MLCC Resin Electrode Paste With Silane Coupling for Crack Prevention
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Solution Overview
Problem
Multilayer ceramic electronic components face issues with cracks due to high void ratios in conductive resin electrode layers, leading to decreased relaxation characteristics and poor adhesiveness between the resin electrode layers and the ceramic element body, resulting in peeling and deterioration of electrical characteristics.
Innovation Solution
Incorporating amine, isocyanate, epoxy, or ureido silane coupling agents in the conductive paste for resin electrodes improves dispersibility and chemical bonding between metal powder and resin, reducing void ratios and enhancing adhesiveness, thereby preventing cracks and maintaining electrical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stearic acid is used as a surface treatment agent in conductive resin paste, then electrical resistivity of the conductive film is reduced, but void ratio of the conductive resin electrode layer increases causing cracks in the ceramic element body
Solution Approach 1:
The patent changes the chemical composition parameters of the conductive resin paste by replacing stearic acid with specific silane coupling agents (amine, isocyanate, epoxy, mercapto, or ureido types) and adjusting the metal powder to resin ratio to 5:95 to 40:60 by weight, thereby achieving both low electrical resistivity and low void ratio simultaneously
Solution Approach 2:
The patent creates a composite conductive resin paste system combining metal powder with resin containing silane coupling agents, where the silane coupling agent forms a chemical bridge between the metal powder surface and the resin matrix, improving both electrical conductivity and mechanical integrity of the conductive electrode layer
2Ease of manufacture
If stearic acid is used in conductive resin paste, then processing is simplified, but adhesiveness between the conductive resin electrode layer and the ceramic element body is insufficient causing peeling
Solution Approach 1:
The silane coupling agent acts as a chemical intermediary between the metal powder and the resin, and between the conductive resin electrode layer and the ceramic element body, forming strong chemical bonds that significantly improve adhesiveness while maintaining ease of manufacture through a single-step paste application process
Solution Approach 2:
The patent changes the chemical composition by introducing silane coupling agents with specific functional groups (amine, isocyanate, epoxy, mercapto, or ureido) that have high reactivity with both metal oxides and resin, thereby enhancing chemical bonding strength without complicating the manufacturing process
3Quantity of substance
If void ratio of the conductive resin electrode layer is high, then material cost is reduced, but relaxation characteristics of the resin decrease causing cracks in the ceramic element body
Solution Approach 1:
The patent develops a composite conductive resin paste where silane coupling agents create strong chemical bonding between metal powder particles and resin matrix, enabling the formation of a dense structure with low void ratio that maintains both mechanical strength and electrical conductivity at optimized material ratios
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 use of silane coupling agents in the conductive paste for resin electrodes results in improved relaxation characteristics, reduced crack occurrence, and enhanced adhesiveness, leading to stable electrical performance and reduced peeling of external electrodes.
Implementation Method 1
resin external electrode layers and a ceramic element body are chemically bonded via a silane coupling agent
Implementation Method 2
adhesiveness between the conductive resin electrode layers and a ceramic element body is improved
Data Source
AI summary
A multilayer ceramic capacitor includes a ceramic element body including ceramic layers and internal electrode layers, and a pair of external electrodes on both end surfaces of the ceramic element body so as to be electrically connected to the internal electrode layers. Each of the external electrodes includes a base electrode layer and a resin external electrode layer stacked on the base electrode layer. The resin external electrode layer includes a thermosetting resin and a metal powder and amine, isocyanate, epoxy, mercapto, and/or ureido silane coupling agents.