Multilayer Ceramic Capacitor Conductive Resin Layer ESR Reduction
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Solution Overview
Problem
Multilayer ceramic capacitors face challenges in achieving high reliability due to infiltration of plating solutions and external shock, which can lead to increased equivalent series resistance (ESR) when a conductive resin layer is applied, and there is a demand for smaller size and higher capacitance with reduced internal electrode thickness.
Innovation Solution
A multilayer ceramic capacitor design incorporating a conductive resin layer with a specific area ratio of conductive particles to fullerenes and a base resin, along with a plating layer, to absorb external shock and prevent plating solution infiltration while minimizing ESR, is proposed. The conductive resin layer contains conductive particles and fullerenes, with an area ratio of 100:1 to 100:85, and a thermosetting base resin, which improves conductivity and shock absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive resin layer is applied to electrode layers to absorb external shock and prevent plating solution infiltration, then reliability is improved, but equivalent series resistance (ESR) increases
Solution Approach 1:
The conductive resin layer is formulated as a composite material containing conductive particles (metal powder), fullerenes (carbon-based conductive material), and base resin. This composite structure combines the shock absorption capability of the resin matrix with the high conductivity of dispersed conductive fillers, achieving both reliability improvement and low ESR performance simultaneously
Solution Approach 2:
The patent optimizes the area ratio parameters of conductive particles to fullerenes (100:1 to 100:85) and conductors to base resin (100:18 to 100:61) in the conductive resin layer. By precisely controlling these compositional parameters, the invention achieves the optimal balance between shock absorption (reliability) and electrical conductivity (ESR reduction)
2Quantity of substance
If internal electrode thickness is reduced to enable more layers to be stacked for high capacitance, then capacitance increases, but manufacturing precision and reliability become more difficult to maintain
Solution Approach 1:
The patent employs thin film technology by reducing internal electrode thickness while maintaining structural integrity through the multi-layer stacking approach. The conductive resin layer also acts as a protective thin film that prevents plating solution infiltration, enabling thinner electrodes without compromising reliability
3Quantity of substance
If internal electrode thickness is reduced to enable more layers to be stacked for high capacitance, then capacitance increases, but reliability decreases due to increased susceptibility to external shock and plating solution infiltration
Solution Approach 1:
The conductive resin layer is applied beforehand to the external electrodes, creating a protective barrier that cushions against external shock and prevents plating solution infiltration. This protective layer is in place before the capacitor is subjected to harsh manufacturing or operating conditions, preventing damage to the thinner internal electrodes
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 solution effectively decreases equivalent series resistance (ESR) and enhances the reliability of multilayer ceramic capacitors by increasing the number of contact points between conductive particles and fullerenes, while maintaining shock absorption and preventing plating solution infiltration, thus addressing the challenges of miniaturization and high capacitance demands.
Implementation Method 1
a conductive resin layer which is formed on the electrode layer and contains conductive particles, fullerenes, and a base resin
Implementation Method 2
a resin composition containing a conductive material is applied to electrode layers of external electrodes to absorb external shock
Data Source
AI summary
A multilayer ceramic capacitor includes a ceramic body including dielectric layers and internal electrodes, electrode layers connected to the internal electrodes, and a conductive resin layer formed on the electrode layer and containing conductive particles, fullerenes, and a base resin.