Multilayer Ceramic Capacitor Electrode Structure for Resistance Control
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Solution Overview
Problem
Multilayer ceramic capacitors face instability in connectivity between internal and external electrodes due to surface irregularities and variations in the contact between conductive layers, leading to inconsistent resistance values and difficulty in controlling the overall resistance of the capacitor.
Innovation Solution
A multilayer ceramic capacitor design featuring a thin film electrode layer directly contacting the internal electrode layer, a resistive electrode layer with a lower resistivity upper electrode layer, and a low-resistance external electrode, all formed through specific coating and firing steps to ensure stable connectivity and resistance control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a paste for the first conductive layer is applied and heat treated to form a resistive electrode layer, then the electrode can be formed on the element main body, but the adhesion between the first conductive layer and the internal electrode layer becomes insufficient due to surface irregularities
Solution Approach 1:
A thin film electrode layer is introduced as an intermediary between the internal electrode layer and the first conductive layer. This thin film electrode layer fills in the irregularities on the internal electrode layer surface, providing a flat base for the first conductive layer and ensuring sufficient adhesion while maintaining stable connectivity.
Solution Approach 2:
The external electrode is divided into multiple functional layers: the thin film electrode layer (for adhesion and filling irregularities), the first conductive layer (for resistance control), and the second conductive layer (for low resistance connection). This segmentation allows each layer to perform its specific function optimally.
2Productivity
If conductive paste is baked to form an electrode, then the electrode can be formed quickly, but the contact with the internal electrode layer varies due to components other than conductive components in the paste
Solution Approach 1:
The thin film electrode layer serves as a mediator that ensures consistent contact between the internal electrode layer and the first conductive layer. It compensates for variations in paste composition and application, providing uniform contact across the entire electrode area.
Solution Approach 2:
The invention changes the physical state and composition parameters by introducing a thin film electrode layer with specific properties (thin, uniform, good adhesion) that differs from the traditional conductive paste. This parameter change ensures consistent contact while maintaining production efficiency.
3Reliability
If the first conductive layer is formed by heat treating paste, then the resistive electrode layer can be created, but low-resistance regions are partially formed due to variation in contact, making it difficult to control the resistance value
Solution Approach 1:
The thin film electrode layer acts as a mediator that ensures uniform contact between the first conductive layer and the internal electrode layer. By filling surface irregularities, it prevents the formation of low-resistance regions and ensures consistent resistance values across the electrode.
Solution Approach 2:
The thin film electrode layer provides localized quality improvement by creating a uniform contact surface specifically at the interface between the internal electrode layer and the first conductive layer, ensuring consistent electrical properties in this critical region.
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 provides stable connectivity between internal and external electrodes, reducing resistance fluctuations and enabling precise control of the capacitor's resistance value, enhancing the reliability and performance of multilayer ceramic capacitors.
Implementation Method 1
a thin film electrode layer in direct contact with the internal electrode layer
Implementation Method 2
a resistive electrode layer provided on the thin film electrode layer, and an upper electrode layer provided on the resistive electrode layer
Data Source
AI summary
A multilayer ceramic capacitor includes a substantially cuboid laminated body including ceramic layers and internal electrode layers laminated, and two or more exposed regions where the plurality of internal electrode layers are exposed, and external electrodes, wherein at least one of the external electrodes is an external electrode with resistance, the internal electrode layers include a first internal electrode layer and a second internal electrode layer opposed to the first internal electrode layer in the lamination direction, and the external electrode with resistance includes a thin film electrode layer in direct contact with the internal electrode layer in the exposed region, a resistive electrode layer provided on the thin film electrode layer, and an upper electrode layer provided on the resistive electrode layer, which has a lower electrical resistivity lower than the resistive electrode layer.