Multilayer Capacitor Electrode Structure for Thin Stable MLCCs
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Solution Overview
Problem
Multilayer ceramic capacitors face challenges in maintaining electrical characteristics and structural stability when thinned for smaller sizes, leading to reduced mechanical rigidity and insufficient electrical performance.
Innovation Solution
A multilayer capacitor design featuring external electrodes with a first layer containing a metal particle and a Z-A-O phase, where element Z is an alkali metal, and a copper plating layer with diffusion regions, enhancing adhesion and electrical conductivity, along with a dummy electrode for improved structural stability and reduced thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the multilayer capacitor is thinned to reduce size, then the capacitor size is reduced, but the mechanical rigidity and electrical characteristics are deteriorated
Solution Approach 1:
The external electrode uses a composite structure with a first layer containing metal particles (Ni, Ag, Pd, or Au) and a second layer of copper plating, creating a multi-material composite that optimizes both mechanical strength and electrical conductivity while maintaining thin dimensions
Solution Approach 2:
The patent applies different material compositions to different layers of the external electrode - the first layer uses metal particles with specific oxide phases for adhesion and structural integrity, while the second layer uses copper plating for electrical conductivity, with each layer optimized for its specific function
2Volume of moving object
If the external electrode is thinned to reduce capacitor size, then the capacitor size is reduced, but the electrical characteristics are deteriorated
Solution Approach 1:
The external electrode employs a composite structure where the first layer contains metal particles (Ni, Ag, Pd, or Au) with specific oxide phases (NiO, Ag2O, PdO, or Au2O3) for adhesion, and the second layer uses copper plating for optimal electrical conductivity, achieving high electrical performance in a thin configuration
Solution Approach 2:
The patent optimizes the thickness and composition parameters of the external electrode layers - the first layer thickness is controlled at 0.1-1.0 μm and the second layer at 1.0-3.0 μm, with specific metal particle sizes (1-10 μm) and oxide phase ratios to achieve optimal electrical characteristics in a thinned capacitor
3Volume of moving object
If the external electrode is thinned to reduce capacitor size, then the capacitor size is reduced, but the adhesion strength is deteriorated
Solution Approach 1:
The first layer of the external electrode is formed as a composite of metal particles (Ni, Ag, Pd, or Au) and their corresponding oxide phases (NiO, Ag2O, PdO, or Au2O3), creating a multi-phase composite material that provides superior adhesion to the dielectric layer while maintaining thin overall dimensions
Solution Approach 2:
The patent creates a functionally graded structure where the first layer contains metal particles with oxide phases specifically positioned to enhance adhesion at the interface with the dielectric layer, while the second copper plating layer provides the outer protective and conductive surface
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 improved electrical characteristics and structural stability, suitable for miniaturized components, with specific resistance measurements showing enhanced performance compared to conventional capacitors, and a thickness of 70 μm or less.
Implementation Method 1
the first layer includes a metal particle including an element A and a Z-A-O phase disposed in the metal particle
Implementation Method 2
The second layer may include a diffusion region of the element A. The diffusion region may exist at a grain boundary of a metal component included in the second layer
Data Source
AI summary
A multilayer capacitor includes a body including a dielectric layer and a plurality of internal electrodes stacked on each other interposing the dielectric layer therebetween, and external electrodes disposed externally on the body, respectively including a first layer connected to the internal electrode and a second layer covering the first layer, wherein the first layer includes a metal particle including an element A and a Z-A-O phase formed in the metal particle, and here, the element Z is an alkali metal.