Capacitor External Electrode with Variable Conductive Resin Thickness
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Solution Overview
Problem
The existing conductive resin layers in capacitors increase equivalent series resistance (ESR) due to increased interface resistance between the metal and resin layers, leading to deteriorated electrical characteristics and potential cracking from external impacts.
Innovation Solution
A capacitor design with a conductive resin layer having a reduced thickness at the end surfaces compared to the upper and lower surfaces, interposed between metal electrode layers, to minimize ESR while preventing cracks from external impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive resin layer is used in the external electrode, then the capacitor can absorb external impacts and prevent cracks, but the equivalent series resistance (ESR) increases due to interface resistance between metal and resin layers
Solution Approach 1:
The patent applies different thicknesses of the conductive resin layer at different locations: a first thickness at the end surface and a second thickness (greater than the first) at the upper and lower surfaces. This local differentiation allows the end surface to have lower ESR while the upper and lower surfaces maintain adequate impact absorption and adhesion.
Solution Approach 2:
The patent introduces a dimensional variation in the conductive resin layer by creating a stepped structure where the layer has different thicknesses in different spatial dimensions (end surface vs. upper/lower surfaces), thereby optimizing both electrical and mechanical properties simultaneously.
2Object-generated harmful factors
If the conductive resin layer thickness is reduced to decrease ESR, then electrical characteristics improve, but the ability to prevent cracks from external impacts may be compromised
Solution Approach 1:
The patent applies different thicknesses of the conductive resin layer at different locations: a first thickness at the end surface and a second thickness (greater than the first) at the upper and lower surfaces. This local differentiation allows the end surface to have lower ESR while the upper and lower surfaces maintain adequate impact absorption and adhesion.
Solution Approach 2:
The patent introduces a dimensional variation in the conductive resin layer by creating a stepped structure where the layer has different thicknesses in different spatial dimensions (end surface vs. upper/lower surfaces), thereby optimizing both electrical and mechanical properties simultaneously.
3Strength
If the conductive resin layer includes an excessive amount of resin, then the layer can provide adequate adhesion, but non-plating occurs and lifting phenomenon separates the capacitor body from the external electrode
Solution Approach 1:
The patent applies different thicknesses of the conductive resin layer at different locations: a first thickness at the end surface and a second thickness (greater than the first) at the upper and lower surfaces. This local differentiation allows the end surface to have lower ESR while the upper and lower surfaces maintain adequate impact absorption and adhesion.
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 reduced thickness of the conductive resin layer at the end surfaces decreases the ESR of the capacitor, enhancing its electrical characteristics and reliability by minimizing interface resistance and preventing plating solution permeation.
Implementation Method 1
A conductive resin layer formed of the conductive resin composition may include metal and a hardening resin for implementing conductivity, and thus may absorb external impacts that may be applied to the capacitor to reduce stress that may occur in the capacitor body
Implementation Method 2
An external electrode of a capacitor may be changed from a sintered-type electrode formed using a metal paste
Implementation Method 3
a hardened-type electrode using a conductive resin composition that is a metal-resin composite
Data Source
AI summary
A capacitor includes a capacitor body having upper and lower surfaces and end surfaces connecting the upper and lower surfaces; and an external electrode disposed on a surface of the capacitor body and having a first electrode layer, a second electrode layer, and a third electrode layer. The second electrode layer includes metal and resin and is interposed between the first electrode layer and the third electrode layer, and a portion of the second electrode layer covering the end surface of the capacitor body has a thickness less than that of a portion of the first electrode layer covering the end surface of the capacitor body.