Multilayer Capacitor Extending Electrodes Bending Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Multilayer capacitors used in automotive applications require enhanced electrical reliability and impact resistance, particularly strong resistance to substrate deformation, which existing technologies fail to adequately address.
Innovation Solution
A multilayer capacitor design featuring dielectric layers and internal electrodes with specific extending portions and conductive resin layers, along with external electrodes and plating layers, to enhance bending strength characteristics, where the average thickness of dielectric layers is greater than internal electrodes, and extending portions are formed to increase the overlapping area, improving tensile strength and resistance to bending cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the internal electrodes are made thinner to reduce size, then the capacitor capacity increases, but the bending strength and resistance to deformation decrease
Solution Approach 1:
The patent extends the internal electrodes in the width direction (lateral dimension) beyond the conventional length direction, creating extending portions that overlap with band portions. This dimensional extension provides additional bonding area and structural support against bending forces, compensating for the reduced thickness of internal electrodes.
Solution Approach 2:
The internal electrodes are designed with non-uniform width, featuring extending portions at specific locations that overlap with band portions. This local reinforcement strategy concentrates structural strength where bending stresses are highest, while maintaining thin overall electrode thickness for high capacitance.
2Reliability
If the internal electrodes are made thinner to achieve high capacity, then the electrical performance improves, but the reliability under impact and deformation increases
Solution Approach 1:
The patent creates a composite structure where internal electrodes with extending portions are integrated with band portions of external electrodes. The overlapping regions form a reinforced composite zone that combines the conductive properties of both electrode types, providing both electrical connectivity and mechanical strength against impact and deformation.
Solution Approach 2:
The extending portions of internal electrodes are nested within the width of the body and overlap with band portions, creating a layered nested structure. This nested arrangement allows the thinner internal electrodes to be supported by the broader band portions, enhancing impact resistance while maintaining high capacitance.
3Volume of moving object
If the internal electrodes are made thinner to increase capacity, then the capacitor size is reduced, but the resistance to substrate deformation decreases
Solution Approach 1:
The patent compensates for reduced electrode thickness (z-dimension) by extending electrodes in the width direction (y-dimension), creating extending portions that provide lateral support. This dimensional substitution maintains mechanical strength against substrate deformation while enabling thinner electrodes for compact size and high capacity.
4Strength
If the extending portions are made wider to improve bending strength, then the bending strength increases, but the cutting defects and manufacturing complexity increase
Solution Approach 1:
The patent optimizes the width of extending portions to specific parameter ranges (e.g., 0.05-0.15 times the body width) that provide sufficient bending strength while remaining compatible with existing manufacturing capabilities. This parameter optimization balances mechanical performance with manufacturability, avoiding excessive width that would cause cutting defects.
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 design significantly improves bending strength and resistance to deformation, ensuring reliable performance under varying conditions, while maintaining production efficiency and minimizing cutting defects.
Implementation Method 1
The first and second internal electrodes may be formed by sintering
Data Source
AI summary
A multilayer capacitor includes a body including dielectric layers and a plurality of first and second internal electrodes having an average thickness less than 1 μm; and first and second external electrodes each including first and second conductive layers including first and second head portions and first and second band portions, and first and second conductive resin layers each covering the first and second conductive layers. An average thickness of the dielectric layers may be greater than the average thickness of the first and second internal electrodes, and portions of the first and second internal electrodes overlapping an end of the first or second band portion in a width direction of the body may be formed as first and second extending portions having a width relatively greater than those of other portions of the first and second internal electrodes, respectively.