Multilayer Ceramic Electrode Structure for Corner Moisture Resistance

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Solution Overview

Problem

Multilayer ceramic electronic components with reduced size and increased capacitance face challenges in corner coverage performance and moisture resistance due to thin external electrodes, which can lead to plating solution permeation and degradation of product quality.

Innovation Solution

The design includes conductive layers on the corners of the ceramic body with a specific area ratio to the cross-sectional surface, covered by base electrodes to enhance corner coverage and prevent moisture permeation, thereby improving moisture resistance reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the external electrode thickness is reduced to achieve smaller component size, then the component size is reduced, but the corner coverage performance degrades and plating solution can permeate through the corner

Engineering Contradiction:

Improvecomponent sizeVSAvoidcorner coverage performance

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The external electrode is segmented into two distinct layers: a base electrode layer that provides corner coverage and moisture barrier functionality, and a conductive layer that provides electrical conductivity. This segmentation allows each layer to be optimized for its specific function, resolving the contradiction between thin electrode design and corner coverage performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The base electrode is designed with extended coverage specifically at the corner regions of the ceramic body, providing enhanced local protection where moisture permeation is most likely to occur. This local quality enhancement ensures reliable corner coverage while maintaining overall electrode thickness reduction.

Inventive Principle:

Principle #3Local quality

2Volume of moving object

If the external electrode thickness is reduced to achieve smaller component size, then the component size is reduced, but plating solution can permeate through the corner

Engineering Contradiction:

Improvecomponent sizeVSAvoidplating solution permeation

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The base electrode acts as an intermediary barrier layer between the external environment (plating solution) and the ceramic body corner regions. This intermediate layer prevents direct contact and permeation of plating solution into the ceramic body, resolving the harmful effect while maintaining reduced component size.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The base electrode is applied in advance to cover the corner regions of the ceramic body before the plating process. This preliminary action creates a protective barrier that prevents plating solution permeation during subsequent manufacturing steps.

Inventive Principle:

Principle #10Preliminary action

3Temperature

If glass with low sintering temperature is used to reduce heat impact, then heat impact is reduced, but glass becomes vulnerable to acid resistance in plating process

Engineering Contradiction:

Improvesintering temperatureVSAvoidacid resistance

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The external electrode uses a composite structure with a base electrode layer providing chemical resistance and a conductive layer providing electrical conductivity. This composite material approach allows the use of low-temperature sintering glass while maintaining acid resistance through the protective base electrode layer.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The base electrode serves as an intermediary protective layer that shields the low-temperature sintering glass from direct exposure to acidic plating solutions. This intermediary protection resolves the acid resistance vulnerability while maintaining the benefits of low-temperature sintering.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If the conductive layer area is increased to improve corner coverage, then corner coverage performance improves, but the external electrode thickness cannot be reduced

Engineering Contradiction:

Improvecorner coverage performanceVSAvoidexternal electrode thickness

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The external electrode is divided into a base electrode layer for corner coverage and a conductive layer for electrical conductivity. This segmentation allows the conductive layer area to be optimized for conductivity while the base electrode provides the corner coverage, resolving the contradiction between coverage and thickness reduction.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12142433B2Multilayer ceramic electronic component

Publication Date: 2024.11.12 SAMSUNG ELECTRO MECHANICS CO LTD

AI summary

A multilayer ceramic electronic component includes a ceramic body; and first and second external electrodes disposed on the ceramic body, wherein the first and second external electrodes include first and second conductive layers disposed on corners of the ceramic body, and first and second base electrodes covering the first and second conductive layers, respectively, and wherein a ratio, A1/A2, of an area, A1, of the first conductive layer disposed on the fifth surface or the second conductive layer disposed on the sixth surface of the ceramic body to an area, A2, of a cross-sectional surface of the ceramic body taken in the second direction and the first direction is in a range of 0.1 to 0.3.