Multilayer Ceramic Component Electrode Structure for Stress and ESR
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Solution Overview
Problem
Existing multilayer ceramic electronic components face issues with mechanical stress-induced cracking and increased resistance when used in harsh environments due to thermal expansion and contraction, which is exacerbated by the application of insulating soft materials for stress absorption.
Innovation Solution
A multilayer ceramic electronic component design featuring a ceramic body with dielectric layers and internal electrodes, where external electrodes consist of a base electrode layer and a resin electrode layer, with specific thickness ratios to maintain electrical conductivity and density, thereby mitigating mechanical stress and resistance increases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a soft material such as an epoxy resin is applied to external electrodes to absorb external impacts or internal stress, then mechanical stress resistance is improved, but electrical characteristics deteriorate due to increased resistance
Solution Approach 1:
The external electrode is segmented into two distinct layers: a base electrode layer (metallic) for electrical conduction and a resin electrode layer (soft material) for mechanical stress absorption. This segmentation allows each layer to perform its specialized function without compromising the other, resolving the contradiction between mechanical resistance and electrical conductivity.
Solution Approach 2:
The external electrode uses a composite structure combining metallic material (for conductivity) and resin material (for softness and stress absorption). This composite approach integrates the beneficial properties of both materials, achieving both electrical performance and mechanical resilience simultaneously.
2Strength
If the thickness of the resin electrode layer is increased to improve stress absorption, then mechanical protection is enhanced, but electrode density decreases and resistance increases
Solution Approach 1:
The patent optimizes the thickness parameter of the resin electrode layer to be within 5-20 μm, and sets the thickness ratio between resin and base electrode layers within 0.1-0.5. These parameter optimizations ensure the resin layer provides sufficient stress absorption while maintaining adequate electrode density and electrical conductivity.
Solution Approach 2:
The resin electrode layer is applied locally on top of the base electrode layer rather than replacing it, allowing the metallic base layer to maintain its density and conductivity functions while the resin layer provides localized mechanical protection where needed.
3Strength
If a base resin with higher modulus of elasticity than metal is used to alleviate cracks, then crack resistance is improved, but electrical conductivity deteriorates
Solution Approach 1:
The electrode structure is segmented into a metallic base electrode layer for electrical conduction and a resin electrode layer for crack resistance. This segmentation ensures that the resin's crack-resistant properties are utilized without compromising the metal's electrical conductivity.
Solution Approach 2:
The composite electrode structure combines metallic material (high conductivity) and resin material (high crack resistance) in a layered configuration, allowing both materials to contribute their superior properties to the overall electrode performance.
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 design effectively prevents deterioration in electrical characteristics and improves equivalent series resistance (ESR) while maintaining electrode density, ensuring reliable performance under mechanical stress.
Implementation Method 1
a base resin has a higher modulus of elasticity than that of metal, so that cracks caused by mechanical stress may be alleviated
Implementation Method 2
expansion and contraction due to high/low temperature cycles are repeated to cause continuous mechanical stress
Data Source
AI summary
A multilayer ceramic electronic component may include: a ceramic body including a dielectric layer and first and internal electrodes disposed to be stacked with the dielectric layer interposed therebetween; a first and a second external electrode disposed on the ceramic body. The first and the second external electrodes may include a first and a second base electrode layers disposed in contact with the ceramic body and a first and a second resin electrode layers disposed on the first and the second base electrode layer respectively, a width of the ceramic body in the second direction may be less than 1.0 mm, and 0.4×ta≤tb≤0.5×ta in which ta is an average thickness of the first base electrode layer and tb is an average thickness of the first resin electrode layer.