MLCC Electrode Exposure Layout for Higher Capacitance
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Solution Overview
Problem
Existing multilayer ceramic capacitors with side margin portions formed by applying a ceramic slurry have a smaller effective area of internal electrodes and require an additional manufacturing step, increasing costs.
Innovation Solution
The multilayer ceramic capacitors expose the internal electrode layers at the lateral surfaces, eliminating the need for dielectric layers at the ends and increasing the effective area of the internal electrodes, thus reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If side margin portions are formed by applying ceramic slurry to internal electrodes, then insulation is improved, but effective area of internal electrodes decreases and manufacturing complexity increases
Solution Approach 1:
The patent extracts the side margin portions from the internal electrode structure by forming them as separate dielectric layers on the outer layers. This separation allows the internal electrodes to extend fully to the lateral surfaces, maximizing their effective area while the side margin portions provide the necessary insulation independently.
Solution Approach 2:
The capacitor structure is segmented into distinct functional regions: internal electrodes that extend to lateral surfaces for maximum capacitance, and separate side margin portions formed as dielectric layers on outer layers for insulation. This segmentation resolves the contradiction by assigning different functions to different parts.
2Reliability
If side margin portions are formed by applying ceramic slurry, then insulation is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The side margin portions are formed preliminarily during the lamination process by including dielectric layers in the outer layers before cutting. This preliminary formation eliminates the need for subsequent slurry application steps, reducing manufacturing complexity while ensuring proper insulation.
Solution Approach 2:
The formation of side margin portions is merged with the lamination process itself. The dielectric layers intended to become side margin portions are incorporated into the outer layers during initial lamination, combining multiple functions into a single manufacturing step.
3Reliability
If internal electrodes are covered by dielectric layers at lateral surfaces, then insulation is improved, but effective area for capacitance generation decreases
Solution Approach 1:
The patent applies local quality by providing dielectric coverage only where necessary for insulation (on the outer layers forming side margin portions) while leaving the internal electrodes exposed at lateral surfaces where capacitance generation is prioritized. This localized approach optimizes both insulation and capacitance.
Data Source
AI summary
A multilayer ceramic capacitor includes a multilayer body, first internal electrode layers exposed at a first end surface of the multilayer body, and second internal electrode layers exposed at a second end surface of the multilayer body. The first internal electrode layers are exposed at a first lateral surface and a second lateral surface of the multilayer body. The second internal electrode layers are exposed at the first lateral surface and the second lateral surface of the multilayer body.