Multilayer Ceramic Capacitor Impact Resistance
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Solution Overview
Problem
Conventional multilayer ceramic capacitors produced by existing methods are susceptible to impact and do not meet reliability standards due to their structural vulnerabilities.
Innovation Solution
The development of a multilayer ceramic capacitor with a laminated body structure featuring external electrodes with a fired electrode layer and resin layer, where the resin layer has a high exposure ratio of metal particles and a smooth surface, providing enhanced impact resistance and reliability through a surface treatment process involving vibration energy application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional conductive paste deposition and pressing method is used, then manufacturing process is simple, but impact resistance is poor
Solution Approach 1:
The external electrode is formed as a composite structure combining a fired electrode layer (containing conductive paste with glass and metal particles) and a resin layer (containing binder resin and metal particles). This composite structure provides both mechanical strength for impact resistance and proper electrical conductivity, resolving the contradiction between simple manufacturing and improved impact resistance.
Solution Approach 2:
The resin layer is applied specifically on the end surface of the laminated body where external electrodes are formed, providing localized reinforcement and protection. This localized application improves impact resistance at the vulnerable end surfaces without adding complexity to the entire capacitor structure.
2Manufacturing precision
If conductive paste is pressed against plate multiple times, then electrode shape is adjusted, but surface roughness increases
Solution Approach 1:
The conductive paste formulation is optimized with specific glass particle size distributions and resin compositions that enable the paste to self-level and form smooth surfaces during firing. This parameter optimization achieves surface smoothness without requiring excessive pressing operations, balancing manufacturing precision and ease of manufacture.
3Reliability
If metal particle exposure ratio is increased, then plating adhesion improves, but surface roughness increases
Solution Approach 1:
The resin layer is designed with specific metal particle content and distribution characteristics, creating an optimal balance where metal particles are sufficiently exposed to provide plating adhesion sites while the resin matrix maintains surface smoothness. This localized optimization in the resin layer resolves the contradiction between plating adhesion and surface roughness.
Solution Approach 2:
The resin layer acts as a composite material combining binder resin and metal particles in specific proportions. This composite structure provides both the metal particle exposure needed for plating adhesion and the resin matrix needed to maintain surface smoothness, resolving the contradiction between reliability and manufacturing precision.
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 proposed solution results in capacitors that are resistant to impact and exhibit excellent reliability, with improved metal particle exposure and surface smoothness enhancing plating adhesion and moisture resistance.
Implementation Method 1
a surface treatment process involving vibration energy application
Data Source
AI summary
An electronic component includes a laminated body including first and second end surfaces, first and second side surfaces, and first and second principal surfaces, a first external electrode, and a second external electrode, in which the first external electrode includes a first fired electrode layer and a first resin layer, the second external electrode includes a second fired electrode layer and a second resin layer, each of the first fired electrode layer and the second fired electrode layer is provided on the laminated body and includes a region including voids and glass, each of the first resin layer and the second resin layer includes metal particles, and a surface layer of each of the first resin layer and the second resin layer has a portion of the metal particles exposed in a ratio of about 72.6% or more and about 90.9% or less.