Chip Electronic Component Electrode Segmentation
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Solution Overview
Problem
Existing chip-shaped electronic components face increased electrical resistance and potential cracking due to the complete coverage of sintered electrode layers by conductive resin electrode layers, which also fail to adequately alleviate stress during heat cycles.
Innovation Solution
A chip-shaped electronic component design featuring an intermediate electrode layer made of conductive resin and metal components that covers the end surfaces and extends to the main surfaces, acting as a buffer to reduce stress and create a current path with lower electrical resistance by exposing underlying electrode layers for surface contact with external electrode layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive resin electrode layer completely covers sintered electrode layer, then stress on ceramic body is alleviated, but electrical resistance of external electrode increases
Solution Approach 1:
The external electrode is segmented into multiple functional layers: sintered electrode layer (for low electrical resistance), conductive resin electrode layer (for stress relief), and plating electrode layer (for protection and connection). This segmentation allows each layer to perform its specialized function without compromising the others.
Solution Approach 2:
The external electrode uses composite material structure combining different materials with complementary properties: ceramic-based sintered electrode for conductivity, polymer-based conductive resin for flexibility and stress absorption, and metallic plating for surface properties. This composite approach resolves the contradiction between rigidity/conductivity and flexibility/stress resistance.
2Strength
If conductive resin electrode layer is used to alleviate stress, then cracking is prevented, but equivalent series resistance increases
Solution Approach 1:
The conductive resin electrode layer is strategically positioned and dimensioned to provide stress relief only where needed (on the outer surface for mechanical flexibility), while the inner sintered electrode layer maintains low electrical resistance for current conduction. This local differentiation of material properties resolves the contradiction between mechanical strength and electrical conductivity.
Data Source
AI summary
An external electrode includes an underlying electrode layer on an end surface of a ceramic body and connected to an internal electrode, an external electrode layer located outside the underlying electrode layer, and an intermediate electrode layer including at least a portion between the underlying electrode layer and the external electrode layer. The intermediate electrode layer includes a conductive resin, and the underlying electrode layer and the external electrode layer include a material lower in electrical resistivity than the conductive resin. The intermediate electrode layer entirely or substantially entirely covers the end surfaces and extends from the end surfaces to portions, respectively, of one main surface, and the underlying electrode layer is partially exposed from the intermediate electrode layer to include an exposed surface and is in surface-contact with the external electrode layer at the exposed surface.