Multilayer Capacitor Burned Layer Segmentation for Stress and Insulation
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Solution Overview
Problem
Multilayer capacitors face issues with stress-induced cracks and insulation failures due to the thickness and area of the burned layer, which can lead to infiltration of the plating solution and subsequent insulation failures.
Innovation Solution
A multilayer capacitor design that includes a burned layer covering the lead conductor and part of a dummy electrode, with a plating layer covering the rest of the dummy electrode and burned layer, preventing excessive stress and ensuring a uniform plating layer formation, thereby preventing cracks and insulation failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the burned layer is formed with greater thickness and area to ensure complete coverage, then the coverage reliability is improved, but excessive stress occurs leading to cracks in the multilayer body
Solution Approach 1:
The burned layer is segmented into two distinct parts: a first burned layer covering the lead conductor and a second burned layer covering part of the dummy electrode. This segmentation allows each layer to be optimized independently - the first layer ensures coverage for insulation while the second layer provides stress distribution without excessive thickness
Solution Approach 2:
Different regions of the terminal electrode structure are assigned different burned layer characteristics. The first burned layer has sufficient thickness for insulation reliability, while the second burned layer has controlled thickness to minimize stress. This local quality differentiation resolves the contradiction between coverage reliability and stress resistance
2Strength
If the burned layer area is reduced to minimize stress, then stress-induced cracks are prevented, but plating solution may infiltrate onto the inner electrode causing insulation failure
Solution Approach 1:
The dummy electrode acts as an intermediary element between the lead conductor and the terminal electrode. The second burned layer covers part of this dummy electrode, creating a protective barrier that prevents plating solution infiltration while maintaining manageable stress levels through the distributed layer structure
Solution Approach 2:
The protective coverage is segmented into two functional zones: the first burned layer provides primary insulation protection with adequate thickness, while the second burned layer extends coverage to the dummy electrode with controlled thickness. This segmentation maintains insulation reliability without requiring excessive overall burned layer area
3Manufacturing precision
If the burned layer covers the entire dummy electrode to ensure uniform plating, then plating uniformity is improved, but stress increases causing cracks
Solution Approach 1:
The burned layer coverage is segmented into two parts with different extents: the first burned layer covers the lead conductor completely, while the second burned layer covers only part of the dummy electrode. This segmentation achieves sufficient plating uniformity on critical surfaces without requiring full dummy electrode coverage, thereby reducing stress
Solution Approach 2:
Different coverage extents are applied to different regions based on functional requirements. The lead conductor area receives complete coverage for plating uniformity, while the dummy electrode receives partial coverage sufficient for stress management. This local quality approach balances plating precision with stress resistance
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively prevents cracks and insulation failures by controlling the stress in the burned layer and ensuring reliable plating layer formation, maintaining capacitance stability and reducing Equivalent Series Inductance (ESL).
Implementation Method 1
end parts of which are then dipped into a conductive paste, which is burned thereafter, so as to form terminal electrodes
Implementation Method 2
there is a case where a plating layer is further formed on the burned layer
Data Source
AI summary
In a multilayer capacitor 1, burned layers 17A, 17B are formed so as to cover all of lead conductors 12A, 12B drawn from inner electrodes 6A, 6B to end faces of a multilayer body 2. This can keep a plating solution from infiltrating onto the inner electrodes 6A, 6B when forming plating layers 18A, 18B and prevent insulation failures from occurring. Since the burned layers 17A, 17B cover a part of dummy electrodes 13C, 13F, 13G, 13H, the area of the burned layers 17A, 17B can be suppressed. This can inhibit excessive stresses from occurring in the burned layers 17A, 17B and thus can prevent cracks from being generated by stresses in the burned layers 17A, 17B.