Multilayer Ceramic Capacitor Side Margins Against Solder Flux Corrosion

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Solution Overview

Problem

Existing multilayer ceramic capacitors face issues with corrosion due to fluxes in solders, leading to degradation of insulation between internal electrodes and potential short circuits, which compromises reliability.

Innovation Solution

The method involves forming a ceramic main body with specific structural features, including side margin parts and external electrodes, to create expanded spacings that protect the internal electrode facing part from solder fluxes, thereby maintaining insulation and reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the protective parts are made smaller to miniaturize the capacitor and increase capacitance, then the device size is reduced and capacitance is increased, but the insulation protection between internal electrodes is weakened

Engineering Contradiction:

Improvedevice sizeVSAvoidinsulation protection

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent applies preliminary action by forming the side margin parts during the lamination process itself, before the final product is completed. The side margin parts are created by not fully extending the internal electrodes to the cut surfaces of the laminated body, thereby pre-establishing the insulation barrier before any corrosion could occur during soldering operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent segments the internal electrode structure by introducing side margin parts that create distinct zones: the internal electrode facing part (where electrodes face each other for capacitance) and the side margin parts (providing insulation). This segmentation allows the protective function to be separated from the capacitance-forming function, enabling miniaturization without compromising insulation.

Inventive Principle:

Principle #1Segmentation

2Productivity

If solder fluxes are used to mount the capacitors, then the mounting process is simplified and productivity is improved, but corrosion occurs that degrades insulation between internal electrodes

Engineering Contradiction:

Improvemounting process efficiencyVSAvoidinsulation integrity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies preliminary anti-action by pre-establishing the side margin parts that will counteract the harmful effects of solder fluxes before the soldering process occurs. These side margin parts act as a pre-built defensive barrier that prevents flux-induced corrosion from reaching the internal electrode facing part, thereby neutralizing the harmful effect before it can degrade insulation.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The side margin parts serve as a cushioning barrier formed beforehand to protect the internal electrode facing part from the corrosive effects of solder fluxes. This prior cushioning ensures that even when aggressive fluxes are used during mounting, the critical insulation regions remain protected from corrosion.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Quantity of substance

If the internal electrode facing region is exposed to reach the cut surfaces, then the capacitance is maximized, but the insulation is vulnerable to corrosion from solder fluxes

Engineering Contradiction:

ImprovecapacitanceVSAvoidcorrosion susceptibility

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality by creating different structural characteristics in different regions of the capacitor. The internal electrode facing part has a configuration optimized for capacitance (with electrodes extending close to each other), while the side margin parts have a configuration optimized for protection (with no internal electrodes reaching the cut surfaces). This local differentiation allows maximum capacitance in the functional region while providing corrosion resistance in the vulnerable side regions.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12512268B2Method of making a multilayer ceramic electronic device

Publication Date: 2025.12.30 TAIYO YUDEN KK

AI summary

A multilayer ceramic electronic device includes a ceramic main body and a pair of external electrodes respectively covering a pair of end surfaces of the ceramic main body, wherein the ceramic main body includes a laminated body including a plurality of internal electrodes laminated vertically therein, and a pair of side margin parts respectively covering a pair of side surfaces of the laminated body, and wherein a distance between a bottom surface of the ceramic main body and the bottommost internal electrode is greater than a distance between the top surface of the ceramic main body and the topmost internal electrode.