Multilayer Capacitor Outer Electrode Structure for Thin End Terminations

Solution Overview

Problem

Existing multilayer ceramic capacitors face challenges in reducing size without compromising capacitance, particularly due to the thickness of outer electrodes which are not effectively minimized.

Innovation Solution

The multilayer ceramic capacitor employs a direct plating method to form outer electrodes with varying particle diameters, where the end-surface electrode portions have smaller average particle diameters than the main-surface electrode portions, enhancing mechanical strength and electrical connectivity while allowing for reduced thickness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the thickness of outer electrodes is reduced to minimize component size, then the size and height of multilayer ceramic capacitors can be reduced, but the mechanical strength and reliability of the outer electrodes deteriorate

Engineering Contradiction:

Improvesize of multilayer ceramic capacitorVSAvoidmechanical strength of outer electrode

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The outer electrode is designed with non-uniform particle diameter distribution, where the average particle diameter in the end-surface electrode portion is smaller than that in the main-surface electrode portion. This local variation in microstructure optimizes both mechanical strength and electrical connectivity at different locations of the electrode.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention changes the particle diameter parameter of the metal particles within the outer electrode, creating a gradient distribution where particle size varies by location. This parameter change enables the thin electrode to maintain adequate mechanical strength while minimizing overall thickness for smaller component size.

Inventive Principle:

Principle #35Parameter changes

2Volume of moving object

If the thickness of outer electrodes is reduced to minimize component size, then the size and height of multilayer ceramic capacitors can be reduced, but the electrical connectivity and reliability deteriorate

Engineering Contradiction:

Improvesize of multilayer ceramic capacitorVSAvoidelectrical connectivity of outer electrode

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The outer electrode is designed with non-uniform particle diameter distribution, where the average particle diameter in the end-surface electrode portion is smaller than that in the main-surface electrode portion. This local variation in microstructure optimizes both mechanical strength and electrical connectivity at different locations of the electrode.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The outer electrode functions as a composite metal particle structure with varying particle sizes distributed throughout. This composite arrangement, combining fine and coarse particles, enhances both electrical conductivity and mechanical integrity, ensuring reliable electrical connectivity despite reduced overall thickness.

Inventive Principle:

Principle #40Composite materials

3Volume of moving object

If the thickness of outer electrodes is reduced to minimize component size, then the size and height of multilayer ceramic capacitors can be reduced, but the outer electrodes become more prone to cracks

Engineering Contradiction:

Improvesize of multilayer ceramic capacitorVSAvoidcrack susceptibility of outer electrode

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The outer electrode is designed with non-uniform particle diameter distribution, where the average particle diameter in the end-surface electrode portion is smaller than that in the main-surface electrode portion. This local variation in microstructure optimizes both mechanical strength and electrical connectivity at different locations of the electrode.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The varied particle diameter distribution acts as a preventive measure against crack formation. The presence of larger particles within the matrix of smaller particles creates a more ductile and crack-resistant structure, cushioning against stress concentrations before cracks can initiate and propagate.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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

This configuration reduces the likelihood of cracks in the outer electrodes, improves mechanical strength, and maintains electrical characteristics, enabling a smaller form factor without sacrificing capacitance.

Implementation Method 1

Since the thickness of the outer electrodes can be reduced by forming the outer electrodes by a direct plating method

Methodology Applied

Scientific EffectDirect plating: Electroplating

Data Source

PatentUS12597565B2Multilayer electronic component

Publication Date: 2026.04.07 KYOCERA CORP

AI summary

A multilayer electronic component includes a multilayer body including stacked inner electrodes and dielectric layers, underlying electrodes, and outer electrodes. The inner electrodes include a first inner electrode and a second inner electrode, the underlying electrodes include a first underlying electrode and a second underlying electrode, and the outer electrodes include a first outer electrode and a second outer electrode. Each of the first outer electrode and the second outer electrode includes a first portion connected to the first inner electrode or the second inner electrode and a second portion connected to one of the underlying electrodes. An average particle diameter of metal particles contained in the first portion is smaller than an average particle diameter of metal particles contained in the second portion.