Multilayer Capacitor Electrode Cutout Structure for Low ESR Durability
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Solution Overview
Problem
Multilayer capacitors used in automotive applications face challenges in durability against external vibrations and deformation, leading to potential cracking and increased equivalent series resistance (ESR) due to the limitations of existing conductive resin layers.
Innovation Solution
A multilayer capacitor design featuring a conductive resin layer with cutout portions that expose edges of the conductive layer, allowing direct contact with a plating layer, and covering only specific corners to enhance durability and reduce ESR, while maintaining flexibility in chip orientation during mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive resin layer completely covers the conductive layer, then protection against external vibrations is improved, but electrical conductivity increases due to increased ESR
Solution Approach 1:
The conductive resin layer is selectively applied to cover only specific corners of the connection portion rather than the entire surface. This local coverage provides vibration protection where most needed at the corners while leaving other areas exposed to maintain electrical conductivity and reduce ESR.
Solution Approach 2:
The conductive resin layer is divided into multiple separate regions, each covering a specific corner area. This segmentation allows different parts of the connection portion to have different levels of protection and conductivity, optimizing both durability and electrical performance.
2Reliability
If the conductive resin layer is made thick to improve vibration resistance, then durability is improved, but flexibility in chip orientation is lost
Solution Approach 1:
The conductive resin layer is applied locally at corner regions rather than uniformly across the entire connection portion. This localized approach provides deformation resistance at critical corners while maintaining overall flexibility and adaptability for different chip orientations.
3Reliability
If the conductive resin layer covers the entire connection portion, then protection is improved, but manufacturing complexity increases
Solution Approach 1:
The conductive resin layer is segmented into discrete corner regions rather than forming a continuous covering. This simplifies the manufacturing process by reducing the complexity of applying and patterning the resin layer while still providing effective protection.
Data Source
AI summary
A multilayer capacitor includes a capacitor body including a dielectric layer and a plurality of internal electrodes, and a pair of external electrodes disposed on opposing ends of the capacitor body and connected to exposed portions of the internal electrodes, wherein the external electrodes respectively include a conductive layer including a connection portion formed on one end surface of the capacitor body and connected to the internal electrode and a band portion extending from the connection portion to a portion of a neighboring surface of the capacitor body, a conductive resin layer covering a corner of the connection portion of the conductive layer and having a cutout portion so that a portion of an edge of the connection portion is exposed, and a plating layer covering the conductive layer and the conductive resin layer and contacting a portion of the conductive layer due to the cutout portion.