Multilayer Ceramic Capacitor Electrode Structure for Lower ESR

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Solution Overview

Problem

Multilayer ceramic capacitors face issues with high equivalent series resistance (ESR) and reduced mechanical strength due to high contact resistance between the epoxy-based thermosetting resin layer and the Ni plated layer, especially under severe environmental conditions such as impact and thermal cycling.

Innovation Solution

A multilayer ceramic capacitor design featuring a base electrode layer with a conductive resin layer containing a metal filler, a Ni plated layer, and a Sn plated layer, where Ni is provided on the surface of the metal filler, enhancing electrical conductivity and mechanical strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If an epoxy-based thermosetting resin layer is formed between the electrode layer and the Ni plated layer, then mechanical strength and deflection resistance are improved, but contact resistance increases resulting in high ESR

Engineering Contradiction:

Improvemechanical strengthVSAvoidcontact resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent uses a composite structure consisting of an epoxy-based thermosetting resin layer combined with a metal filler layer (Ni, Cu, or Ag). This composite material approach allows the resin layer to provide mechanical strength and deflection resistance while the metal filler particles provide electrical conductivity pathways, thereby reducing contact resistance and ESR. The metal filler content is controlled at 1-50 wt% to optimize both mechanical and electrical properties.

Inventive Principle:

Principle #40Composite materials

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 design achieves reduced ESR and improved mechanical strength, effectively preventing cracks and ensuring reliable performance under impact and thermal stress.

Implementation Method 1

an electrically conductive resin layer on the base electrode layer and includes a thermosetting resin and a metal filler

Methodology Applied

Scientific EffectThermosetting:

Implementation Method 2

a electrically conductive resin layer on the base electrode layer and includes a thermosetting resin and a metal filler

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20250364184A1Multilayer ceramic capacitor

Publication Date: 2025.11.27 MURATA MFG CO LTD

AI summary

A multilayer ceramic capacitor includes a laminate, first and second internal electrode layers on dielectric layers, and first and second external electrodes on first and second end surfaces. The first and second external electrodes include a conductive resin layer including an underlayer electrode layer including a metal component and a thermosetting resin and a metal filler on the underlayer electrode layer, a Ni plating layer on the conductive resin layer, and a Sn plating layer on the Ni plating layer. Ni is provided on at least a portion of a surface of the metal filler, as a component of the Ni plating layer.