Multilayer Ceramic Capacitor Surface Structure for Crack Resistance
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Solution Overview
Problem
Multilayer ceramic capacitors face challenges with reduced mechanical strength due to thinning, leading to potential cracks from external impacts during mounting and insufficient bonding strength with resin, which can result in insulation resistance failures.
Innovation Solution
The design incorporates embossed holes on the second main surface of the ceramic element body, enhancing impact resistance and bonding strength with resin, while allowing for optional use with or without resin sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If multilayer ceramic capacitors are thinned to reduce size, then the capacitor size is reduced, but the mechanical strength against external force decreases
Solution Approach 1:
The patent applies the porous materials principle by forming recessed portions (voids or cavities) within the ceramic element body. These recessed portions act as stress-absorbing features that prevent crack propagation when external forces are applied. The controlled porosity or cavity structure allows the thin capacitor to maintain mechanical strength despite its reduced thickness, resolving the contradiction between size reduction and strength maintenance.
2Volume of moving object
If multilayer ceramic capacitors are thinned to reduce size, then the capacitor size is reduced, but cracks may occur in the ceramic element body due to impact
Solution Approach 1:
The patent applies the beforehand cushioning principle by pre-forming recessed portions within the ceramic element body before mounting. These recessed portions serve as cushioning features that absorb impact energy when the capacitor is suctioned by the mounter nozzle or subjected to external shocks. By providing this protective structure in advance, the capacitor's reliability against impact-induced cracks is significantly improved despite its thinned design.
3Ease of manufacture
If the top surface of the ceramic element body is made flat, then the manufacturing process is simple, but the bonding strength with resin is insufficient
Solution Approach 1:
The patent applies the local quality principle by creating recessed portions at specific locations on the top surface of the ceramic element body. Instead of making the entire surface complex, the recesses are localized features that significantly enhance resin bonding strength. This localized modification maintains manufacturing simplicity while solving the bonding strength issue, as the recessed portions provide mechanical interlocking and increased surface area for resin adhesion only where needed.
Data Source
AI summary
A multilayer ceramic capacitor includes a ceramic element including ceramic layers, first and second internal electrodes that are laminated in a height direction, a first main surface and a second main surface opposed in the height direction, a first and second end surface opposed in a length, and a first and second lateral surface opposed in a width direction, and a first and second external electrode on an outer surface of the ceramic element. Each of the first internal electrodes extends toward and is exposed at the first end surface, and is electrically connected with the first external electrode. Each of the second internal electrodes extends toward and is exposed at the second end surface, and is electrically connected with the second external electrode. The first and the second external electrodes have an L-shape. The second main surface includes embossed holes.