External Electrode Corner Beveling to Reduce Ceramic Cracks
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Solution Overview
Problem
Ceramic electronic components face issues with cracks originating from the end portions of external terminal electrodes, despite having a protective coating.
Innovation Solution
The electronic component features a beveled first external edge corner and/or a beveled first exposed portion corner to distribute stress, reducing the likelihood of cracks from occurring at these critical points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coating layer is provided to cover the peripheral portion of the external terminal electrode, then the external terminal electrode is protected from separating from the ceramic layer, but cracks may still occur from the end portion of the external terminal electrode in the ceramic layer
Solution Approach 1:
The patent applies different geometric treatments to different locations of the external terminal electrode. Specifically, the corner portions (first and second corners) are formed with rounded corners having a radius of curvature, while other portions maintain their original shape. This local differentiation addresses stress concentration at critical corner locations without unnecessarily modifying the entire electrode structure, thereby preventing cracks while maintaining bonding strength.
Solution Approach 2:
The patent introduces rounded corners at the corner portions of the external terminal electrode by forming a curvature with a specific radius. This curvature transformation eliminates sharp angles that cause stress concentration, distributing mechanical stress more evenly across the electrode-ceramic interface and preventing crack initiation at these vulnerable locations.
2Stability of the object's composition
If the external terminal electrode is fully covered by the coating layer, then separation is prevented, but stress concentration occurs at the end portion leading to cracks
Solution Approach 1:
The patent selectively modifies only the corner portions of the external terminal electrode by rounding them, while leaving other portions unchanged. This localized approach addresses stress concentration at the most vulnerable locations (corners) without compromising the overall structural integrity and bonding coverage provided by the coating layer on the entire electrode surface.
Solution Approach 2:
By rounding the corner portions with a specified radius of curvature, the patent transforms the geometric configuration at stress-prone locations. This curvature eliminates sharp corners that act as stress concentrators, thereby reducing stress concentration while maintaining the coating layer's protective coverage over the entire electrode including the rounded corners.
Data Source
AI summary
An electronic component includes a component main body, an external electrode, and a protective member. The component main body has a lower surface of a rectangular shape. The external electrode includes a base layer in contact with the lower surface. The protective member is in contact with the lower surface and the base layer, is along an external edge of the base layer to surround the base layer, and has an inner and outer edges each having a rectangular shape. At least one of a first external edge corner and a first exposed portion corner is beveled. The first external edge cornier is farthest from an intersection point of two diagonal lines of the lower surface, among four external edge corners. The first exposed portion corner is farthest from the intersection point of the two diagonal lines of the lower surface among four exposed portion corners of an exposed portion.