Multilayer Ceramic Capacitor Outer Electrodes Preventing Glass Diffusion
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Solution Overview
Problem
Conventional multilayer ceramic capacitors face issues with glass thermal diffusion and plating solution penetration, leading to structural weakness, reduced stability, and poor quality due to uneven glass distribution and thermal expansion mismatches between materials.
Innovation Solution
A multilayer ceramic capacitor design featuring first outer electrodes formed by sintering with the base part and second outer electrodes made from metal powder and resin, which are solidified at a lower temperature to prevent glass diffusion and plating solution penetration, enhancing structural strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If glass material is used in the outer electrode layer, then the capacitor can be formed by conventional sintering processes, but glass thermal diffusion occurs during subsequent plating processes, causing structural weakness and reduced stability
Solution Approach 1:
The invention extracts the glass material from the outer electrode layer formulation, replacing it with metal powder and resin binder. This eliminates the glass thermal diffusion problem that occurs during subsequent plating processes while maintaining the ability to form outer electrodes through conventional sintering processes. The metal powder-resin combination provides a stable base that does not diffuse thermally during plating.
Solution Approach 2:
The invention uses a composite material system consisting of metal powder (such as nickel powder) and resin binder to form the outer electrode layer. This composite replaces the conventional glass-containing materials and provides both manufacturability through sintering and stability by preventing thermal diffusion during subsequent plating operations. The resin binder holds the metal powder in place without undergoing thermal diffusion.
2Reliability
If sequential plating process is performed to form outer electrodes, then the capacitor achieves proper electrical connections, but plating solution penetrates into the ceramic dielectric, causing poor quality and reduced yield
Solution Approach 1:
The invention introduces an intermediary layer composed of metal powder and resin binder between the ceramic dielectric and the plated outer electrode. This intermediary layer acts as a barrier that prevents plating solution from penetrating into the ceramic dielectric during the plating process, while still allowing proper electrical connections to be formed. The resin binder creates a protective matrix that blocks solution penetration paths.
3Ease of manufacture
If inner electrode terminals are exposed out of the ceramic dielectric, then the outer electrode layer can be formed, but the contact area between inner electrodes and outer electrodes is limited, affecting capacitance
Solution Approach 1:
The invention extends the outer electrode layer laterally beyond the exposed inner electrode terminals, creating a broader contact area in the planar dimension. By forming the metal powder-resin outer electrode layer to extend beyond the terminal edges, the effective contact area is increased without requiring deeper exposure of the inner electrodes, thus maintaining manufacturability while increasing capacitance.
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 effectively prevents glass material and plating solution from penetrating into the ceramic dielectric, resulting in improved structural strength, higher compactness, and enhanced quality and yield of the multilayer ceramic capacitors.
Implementation Method 1
the first outer electrodes formed with the base part together by a sintering manner
Implementation Method 2
the second outer electrodes formed by solidifying a mixture of metal powder and resin
Data Source
AI summary
A multilayer ceramic capacitor and a method of manufacturing the same are disclosed. A base part of the multilayer ceramic capacitor includes ceramic dielectric and inner electrodes formed inside the ceramic dielectric, and a terminal of each of the inner electrodes is exposed out of one of the two opposite sides of the base part, to form inner electrode terminals. First outer electrodes are formed on the two sides of the base part and the outside of the inner electrode terminals, and second outer electrodes are formed on the first outer electrodes. The first outer electrodes and the base part are formed together by sintering manner, and the second outer electrodes are formed by metal powder and resin material, thereby solving the problem that the vitreous component diffuses around, or solving the problem that plating solution permeates into the base part or the ceramic dielectric during plating process.