Multi-Layer Ceramic Capacitor Electrode Alignment and Protective Barrier
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Solution Overview
Problem
Large-size multi-layer ceramic capacitors face issues with increased weight and moisture resistance due to size enlargement, leading to potential cracking and compromised insulation properties when dropped, which affects their capacitance and reliability.
Innovation Solution
A multi-layer ceramic capacitor design featuring internal electrodes with aligned end portions and a protective unit with a thickness that ensures the shortest distance between the outer surface and the internal electrodes' end portions exceeds 10 μm, reducing the likelihood of cracking and maintaining moisture resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the size of the multi-layer ceramic capacitor is enlarged to increase capacitance, then the capacitance increases, but the weight increases and the capacitor becomes prone to cracking
Solution Approach 1:
The patent applies local quality by aligning the end portions of internal electrodes within a specific range (0.5 μm) to create a concentrated protection zone. This localized alignment allows the protective unit to effectively shield the critical electrode regions without requiring uniform thickness throughout, enabling capacitance increase through optimized local structure rather than overall size enlargement.
2Quantity of substance
If the size of the multi-layer ceramic capacitor is enlarged to increase capacitance, then the capacitance increases, but the capacitor becomes prone to cracking when dropped
Solution Approach 1:
The patent implements beforehand cushioning by designing the protective unit with a minimum thickness of 10 μm from the outer surface to the end portions of internal electrodes. This pre-established protective barrier cushions the electrodes against impact forces during dropping, preventing crack initiation and propagation before they can compromise the capacitor's reliability.
Solution Approach 2:
The aligned end portions of internal electrodes create a localized region that receives concentrated protection from the protective unit. This local quality approach ensures that the most vulnerable areas (electrode ends) are adequately shielded without requiring uniform thickening throughout the entire capacitor structure.
3Reliability
If cracks occur in the protective unit, then moisture can infiltrate to the internal electrodes, but the aligned end portions and sufficient thickness prevent moisture from reaching the electrodes
Solution Approach 1:
The protective unit is designed with a minimum thickness of 10 μm from the outer surface to the end portions of internal electrodes, creating a pre-established barrier against moisture infiltration. This beforehand cushioning ensures that even if cracks develop in the protective unit, the moisture must traverse a sufficient distance to reach the electrodes, maintaining insulation properties.
Solution Approach 2:
The protective unit serves as an intermediary barrier between the external environment (moisture) and the internal electrodes. The aligned end portions of electrodes within 0.5 μm create a concentrated target zone that the protective unit mediates, ensuring moisture must pass through sufficient protective material before reaching conductive elements.
Data Source
AI summary
A multi-layer ceramic capacitor having a weight of 8 mg or more includes a capacitance forming unit and a protective unit. The capacitance forming unit includes internal electrodes that are laminated in a first direction and includes end portions, positions of the end portions in a second direction orthogonal to the first direction being aligned with one another within a range of 0.5 μm in the second direction. The protective unit covers the capacitance forming unit in the first direction and the second direction and includes an outer surface, a shortest distance between the outer surface and the end portion of an outermost layer in the internal electrodes in the first direction exceeding 10 μm.