Multilayer Ceramic Capacitor Coating for Crack-Resistant Curved Edges

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Solution Overview

Problem

Multilayer ceramic capacitors face issues of cracks and chips at boundary portions between ineffective regions due to pointed shapes and structural differences leading to cracks and chips at the boundary portions between the ineffective regions during manufacturing and transport.

Innovation Solution

A protection film including carbon and silicon is applied on the contiguous curved surfaces at the boundary portions between the end-surface-side ineffective portions and perpendicular/horizontal ridge ineffective portions to prevent cracks and chips.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the multilayer body is formed with pointed ridge portions and corner portions, then the manufacturing process is simplified, but cracks and chips are easily generated at these portions during manufacturing and transport

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidresistance to cracks and chips

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies barrel polishing to round the pointed ridge portions and corner portions of the multilayer body, transforming sharp edges into curved surfaces. This curvature eliminates stress concentration points that would otherwise lead to cracks and chips during handling and transport, while maintaining manufacturing efficiency through a standardized polishing process.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent forms a protective film on the rounded surfaces of the multilayer body before subsequent manufacturing steps and transport. This film acts as a cushioning layer that protects the rounded portions from mechanical damage, further reducing the risk of cracks and chips while the rounded shape already provides stress distribution benefits.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If barrel polishing is applied to round the ridge portions, then cracks and chips are reduced, but the boundary portions become curved surfaces that protrude outward and easily receive stress

Engineering Contradiction:

Improvereduction of cracks and chipsVSAvoidstress concentration at boundary portions

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies a protective film specifically to the boundary portions between the effective portion and ineffective portions, where stress concentration occurs. This localized protection targets the specific areas that are most vulnerable to stress while leaving other areas with their original rounded characteristics, providing differentiated protection where needed most.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The protective film serves as an intermediary layer between the curved boundary surfaces and external stresses. This film absorbs and distributes the stress that would otherwise concentrate at the protruding boundary portions, preventing crack initiation while maintaining the beneficial rounded shape of the multilayer body.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If the multilayer body has exposed boundary portions between ineffective regions, then the structure is simplified, but cracks and chips are easily generated due to structural differences

Engineering Contradiction:

Improvestructural simplicityVSAvoidresistance to cracks and chips

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The protective film serves multiple functions: it protects the exposed boundary portions from cracks and chips, provides stress distribution at the interface between different regions, and maintains the simplified structural design. This single layer addresses multiple vulnerability points without adding complex structural elements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 application of the carbon-silicon protection film effectively reduces or prevents cracks and chips at these boundary portions, enhancing the structural integrity and reliability of the multilayer ceramic capacitors.

Implementation Method 1

a protection film including carbon and silicon is provided on the curved surface

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Data Source

PatentUS20250372304A1Multilayer ceramic capacitor

Publication Date: 2025.12.04 MURATA MFG CO LTD

AI summary

A multilayer ceramic capacitor includes a multilayer body including dielectric layers and inner electrode layers that are laminated, and an outer electrode to establish electrical continuity with the inner electrode layers. In the multilayer body, an outer surface at a boundary portion between an end-surface-side ineffective portion and a perpendicular ridge ineffective portion, an outer surface of the perpendicular ridge ineffective portion, and an outer surface at a boundary portion between the perpendicular ridge ineffective portion and a side-surface-side ineffective portion define a contiguous curved surface protruding outward in plan view in a lamination direction, and a protection film including carbon and silicon is provided on the curved surface.