Ceramic Electronic Device Corner Plating for Humidity Resistance

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Solution Overview

Problem

Ceramic electronic devices, such as multilayer ceramic capacitors, face challenges in achieving high humidity resistance due to discontinuities in the ground layer, particularly at the round edge corners, which affect the continuity of the plated layer and insulating resistance.

Innovation Solution

A ceramic electronic device with a metal-based ground layer extending to the side faces, where the plated layer covers the corner portions with an average thickness of 30% or more relative to the maximum spaced distance of 10 μm or less, ensuring comprehensive coverage and maintaining the device's size without excessive thickness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the ground layer thickness is increased to cover corner portions, then humidity resistance is improved, but the device size increases

Engineering Contradiction:
Improvehumidity resistanceVSAvoiddevice size
Core Design Contradiction:
ReliabilityVSVolume of moving object

Solution Approach 1:

The patent applies local quality by making the ground layer thickness non-uniform: thicker at corner portions (10 μm or more) to ensure coverage and humidity resistance, and thinner at other areas to minimize overall device size. This spatial variation in thickness optimizes both protection and compactness.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent changes the thickness parameter of the ground layer from a uniform value to a variable value that depends on position. Specifically, the thickness is set to 10 μm or more at corner portions and 5 μm or less at other portions, creating a gradient structure that balances protection and size.

Inventive Principle:
Principle #35Parameter changes

2Reliability

If the ground layer is made thicker to ensure continuous coverage, then discontinuous portions are eliminated, but manufacturing complexity increases

Engineering Contradiction:
Improveground layer continuityVSAvoidmanufacturing complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent uses local quality by applying different thickness requirements to different regions: corner portions require 10 μm or more to ensure continuous coverage and eliminate discontinuities, while other areas use 5 μm or less to simplify manufacturing and reduce material usage.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent applies partial action by providing excessive thickness (10 μm or more) only where absolutely necessary (corner portions prone to discontinuities), rather than uniformly throughout the entire ground layer. This targeted approach ensures continuity where needed while avoiding unnecessary complexity elsewhere.

Inventive Principle:
Principle #16Partial or excessive action

3Reliability

If the plated layer thickness is increased to cover spaced distances, then coverage is improved, but material consumption increases

Engineering Contradiction:
Improveplated layer coverageVSAvoidplated material consumption
Core Design Contradiction:
ReliabilityVSQuantity of substance

Solution Approach 1:

The patent applies local quality by varying the plated layer thickness according to position: the plated layer is made thicker at corner portions where the ground layer has larger spaced distances, and thinner in other areas. This ensures adequate coverage where needed while minimizing material consumption.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent changes the plated layer thickness parameter from uniform to variable, adjusting it based on the underlying ground layer structure and the spaced distance that needs to be covered. This optimized parameter distribution achieves necessary coverage with reduced material usage.

Inventive Principle:
Principle #35Parameter changes

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 enhances humidity resistance by preventing water-soluble flux intrusion and maintaining insulating resistance, while avoiding size enlargement of the ceramic capacitor.

Implementation Method 1

forming a plated layer on the ground layer by a plating process that has an average thickness of 30% or more with respect to the maximum spaced distance and covers the first portion

Methodology Applied
Scientific EffectPlating: Electroplating

Data Source

PatentUS11551868B2Ceramic electronic device and manufacturing method of ceramic electronic device
Publication Date: 2023.01.10 TAIYO YUDEN KK
  • US11551868B2 patent drawing
  • US11551868B2 patent drawing
  • US11551868B2 patent drawing

AI summary

A ceramic electronic device includes: a ceramic main body of a parallelepiped shape having at least two edge faces facing each other, and having an internal electrode layer inside; and external electrodes formed on the two edge faces and having a structure in which a plated layer is formed on a ground layer having a metal, as a main component, and ceramic; the external electrodes have an extension region which extends to at least one of four side faces from the two edge faces, and a part of which corresponds to a corner portion of the ceramic main body and includes a portion with the ground layer and a first portion, without the ground layer, arranged at a position where one of the two end faces and one of the four side faces are connected; and the plated layer covers the ground layer and the first portion.