielectric sheet on which the pattern of the first internal electrode layer 31 is formed and a dielectric sheet on which the pattern of the second internal electrode layer 32 is formed are prepared.

[0105] A predetermined number of dielectric sheets on which the pattern of the internal electrode layer is not printed are stacked to form a portion that will become the first main surface-side outer layer portion 12 on the first main surface TS1 side. A dielectric sheet on which the pattern of the first internal electrode layer 31 and a dielectric sheet on which the pattern of the second internal electrode layer 32 are printed are stacked in this order on top of that to form a portion that will become the internal layer portion 11. A predetermined number of dielectric sheets on which the pattern of the internal electrode layer is not printed are stacked on top of this portion that will become the second main surface-side outer layer portion 13 on the second main surface TS2 side. In this way, a laminated sheet is produced.

[0106] The laminated sheets are pressed in the lamination direction by means of a hydrostatic press or the like to produce a laminated block.

[0107] The laminated block is cut to a predetermined size to obtain laminated chips, and at this time, corners and ridges of the laminated chips may be rounded by barrel polishing or the like.

[0108] The laminated chip is fired to produce the laminate 10. The firing temperature depends on the materials of the dielectric layers 20 and the internal electrode layers 30, but is preferably 900°C or higher and 1400°C or lower.

[0109] A conductive paste that will become the base electrode layer 50 is applied to both end surfaces of the laminate 10. In this embodiment, the base electrode layer 50 is a baked layer. A conductive paste containing a glass component and a metal is applied to the laminate 10 by a method such as dipping. A baking process is then performed to form the base electrode layer 50. The temperature of the baking process at this time is preferably 700°C or higher and 900°C or lower.

[0110] Next, the conductive resin layer 60 is formed. The conductive resin layer 60 may be formed on the surface of the base electrode layer 50, or may be formed directly on the laminate 10. In this embodiment, the conductive resin layer 60 is formed on the surface of the base electrode layer 50.

[0111] First, a conductive resin paste is prepared by dispersing conductive filler 62 in a thermosetting resin as a base resin for the resin portion 61. This conductive resin paste is produced by stirring and mixing the thermosetting resin and the conductive filler 62. Therefore, the conductive filler 62 is uniformly dispersed within the conductive resin paste. Here, the thermosetting resin is, for example, an epoxy resin. The conductive filler 62 is, for example, Ag metal powder.

[0112] Thereafter, a conductive resin paste is applied onto the base electrode layer 50 and subjected to a heat treatment at a temperature of 250°C to 550°C, inclusive. This thermally hardens the resin portion 61. The atmosphere during this heat treatment is preferably an air atmosphere or an N2 atmosphere. Furthermore, to prevent the resin from scattering and to prevent the metal components constituting the conductive filler 62 from oxidizing, it is preferable that the oxygen concentration be kept below 100 ppm.

[0113] The conductive filler 62 is dispersed and present with a uniform distribution even in the heat-cured resin portion 61. Therefore, the ratio of the conductive filler 62 to the resin portion 61 is approximately the same on the laminate 10 side of the conductive resin layer 60 and on the side of the conductive resin layer 60 where the plating layer 70 is applied.

[0114] Next, the resin portion 61 after thermal curing is impregnated with an organometallic complex or metal ions that are converted into metal particles 63 .

[0115] For example, the laminate 10 provided with the resin portion 61 is exposed to an atmosphere of a supercritical fluid in which an organometallic complex is dissolved, thereby simultaneously causing the resin portion 61 to swell and the swollen resin portion 61 to be impregnated with the organometallic complex.

[0116] The supercritical fluid may contain at least one selected from supercritical fluids such as CO2, N2, and H2O. Preferably, the supercritical fluid is supercritical CO2, which has high solubility. The critical temperature of CO2 is 31°C, and the critical pressure is 73 atmospheres. The supercritical CO2 comes into contact with the resin part 61 under conditions of above its critical temperature and above its critical pressure. A syringe pump, for example, is used as a supercritical fluid generator.

[0117] The organometallic complex may be any metal that dissolves in a supercritical fluid, and may be, for example, an organometallic complex containing Au, Pt, Pd, Ag, or Cu, although the organometallic complex is preferably an organic Pd complex (organic palladium complex).

[0118] The organometallic complex is dissolved in a supercritical fluid, and then the supercritical fluid is brought into contact with the resin portion 61. Alternatively, the organometallic complex may be dissolved in the supercritical fluid while the supercritical fluid is brought into contact with the resin portion 61. The method for bringing the supercritical fluid into contact with the resin portion 61 is not particularly limited. For example, the laminate 10 including the resin portion 61 is left in a pressure-resistant container for a certain period of time so that the resin portion 61 comes into contact with the supercritical fluid in which the organometallic complex is dissolved. This allows the resin portion 61 to be impregnated with the organometallic complex.

[0119] By the impregnation process, the organometallic complex penetrates into the resin part 61 and is also arranged in the gaps between the plurality of conductive fillers 62. Furthermore, the organometallic complex is arranged more densely near the surface of the resin part 61 than on the laminate 10 side of the resin part 61.

[0120] The organometallic complexes arranged near the surface of the resin part 61 and the organometallic complexes that have permeated into the interior of the resin part 61 are then reduced by heat treatment or chemical reduction treatment and converted into metal particles 63. As a result, a conductive resin layer 60 containing the metal particles 63 is formed.

[0121] By the treatment using such a supercritical fluid and an organometallic complex, the metal particles 63 are present at a high density on the side of the conductive resin layer 60 where the plating layer 70 is applied. Moreover, the metal particles 63 are present at a lower density on the side of the conductive resin layer 60 where the laminate 10 is applied than on the side where the plating layer 70 is applied.

[0122] Instead of the treatment using a supercritical fluid and an organometallic complex, a treatment using a solution in which metal ions are dissolved can also be employed.

[0123] In this case, first, a swelling treatment using an organic solution or the like is performed on the resin portion 61 provided on the laminate 10. Next, the swollen resin portion 61 is immersed in a solution in which metal ions are dissolved. As a result, the metal ions that are converted into metal particles 63 are impregnated into the resin portion 61 after thermal curing.

[0124] The impregnated metal ions may be, for example, Au, Pt, Pd, Ag, or Cu ions. However, the metal ions are preferably Pd ions (palladium ions). The metal ions are preferably monovalent or more and tetravalent or less. When Pd ions are used, divalent Pd ions are preferably used.

[0125] The metal ions present on the surface of the resin portion 61 and the metal ions that have penetrated into the resin portion 61 are then reduced by a heat treatment or a chemical reduction treatment and converted into metal particles 63. As a result, a conductive resin layer 60 containing the metal particles 63 is formed.

[0126] Even with the treatment using such a solution in which metal ions are dissolved, the metal particles 63 are present at a high density on the side of the conductive resin layer 60 on which the plating layer 70 is applied. Moreover, the metal particles 63 are present at a lower density on the side of the conductive resin layer 60 on which the laminate 10 is applied than on the side on which the plating layer 70 is applied.

[0127] The organometallic complex and metal ions used in the impregnation treatment and converted into the metal particles 63 are much smaller than the conductive filler 62, and therefore can easily penetrate into the gaps between the plurality of conductive fillers 62 by the impregnation treatment. Therefore, the metal particles 63 converted from the organometallic complex and metal ions can easily form electrical paths between the plurality of conductive fillers 62.

[0128] The metal particles 63 used for impregnation include Au, Pt, Pd, Ag, and Cu, preferably Au, Pt, and Pd. Pd is more preferred. However, these metals are expensive. Therefore, if the metal particles 63 are mixed with the base resin during the production of the conductive resin paste, the metal particles 63, like the conductive filler 62, will be uniformly dispersed throughout the conductive resin paste. This results in many metal particles 63 in locations that are unlikely to contribute to reducing ESR and improving plating adhesion, leading to increased costs. However, by impregnating the resin portion 61 with an organometallic complex or metal ions that convert into metal particles 63 after curing, it is possible to reduce the amount of metal particles 63 used and prevent costs from increasing while still achieving a lower ESR and improving plating adhesion.

[0129] In particular, when the conductive filler 62 contained in the conductive resin layer 60 is contained in an amount of 35 vol% or more and 75 vol% or less, more preferably 40 vol% or more and 60 vol% or less, relative to the total volume of the conductive resin layer 60, impregnating the resin part 61 of the conductive resin layer 60 with an organometallic complex or metal ion, which is a precursor of the metal particles 63, can more effectively achieve a low ESR and improve plating defects while suppressing cost increases.

[0130] Thereafter, a plating layer 70 is formed on the surface of the conductive resin layer 60. In this embodiment, a Ni plating layer 71 and a Sn plating layer 72 are formed on the conductive resin layer 60. The Ni plating layer 71 and the Sn plating layer 72 are formed in this order by, for example, barrel plating. By the above manufacturing method, the multilayer ceramic capacitor 1 is manufactured.

[0131] As described above, the manufacturing method of the multilayer ceramic capacitor 1 of this embodiment includes the steps of stirring and mixing the conductive filler 62 to disperse it in the base resin that will become the resin portion 61 of the conductive resin layer 60, applying the base resin with the dispersed conductive filler 62 to the exposed portion of the internal electrode layer 30 of the laminate 10, curing the applied base resin to form the resin portion 61, bringing the resin portion 61 into contact with a solvent in which an organometallic complex or metal ions that are converted into metal particles 63 are dissolved, thereby impregnating the resin portion 61 with the organometallic complex or metal ions, and reducing the impregnated organometallic complex or metal ions to form a conductive path between the conductive fillers 62 using the metal particles 63.

[0132] The configuration of the multilayer ceramic capacitor 1 is not limited to the configurations shown in Figures 1 to 4. For example, the multilayer ceramic capacitor 1 may be a multilayer ceramic capacitor having a double structure, a triple structure, or a quadruple structure as shown in Figures 6A, 6B, and 6C.

[0133] The multilayer ceramic capacitor 1 shown in FIG. 6A is a double-structure multilayer ceramic capacitor 1, and includes, as the internal electrode layers 30, a first internal electrode layer 33, a second internal electrode layer 34, and a floating internal electrode layer 35 that is not extended to either the first end face LS1 or the second end face LS2. The multilayer ceramic capacitor 1 shown in FIG. 6B is a triple-structure multilayer ceramic capacitor 1, which includes a first floating internal electrode layer 35A and a second floating internal electrode layer 35B as the floating internal electrode layers 35. The multilayer ceramic capacitor 1 shown in FIG. 6C is a quadruple-structure multilayer ceramic capacitor 1, which includes a first floating internal electrode layer 35A, a second floating internal electrode layer 35B, and a third floating internal electrode layer 35C as the floating internal electrode layers 35. By providing the floating internal electrode layers 35 as the internal electrode layers 30, the multilayer ceramic capacitor 1 has a structure in which the opposing electrode portion is divided into multiple parts. As a result, multiple capacitor components are formed between the opposing internal electrode layers 30, and these capacitor components are connected in series. This reduces the voltage applied to each capacitor component, thereby achieving a high withstand voltage for the multilayer ceramic capacitor 1. It goes without saying that the multilayer ceramic capacitor 1 of this embodiment may have a multi-row structure of four or more rows.

[0134] The multilayer ceramic capacitor 1 may be a two-terminal type having two external electrodes, or may be a multi-terminal type having many external electrodes.

[0135] The multilayer ceramic capacitor 1 of this embodiment provides the following effects.

[0136] (1) The multilayer ceramic capacitor 1 according to this embodiment is a multilayer ceramic capacitor 1 having a laminate 10 including a plurality of laminated dielectric layers 20 and a plurality of laminated internal electrode layers 30, and an external electrode 40 connected to the internal electrode layer 30, wherein the external electrode 40 has a conductive resin layer 60 and a plating layer 70 disposed on the conductive resin layer 60, and the conductive resin layer 60 has a resin portion 61, conductive filler 62 dispersed within the resin portion 61, and metal particles 63 that are unevenly distributed in the conductive resin layer 60 and different from the conductive filler 62, and the abundance ratio of the metal particles 63 to the resin portion 61 is higher on the plating layer 70 side of the conductive resin layer 60 than on the laminate 10 side of the conductive resin layer 60.

[0137] This can reduce ESR by improving electrical contact within the conductive resin layer 60 and electrical contact between the conductive resin layer 60 and the plating layer 70. Furthermore, since the multilayer ceramic capacitor 1 has metal particles 63 that are biased toward the plating layer 70 side of the conductive resin layer 60, the occurrence of plating defects is suppressed, and the occurrence of solder explosion defects associated with plating defects is also suppressed.

[0138] (2) In the multilayer ceramic capacitor 1 of this embodiment, the ratio of the conductive filler 62 to the resin portion 61 is approximately the same on the laminate 10 side of the conductive resin layer 60 and on the plating layer 70 side of the conductive resin layer 60.

[0139] Even if the conductive filler 62 is uniformly dispersed within the conductive resin layer 60, the above-mentioned effect can be obtained because the conductive resin layer 60 contains metal particles 63 that are unevenly distributed differently from the conductive filler 62.

[0140] (3) In the multilayer ceramic capacitor 1 of this embodiment, the abundance ratio of the metal particles 63 to the conductive filler 62 is higher on the plating layer 70 side of the conductive resin layer 60 than on the laminate 10 side of the conductive resin layer 60.

[0141] For example, even if the amount of conductive filler 62 in the conductive resin layer 60 is relatively small, the ratio of metal particles 63 to conductive filler 62 is increased on the plating layer side of the conductive resin layer 60, and therefore the presence of both the conductive filler 62 and the metal particles 63 suppresses the occurrence of poor plating.

[0142] (4) The metal particles 63 of the multilayer ceramic capacitor 1 of this embodiment include primary metal particles 63A and secondary metal particles 63B composed of the primary metal particles 63A, and the average particle diameter of the primary metal particles 63A is one-tenth or less of the average particle diameter of the conductive filler 62.

[0143] Because the metal particles 63 are sufficiently smaller than the conductive fillers 62, the metal particles 63 can easily enter between the plurality of conductive fillers 62. Therefore, the metal particles 63 effectively form electrical paths between the plurality of conductive fillers 62. This makes it possible to achieve a low ESR.

[0144] (5) The conductive filler 62 of the multilayer ceramic capacitor 1 of this embodiment has an average particle diameter of 1 μm or more.

[0145] Even when conductive fillers 62 with an average particle diameter of 1 μm or more are used, by using metal particles 63 that are sufficiently smaller than the conductive fillers 62, the metal particles 63 can easily enter between the plurality of conductive fillers 62. Therefore, the metal particles 63 can easily form electrical paths between the plurality of conductive fillers 62. This makes it possible to achieve a low ESR.

[0146] (6) The average particle size of the primary metal particles 63A of the multilayer ceramic capacitor 1 of this embodiment is 0.1 μm or less.

[0147] Since the metal particles 63 are composed of primary metal particles 63A with an average particle diameter of 0.1 μm or less, the metal particles 63 can easily enter between the plurality of conductive fillers 62. Therefore, the metal particles 63 can easily form electrical paths between the plurality of conductive fillers 62. This can reduce the ESR.

[0148] (7) In the multilayer ceramic capacitor 1 of this embodiment, the metal particles 63 are disposed between the conductive fillers 62 in the resin portion 61 and form electrical paths between the conductive fillers 62 .

[0149] The metal particles 63 are disposed between the conductive fillers 62 and form current paths between the conductive fillers 62, thereby achieving a low ESR.

[0150] (8) The ionization tendency of the metal particles 63 in the multilayer ceramic capacitor 1 of this embodiment is lower than the ionization tendency of the conductive filler 62 .

[0151] Metals with low ionization tendency are easily reduced after being impregnated in the form of organometallic complexes or metal ions, and are therefore easily precipitated as metals. Therefore, even when the relationship with the ionization tendency of the conductive filler 62 is taken into consideration, the metal particles 63 are easily precipitated as metals, and form current paths with good electrical conductivity.

[0152] (9) The conductive resin layer 60 of the multilayer ceramic capacitor 1 of this embodiment contains an organometallic complex or metal ions.

[0153] As long as it is possible to achieve a low ESR, it is acceptable for a certain amount of organometallic complex or metal ions to remain. For example, the preferred conductive resin layer 60 of this embodiment can be formed by contacting the resin portion 61 with a solvent in which the organometallic complex or metal ions that are converted into metal particles 63 are dissolved, thereby impregnating the resin portion 61 with the organometallic complex or metal ions.

[0154] The present invention is not limited to the configurations of the above-described embodiments, and can be appropriately modified and applied within the scope of the present invention. Note that the present invention also includes a combination of two or more of the individual desirable configurations described in the above-described embodiments. [Explanation of symbols]

[0155] 1. Multilayer ceramic capacitors 10 Laminate 11 Inner layer 11E Counter electrode section 12 First main surface side outer layer portion 13 Second main surface side outer layer LS1 First end face LS2 Second end face WS1 First Aspect WS2 Second Aspect TS1 First principal surface TS2 Second principal surface 20 dielectric layer 30 Internal electrode layer 31 First internal electrode layer 31A First opposing part 31B First drawer 32 Second internal electrode layer 32A Second opposing part 32B Second drawer 40 External electrode 40A First outer electrode 40B Second external electrode 50 Base electrode layer 50A First base electrode layer 50B Second base electrode layer 60 Conductive resin layer 60A First conductive resin layer 60B Second conductive resin layer 61 Resin part 62 Conductive filler 63 Metal particles 63A Primary metal particles 63B Metal secondary particles 70 plating layer 70A First plating layer 70B Second plating layer 71 Ni plating layer 71A First Ni plating layer 71B Second Ni plating layer 72 Sn plating layer 72A First Sn plating layer 72B Second Sn plating layer L lengthwise W width direction T Stacking direction

Claims

1. a laminate including a plurality of dielectric layers and a plurality of internal electrode layers stacked together; an external electrode connected to the internal electrode layer, the external electrode has a conductive resin layer and a plating layer disposed on the conductive resin layer, the conductive resin layer has a resin portion, a conductive filler, and metal particles that are unevenly distributed in the conductive resin layer and have a distribution different from that of the conductive filler; When the conductive resin layer is divided into two parts in the thickness direction at the end side of the laminate, one part on the plating layer side and the other part on the laminate side, the conductive filler is present on both the laminate side and the plating layer side, the metal particles are present on both the laminate side and the plating layer side, When the abundance ratio of the metal particles to the resin portion on each of the laminate side and the plating layer side is calculated, The multilayer ceramic capacitor has a higher abundance ratio of the metal particles on the plating layer side than on the laminate side.

2. 2. The multilayer ceramic capacitor according to claim 1, wherein the ratio of the conductive filler to the resin portion is approximately equal between the laminate side of the conductive resin layer and the plating layer side of the conductive resin layer.

3. 3. The multilayer ceramic capacitor according to claim 1, wherein a ratio of the metal particles to the conductive filler is higher on the plating layer side of the conductive resin layer than on the laminate side of the conductive resin layer.

4. the metal particles include metal primary particles and metal secondary particles constituted by the metal primary particles, 4. The multilayer ceramic capacitor according to claim 1, wherein the average particle size of the primary metal particles is not more than one-tenth of the average particle size of the conductive filler.

5. 5. The multilayer ceramic capacitor according to claim 4, wherein the conductive filler has an average particle size of 1 [mu]m or more.

6. 6. The multilayer ceramic capacitor according to claim 4, wherein the average particle size of the primary metal particles is 0.1 μm or less.

7. 7. The multilayer ceramic capacitor according to claim 1, wherein the metal particles are disposed between the conductive fillers in the resin portion to form electrical paths between the conductive fillers.

8. 8. The multilayer ceramic capacitor according to claim 1, wherein the ionization tendency of the metal particles is lower than the ionization tendency of the conductive filler.

9. 9. The multilayer ceramic capacitor according to claim 1, wherein the conductive resin layer contains an organometallic complex or a metal ion.

Images