Multilayer Ceramic Capacitor Aluminum Oxide Insulating Layer
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Solution Overview
Problem
Multilayer ceramic capacitors (MLCCs) face challenges in achieving smaller size and higher capacitance while maintaining reliability, as thinner internal electrodes and dielectric layers make them vulnerable to moisture and plating solution penetration, leading to reduced reliability, especially when mounted in limited spaces.
Innovation Solution
The design incorporates a multilayer electronic component with a dielectric layer and alternately disposed internal electrodes, featuring external electrodes with band portions and insulating layers containing aluminum oxide to prevent moisture and plating solution penetration, enhancing reliability and capacitance per unit volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of stacks is increased by making internal electrodes and dielectric layers thinner, then capacitance per unit volume is improved, but reliability deteriorates due to vulnerability to moisture and plating solution penetration
Solution Approach 1:
The patent applies the principle of flexible shells and thin films by introducing an insulating layer that conformally coats the external electrode, including band portions and corner portions. This thin film structure effectively seals the electrode interface, preventing moisture and plating solution penetration while accommodating the compact design with increased stacks and thinner layers.
Solution Approach 2:
The patent employs composite materials by combining the insulating layer with the external electrode structure. The insulating layer material is specifically selected to provide both electrical insulation and environmental barrier properties, creating a composite structure that simultaneously achieves high capacitance density and enhanced reliability against moisture and chemical ingress.
2Volume of moving object
If the size of MLCC is reduced, then mounting space is minimized, but reliability deteriorates due to thinner margins vulnerable to penetration
Solution Approach 1:
The insulating layer acts as a protective thin film that seals the external electrode interfaces, including corner portions where penetration is most likely to occur. This enables the MLCC to maintain reduced size with thinner margins while preventing environmental degradation through effective sealing at all electrode-exposed surfaces.
Solution Approach 2:
The insulating layer is applied in advance to the external electrode before the component is subjected to environmental conditions. This preliminary protective action prevents moisture and plating solution from penetrating through the thinner margins and corner portions, thereby maintaining reliability in the reduced-size configuration.
3Quantity of substance
If band portions of external electrodes are extended onto the first surface, then capacitance per unit volume is improved, but manufacturing precision requirements increase to ensure proper coverage
Solution Approach 1:
The insulating layer is formed to conformally cover the external electrode, including the band portions extending onto the first surface and the corner portions. This conformal coating approach automatically adapts to the electrode geometry, ensuring proper coverage without requiring extremely tight tolerances on the band portion dimensions, thereby reducing manufacturing precision requirements.
Data Source
AI summary
A multilayer electronic component includes: a body including a dielectric layer and first and second internal electrodes, and including first to sixth surfaces; a first external electrode including a first connection portion on the third surface, a first band portion extending from the first connection portion onto the first surface, and a third band portion extending from the first connection portion onto the second surface; a second external electrode including a second connection portion on the fourth surface, a second band portion extending from the second connection portion onto the first surface, and a fourth band portion extending from the second connection portion onto the second surface; an insulating layer including oxide including aluminum (Al), disposed on the first and second connection portions, and covering the second surface and the third and fourth band portions; and first and second plating layers respectively disposed on the first and second band portions.