Carbon Fuse Electrode in Multilayer Ceramic Components

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Solution Overview

Problem

Laminated ceramic electronic components face issues with short circuits and overheating due to thermal and mechanical stresses, leading to potential fuming, firing, and loss of function when mounted on substrates, as existing technologies fail to effectively manage overcurrents and maintain functionality.

Innovation Solution

Incorporating an intermediate electrode made of conductive carbon material that functions as a fuse, electrically connecting electrode layers and external electrodes, which burns and cuts off the current when a short circuit occurs, thereby blocking overcurrents and reducing the risk of fuming and firing, while maintaining the component's functionality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional electrode layers are used without intermediate electrodes, then the structure is simpler, but short circuits and overheating occur under thermal and mechanical stresses

Engineering Contradiction:

Improveresistance to short circuit and overheatingVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

An intermediate electrode layer containing conductive carbon material is inserted between the external electrode and the internal electrode layers. This intermediate layer acts as a mediator that provides overcurrent protection by burning out during short circuit conditions, preventing direct contact between the external electrode and internal electrodes, thereby blocking harmful current paths while maintaining the overall structural simplicity of the ceramic component.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the intermediate electrode is made of conductive carbon material, then overcurrent blocking capability is improved, but the material stability under thermal stress deteriorates

Engineering Contradiction:

Improveovercurrent blocking capabilityVSAvoidmaterial stability under thermal stress

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The conductive carbon material in the intermediate electrode is deliberately chosen for its property to burn out under excessive current conditions. This transformation converts the potential harm of carbon decomposition into a beneficial protective function: when a short circuit occurs, the intermediate electrode burns out and forms an insulating carbonaceous residue that blocks the current path, preventing damage to the main ceramic body while the carbon material itself undergoes controlled decomposition.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The intermediate electrode's material composition is specifically designed to change parameters under thermal and electrical stress. The conductive carbon material undergoes phase and compositional changes at elevated temperatures and current loads, transitioning from a conductive state to an insulating carbonaceous residue, thereby dynamically adapting its electrical properties to protect the component during fault conditions.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the intermediate electrode electrically connects electrode layers and external electrodes, then electrical connectivity is improved, but the risk of fuming and firing increases under short circuit conditions

Engineering Contradiction:

Improveelectrical connectivityVSAvoidfuming and firing risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The electrical connection path is segmented into multiple sections: the external electrode, the intermediate electrode layer, and the internal electrode layers are separated by distinct interfaces. The intermediate electrode acts as an isolated segment that can be sacrificially consumed during short circuits, breaking the continuous electrical path and preventing direct energy transfer that would cause fuming and firing of the ceramic material.

Inventive Principle:

Principle #1Segmentation

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 conductive carbon intermediate electrode effectively suppresses temperature rises and prevents fuming and firing, ensuring the laminated ceramic electronic component's functionality is maintained even after the fuse is burned, by blocking overcurrents and reducing the likelihood of defects and electrostatic capacitance reduction.

Implementation Method 1

an intermediate electrode configured to electrically connect at least one electrode layer and one of the external electrodes, wherein the intermediate electrode contains a conductive carbon material

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

functions as a fuse, electrically connecting electrode layers and external electrodes, which burns and cuts off the current when a short circuit occurs, thereby blocking overcurrents

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS12136520B2Laminated multilayer ceramic electronic component with alternating layers

Publication Date: 2024.11.05 KYOCERA CORP

AI summary

A laminated ceramic electronic component according to the present disclosure includes a laminated body in which ceramic layers and electrode layers are alternately laminated, a pair of external electrodes provided at end portions of the laminated body, and an intermediate electrode configured to electrically connect at least one electrode layer and one of the external electrodes, wherein the intermediate electrode contains a conductive carbon material.