Multilayer Ceramic Capacitor Resin Layer Design for Crack Resistance

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Solution Overview

Problem

Multilayer ceramic capacitors face challenges in withstanding shock and maintaining low equivalent series resistance (ESR) due to high contact resistance between thermosetting resin layers and Ni plated layers, leading to potential cracks and increased ESR.

Innovation Solution

A multilayer ceramic capacitor design featuring a resin layer on the external electrode with a plated layer covering the underlying electrode and resin, where the resin layer covers specific portions of the electrode to enhance mechanical strength and reduce ESR, including a region not covered with resin to prevent solder burst and ensure stable mounting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an epoxy-based thermosetting resin layer is formed between the electrode layer and the Ni plated layer, then crack resistance is improved, but contact resistance increases and ESR becomes high

Engineering Contradiction:

Improvecrack resistanceVSAvoidESR

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The resin layer is applied selectively only to the side surfaces and end surfaces of the external electrode, not covering the entire electrode surface. This localized application provides crack resistance where mechanical stress occurs while preserving good contact area for electrical conduction, thus resolving the contradiction between reliability and energy loss

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The external electrode structure uses a composite design combining metal electrode material with thermosetting resin material. The metal provides electrical conductivity while the resin provides mechanical strength and crack resistance, achieving both low ESR and high reliability through material composition

Inventive Principle:

Principle #40Composite materials

2Strength

If a resin layer is provided on the external electrode to improve mechanical strength, then shock resistance is improved, but contact resistance may increase

Engineering Contradiction:

Improvemechanical strengthVSAvoidcontact resistance

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

The resin layer is positioned specifically on the side surfaces and end surfaces where mechanical strength is needed, while leaving the main contact areas of the electrode exposed. This localized placement provides shock resistance without significantly increasing contact resistance

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The resin layer covers only a portion of the external electrode surface rather than the entire surface. This partial coverage provides sufficient mechanical protection while maintaining adequate exposed metal area for electrical contact, balancing strength improvement with minimal impact on conductivity

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS11398351B2Multilayer ceramic capacitor, mount structure of multilayer ceramic capacitor, and series of electronic components

Publication Date: 2022.07.26 MURATA MFG CO LTD

AI summary

A multilayer ceramic capacitor includes a multilayer body and first and second external electrodes. The first and second external electrodes include first and second underlying electrode layers, first and second main-surface-side resin layers, and first and second plated layers, respectively. The first and second main-surface-side resin layers cover respective ends of the first and second underlying electrode layers on a first main surface and cover respective portions of a first side surface and a second side surface continuously from the first main surface.