Multilayer Ceramic Component Dummy Electrode Warpage Endurance
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Solution Overview
Problem
Multilayer ceramic electronic components face challenges in warpage endurance and tensile endurance, which are critical for their reliability and durability in electronic devices.
Innovation Solution
Incorporating a protective layer with dummy electrodes on the internal electrodes, where the thickness and number of these dummy electrodes are optimized to enhance the ceramic body's strength against external impacts without significantly increasing the component's size, thereby improving warpage and tensile endurance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of internal electrodes is increased to improve strength, then tensile endurance improves, but the number of electrodes per unit length decreases, reducing capacitance density
Solution Approach 1:
The patent divides the internal electrode structure into two functional parts: standard-thickness electrodes that provide capacitance and thicker protective dummy electrodes that provide mechanical strength. This segmentation allows each part to optimize for its specific function without compromising the other.
Solution Approach 2:
The protective dummy electrodes act as intermediary elements between the standard internal electrodes and the external environment. These dummy electrodes absorb mechanical stress and protect the capacitance-forming electrodes from damage during warpage and tensile testing.
2Reliability
If a protective layer is added to improve warpage endurance, then reliability improves, but device complexity increases
Solution Approach 1:
The patent merges the protective layer function with the electrode structure by forming dummy electrodes from the same conductive paste material used for the internal electrodes. This integration eliminates the need for separate protective materials and simplifies the manufacturing process.
Solution Approach 2:
The conductive paste material serves multiple functions: it forms the capacitance-providing internal electrodes and also forms the protective dummy electrodes. This multi-functionality reduces the number of different materials needed and simplifies the overall device structure.
3Strength
If thicker protective dummy electrodes are used to prevent delamination, then bonding strength improves, but the component size increases
Solution Approach 1:
The patent optimizes the thickness parameter of protective dummy electrodes to a specific range (greater than 0.6 times the thickness of internal electrodes) to achieve the minimum required bonding strength while minimizing size increase. This parameter optimization balances protection needs with compactness.
Data Source
AI summary
A multilayer ceramic electronic component includes: a ceramic body including a dielectric layer and first and second internal electrodes alternately exposed to first and second outer surfaces with the dielectric layer interposed therebetween; and first and second external electrodes disposed on the first and second outer surfaces of the ceramic body so as to be connected to the first and second internal electrodes, respectively. The ceramic body further includes a protective layer including a protective layer dummy electrode disposed on at least one of upper and lower portions of the first and second internal electrodes, and the protective layer dummy electrode has a thickness ranging from greater than to 1.2 times or less a thickness of each of the first and second internal electrodes.