Dummy Electrode Layout in Multilayer Capacitors for Flexural Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Multilayer ceramic capacitors face challenges in achieving high flexural strength and reliability due to external shocks and thermal stress, particularly in automotive applications, where the addition of dummy electrodes increases manufacturing costs and time without optimizing the structure effectively.
Innovation Solution
A multilayer electronic component design featuring a body with alternately disposed dielectric and internal electrodes, upper and lower cover portions with dummy electrodes, and external electrodes with conductive resin layers, where the ratio of the area occupied by dummy electrodes to the total area in a specific triangle configuration is set to 20% or more, enhancing flexural strength while minimizing the dummy electrode presence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If dummy electrodes are added to the cover portions, then flexural strength characteristics are improved, but manufacturing process time and costs increase
Solution Approach 1:
The patent combines the dummy electrode formation process with the existing internal electrode formation process. Both dummy electrodes and internal electrodes are formed simultaneously in the same green sheet stacking and firing process, eliminating separate manufacturing steps and reducing production time while maintaining the flexural strength benefits of dummy electrodes
Solution Approach 2:
The green sheets serve multiple functions: they provide both internal electrodes for capacitance and dummy electrodes for mechanical strength. By making the cover portions and active portions from the same type of green sheets with similar electrode structures, the manufacturing process becomes universal and efficient, producing both functional and structural elements in one process
2Reliability
If dummy electrodes are added to improve flexural strength, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent applies dummy electrodes locally only in the cover portions where mechanical strength is needed, while the active portions maintain their standard internal electrode structure for electrical function. This localized approach provides reliability improvement without unnecessarily complicating the entire device structure
Solution Approach 2:
The multilayer body is segmented into active portions and cover portions, each with specific functions. The cover portions contain dummy electrodes for mechanical support, while active portions contain internal electrodes for capacitance. This segmentation allows each part to be optimized for its specific function without compromising the other
3Strength
If the ratio of dummy electrode area is increased, then flexural strength is improved, but visible defects from dummy electrodes increase
Solution Approach 1:
The patent makes the dummy electrodes visually indistinguishable from internal electrodes by forming both with the same conductive paste material and firing process. Since both electrode types have identical appearance after firing, no additional masking or aesthetic treatments are needed, allowing the dummy electrode area ratio to be optimized for strength without concern for visible defects
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 improves flexural strength characteristics, reduces manufacturing costs, and minimizes visible defects from dummy electrodes, ensuring reliability and efficiency in high-stress environments like automotive systems.
Implementation Method 1
improve flexural strength characteristics by applying a resin composition containing a conductive material on the electrode layer to absorb external shocks and relieve internal stress
Implementation Method 2
disposing a cover portion including a dummy electrode on upper and lower surfaces of an active portion
Data Source
AI summary
A multilayer electronic component includes a body including an active portion inducing dielectric layers and internal electrodes, and upper and lower cover portions, and external electrodes including connection portions and band portions extending onto portions of first and second surfaces of the body, and including an electrode layer and a conductive resin layer. In a cross-section of the body, when a line along which the band portion of the conductive resin layer is in contact with the first surface is d, an area of an isosceles right triangle, in which d is a base and an extension line extending from an end of the electrode layer by a length of d is a height, is K1, and a ratio of the area occupied by dummy electrodes in the lower cover portion and the internal electrodes in K1 to K1 is K2, K2 is 20% or more.