Multilayer Ceramic Electrode Structure for Uniform End-Termination Thickness

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Solution Overview

Problem

Existing methods for forming external electrodes on ceramic electronic components result in uneven thickness, with the surface thickness being thicker than the edge thickness, leading to variations that affect the quality and performance of the component.

Innovation Solution

A ceramic electronic component with a multilayer electrode structure comprising NiCr, NiCu, CuAgNi, and Sn layers, formed through sputtering, which ensures a standard deviation in thickness of 0.2 μm or less and a coefficient of variation of 9.0% or less, thereby stabilizing the electrode thickness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a surface of a ceramic body is immersed in conductive paste to form an external electrode, then the external electrode can be formed on the ceramic body, but the thickness of the external electrode becomes uneven (thicker on the surface than on the edge portion)

Engineering Contradiction:

Improvethickness uniformity of external electrodeVSAvoidsimplicity of electrode formation process

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The external electrode is divided into multiple distinct layers (first electrode layer, second electrode layer, third electrode layer, and fourth electrode layer) with different materials and functions. This segmentation allows each layer to be optimized for specific purposes: adhesion, conductivity, solderability, and protection, while collectively achieving uniform thickness control that cannot be accomplished with a single paste layer.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the fundamental parameter of electrode formation from a single thick paste layer to multiple thin controlled layers. By controlling the thickness of each individual layer (first electrode layer: 0.5-2.0 μm, second electrode layer: 0.5-2.0 μm, third electrode layer: 0.5-2.0 μm, fourth electrode layer: 1.0-3.0 μm), the total thickness uniformity is significantly improved compared to traditional single-layer paste application.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If multiple times pressing and separating is performed to ensure appropriate thickness on edge portion, then edge thickness is improved, but the surface thickness becomes excessively thick

Engineering Contradiction:

Improveedge portion thickness controlVSAvoidoverall electrode thickness distribution

Core Design Contradiction:

Manufacturing precisionVSShape

Solution Approach 1:

Each electrode layer is designed with specific local properties: the first electrode layer (NiCr alloy) provides adhesion to the ceramic body, the second electrode layer (NiCu alloy) provides electrical conductivity, the third electrode layer (CuAgNi alloy) provides solderability, and the fourth electrode layer (Sn) provides protection. This local quality optimization allows precise control of thickness at different locations without excessive buildup on the surface.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If a single layer conductive paste is used, then the manufacturing process is simple, but the thickness variation and quality consistency are poor

Engineering Contradiction:

Improvesimplicity of manufacturing processVSAvoidquality consistency of external electrode

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The external electrode uses a composite multi-layer structure with different materials optimized for specific functions. The first electrode layer uses NiCr alloy for adhesion, the second uses NiCu alloy for conductivity, the third uses CuAgNi alloy for solderability, and the fourth uses Sn for protection. This composite structure significantly improves quality consistency and reliability while maintaining manufacturing feasibility through standardized deposition processes.

Inventive Principle:

Principle #40Composite materials

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 multilayer electrode structure significantly reduces thickness variation, enhancing the quality and reliability of the ceramic electronic component by preventing stress and cracking, allowing for a larger ceramic body size and improved electrostatic capacity.

Implementation Method 1

formed through sputtering, which ensures a standard deviation in thickness of 0.2 μm or less and a coefficient of variation of 9.0% or less

Methodology Applied

Scientific EffectSputtering: Sputtering

Data Source

PatentUS20260024703A1Ceramic electronic component

Publication Date: 2026.01.22 MURATA MFG CO LTD

AI summary

A multilayer ceramic electronic component includes a ceramic body having opposing first and second main surfaces, opposing first and second side surfaces, and opposing first and second end surfaces. A first external electrode is on the first end surface and a second external electrode is on the second end surface, each extending onto at least one of the first main surface, the second main surface, the first side surface, and the second side surface. Each of the first and second external electrodes includes a first electrode layer containing mainly NiCr, a second electrode layer on the first electrode layer containing mainly NiCu, a third electrode layer on the second electrode layer containing mainly CuAgNi, and a fourth electrode layer on the third electrode layer containing mainly Sn. The standard deviation in thicknesses of each of the first to fourth electrode layers is 0.2 μm or less.