Multilayer Ceramic Capacitor Coating for Mounting Stress Resistance
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Solution Overview
Problem
Multilayer ceramic capacitors face a reduction in strength when slimmed down, leading to potential damage from mounting stress, which can cause cracks in ceramic layers and degrade insulation properties if moisture infiltrates.
Innovation Solution
A multilayer ceramic capacitor design incorporating a stress relief film made of insulating material that extends along the main and end surfaces of the capacitor, mitigating stress and preventing cracks by dispersing mounting forces and maintaining insulation integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the multilayer ceramic capacitor is slimmed down to reduce size, then the volume and thickness are reduced, but the strength of the multilayer body decreases making it vulnerable to mounting stress
Solution Approach 1:
A stress relief film is introduced as an intermediary element between the multilayer body and the external environment. This film absorbs and distributes mounting stress, preventing it from concentrating on the weakened multilayer body. The stress relief film acts as a protective mediator that allows the capacitor to maintain small dimensions while gaining enhanced stress resistance.
Solution Approach 2:
The capacitor structure is transformed into a composite system by combining the ceramic multilayer body with a stress relief film having different mechanical properties. This composite structure leverages the electrical properties of the ceramic and the mechanical flexibility of the stress relief film, achieving both size reduction and stress resistance through material composition rather than relying solely on the ceramic's inherent strength.
2Length of stationary object
If the multilayer body is thinned to achieve slimming, then the thickness is reduced, but cracks may occur in the ceramic layers under external stress
Solution Approach 1:
The stress relief film is applied in advance to the thinned multilayer body before mounting operations. This pre-applied film creates a cushioning effect that anticipates and mitigates the impact of future mounting stress, preventing cracks from forming in the vulnerable thin ceramic layers during the mounting process or subsequent operation.
Solution Approach 2:
A flexible stress relief film is introduced as a protective layer that can deform elastically under stress, accommodating thermal expansion and mechanical loads without transmitting concentrated forces to the rigid thin ceramic layers. This flexible film acts as a protective skin that preserves the integrity of the underlying brittle structure.
3Length of moving object
If the capacitor is slimmed down, then the dimensions are reduced, but mounting stress from automated mounters may damage the multilayer body
Solution Approach 1:
The stress relief film serves as a mediator between the automated mounter and the multilayer body. During automated mounting, the film interfaces with the mounting equipment and absorbs the impact forces, preventing direct transmission of harmful mounting stress to the delicate multilayer structure. This intermediary layer enables safe integration into automated assembly processes.
Solution Approach 2:
The stress relief film converts the potentially harmful mounting stress into beneficial distributed pressure. By designing the film with appropriate mechanical properties, the mounting force that would otherwise damage the thin capacitor is transformed into a controlled compressive load that enhances contact between the capacitor and the mounting board while being safely absorbed by the film's elastic deformation.
Data Source
AI summary
A multilayer ceramic capacitor includes a multilayer body including dielectric layers and internal electrode layers, external electrodes on at least a second main surface of the multilayer body, and a stress suppression film to suppress stress provided on the multilayer body and the external electrodes. The stress suppression film includes an insulating material and extends along a first main surface and two end surfaces, or along the first main surface and two side surfaces to cover the multilayer body and the external electrodes. Ends of the stress suppression film protrude with respect to outermost surfaces of the external electrodes on a side of the second main surface.