Multilayer Ceramic Capacitor Outer Electrodes Resin Layer Stress Absorption
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Solution Overview
Problem
Multilayer ceramic capacitors face challenges in withstanding impacts and heat cycles due to inadequate coverage of resin layers over electrode ends, leading to potential cracks and reduced mechanical strength, especially in miniaturized devices where precise resin electrode layer formation is difficult.
Innovation Solution
A multilayer ceramic capacitor design featuring outer electrodes with base electrode layers, resin electrode layers, and resin layers that cover the base electrode layers, ensuring the leading ends are covered without precise control, and providing higher elasticity to absorb stress, with plating layers for enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a resin layer is formed to cover the electrode layer, then mechanical strength is improved, but manufacturing precision deteriorates due to difficulty in ensuring accurate coverage of the leading end
Solution Approach 1:
The outer electrode is divided into two distinct layers: a base electrode layer (metal + glass) and a resin electrode layer (thermosetting resin + metal). This segmentation allows each layer to perform its specific function - the base layer provides structural foundation while the resin layer provides stress-absorbing coverage, making it easier to ensure complete coverage of the leading end without requiring high manufacturing precision.
Solution Approach 2:
The patent uses composite materials in both layers. The base electrode layer combines metal and glass, while the resin electrode layer combines thermosetting resin and metal. These composite structures provide complementary properties - the glass-metel base provides rigidity and adhesion, while the resin-metal composite provides flexibility and stress absorption, together ensuring both mechanical strength and reliable coverage.
2Productivity
If the device is miniaturized, then productivity is improved, but manufacturing precision deteriorates due to increased difficulty in controlling resin electrode layer formation
Solution Approach 1:
By segmenting the electrode structure into base and resin layers, the patent simplifies the formation process. The base electrode layer can be formed first as a stable foundation, then the resin electrode layer is applied to cover it. This two-step segmented approach is more controllable in miniaturized devices than attempting to form a single precise resin layer, thereby maintaining manufacturing precision while enabling productivity through miniaturization.
Solution Approach 2:
The base electrode layer is formed in advance before applying the resin electrode layer. This preliminary action creates a stable foundation that defines the coverage area, making it easier to ensure complete coverage in subsequent steps. This preliminary structuring approach reduces the precision requirements for the final resin layer formation, enabling reliable manufacturing in miniaturized devices.
3Device complexity
If a single resin electrode layer is used, then device complexity is reduced, but reliability deteriorates because stress cannot be adequately absorbed when the leading end is not covered
Solution Approach 1:
The electrode structure is segmented into a base electrode layer and a resin electrode layer. This segmentation enables the resin layer to fully cover the base layer including the leading end, creating a reliable stress-absorbing structure that prevents cracks. The segmented design ensures that the resin layer can adequately cover the electrode end without requiring complex additional structures.
Solution Approach 2:
The composite structure of base electrode layer (metal + glass) and resin electrode layer (thermosetting resin + metal) provides complementary mechanical properties. The resin component absorbs stress and prevents crack propagation, while the metal and glass components provide structural integrity. This composite approach enhances reliability through stress absorption without significantly increasing device complexity.
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 ensures reliable mechanical strength and reduced crack occurrence during impacts and heat cycles, allowing for easier manufacturing and flexible mounting options without determining the mounting direction, while maintaining product dimensions.
Implementation Method 1
a resin electrode layer that includes a thermosetting resin and a metal component... providing higher elasticity to absorb stress
Data Source
AI summary
A multilayer ceramic capacitor includes a multilayer body including dielectric layers and inner electrode layers, and a pair of outer electrodes on end surfaces of the multilayer body and electrically connected to the inner electrode layers. The outer electrodes each include a base electrode layer, a resin electrode layer on a surface of the base electrode layer and including a thermosetting resin and a metal component, a resin layer not containing an electrically conductive component, and a plating layer on the resin electrode layer. The resin layers cover the base electrode layers in regions located on the second main surface side of the multilayer body, and the resin electrode layers cover the base electrode layers in portions where the resin layers are not located and cover the resin layers.