Multilayer Ceramic Capacitor Spacer Structure for Stronger Bonding
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Solution Overview
Problem
Multilayer ceramic capacitors face issues with weak bonding strength between the capacitor main body and the spacer, leading to potential peeling off when mounted, which affects durability.
Innovation Solution
The capacitors are designed with spacers that are longer in the length direction than the external electrodes, incorporating a metal component and a protective material with varying content ratios of protective material along the length and lamination directions to enhance bonding strength, and a reinforcement portion between the spacers to improve durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a spacer is added to suppress acoustic noise, then acoustic noise is reduced, but bonding strength between capacitor main body and spacer becomes weak causing peeling
Solution Approach 1:
The spacer is constructed as a composite material consisting of a metal component and a protective material. The metal component (e.g., Cu, Ni, or their alloys) provides structural integrity and bonding strength to the capacitor main body, while the protective material (e.g., resin or glass) enhances adhesion and prevents peeling. This composite structure resolves the contradiction by simultaneously achieving acoustic noise suppression and strong bonding.
Solution Approach 2:
The protective material is selectively applied to specific regions of the spacer, particularly at the bonding interfaces with the capacitor main body and external electrodes. This local concentration of protective material maximizes bonding strength at critical areas while maintaining the overall spacer function for acoustic noise suppression, effectively resolving the bonding weakness issue.
2Object-affected harmful factors
If spacer length is increased to improve acoustic noise suppression, then acoustic noise is better suppressed, but manufacturing precision and structural integrity become more difficult to maintain
Solution Approach 1:
The composite structure of metal component and protective material provides different functional benefits: the metal component maintains structural rigidity and positioning precision even at increased lengths, while the protective material ensures reliable bonding. This combination allows the spacer to be longer for better acoustic noise suppression without compromising manufacturing precision.
3Strength
If protective material content is increased in spacer to improve bonding strength, then bonding strength increases, but electrical conductivity and other functional properties may deteriorate
Solution Approach 1:
The protective material is strategically positioned at the bonding interfaces between the spacer and the capacitor main body/external electrodes, where it is most needed for adhesion. The metal component remains exposed in areas requiring electrical conductivity. This localized application of protective material maximizes bonding strength while preserving electrical connectivity, resolving the contradiction between bonding strength and electrical reliability.
Data Source
AI summary
A multilayer ceramic electronic component includes a multilayer body and external electrodes on end surfaces of the multilayer body, connected to an internal electrode layer, and extending to main surfaces of the multilayer body, and spacers on both end surface sides of one main surface side of the multilayer body, and sandwiching the external electrodes. The spacers are longer than the external electrodes, in a length direction, and each include an intermetallic compound including at least one of Cu, Ni, or Sn, and a protective material. If each of the spacers is divided into two portions in the length direction along a line extending in a stacking direction, a content ratio of the protective material is higher in a region closer to a central portion of the multilayer body in the length direction than in a region farther from the central portion.