Multi-Layer Ceramic Capacitor Terminal Electrode Design
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Solution Overview
Problem
Conventional multilayer ceramic capacitors face challenges in achieving a low profile and strengthening the element body, as thin elements are prone to breakage during processing and plating, and existing solutions do not effectively enhance the bending strength or capacitance.
Innovation Solution
A multi-layer ceramic electronic device with terminal electrodes formed on external surfaces, excluding the lower surface, and incorporating reinforcement layers and cover layers made of materials like glass, which increases bending strength and allows for a thinner profile, improving capacitance and humidity resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the element body is thinned to achieve low profile, then the height of the capacitor is reduced, but the element body becomes prone to breakage during processing and plating
Solution Approach 1:
The patent applies composite materials by forming a reinforcement layer containing inorganic filler particles (such as alumina, silica, or zirconia) dispersed in a glass matrix on the element body. This composite structure provides mechanical strength to the thinned element body while maintaining the low profile, directly resolving the contradiction between reduced height and maintained bending strength.
Solution Approach 2:
The reinforcement layer is applied locally on specific surfaces of the element body rather than throughout the entire structure. This localized application provides strength enhancement exactly where needed during handling and plating processes, while keeping the overall height minimal and maintaining electrical performance characteristics.
2Length of stationary object
If the element body is thinned to achieve low profile, then the capacitor height is reduced, but the element body easily breaks during handling and plating processes
Solution Approach 1:
The reinforcement layer with inorganic filler particles creates a composite structure that significantly improves handling reliability. The filler particles provide structural support and crack resistance, enabling the thinned element body to withstand handling and plating processes without breaking, thus resolving the contradiction between low profile and handling reliability.
3Quantity of substance
If terminal electrodes are formed on both upper and lower surfaces, then the capacitance is increased, but the height of the capacitor increases
Solution Approach 1:
The patent applies asymmetry by forming terminal electrodes and reinforcement layers only on the upper surface of the element body, while leaving the lower surface without these additions. This asymmetric configuration allows the capacitor to achieve adequate capacitance through optimized internal electrode structures without increasing height from bottom electrodes, resolving the contradiction between capacitance and height.
Solution Approach 2:
The patent compensates for the reduced height by optimizing the internal electrode layer configuration and increasing the surface area utilization in the planar dimensions. This dimensional shift allows capacitance to be maintained or improved while achieving low profile through reduced height.
Data Source
AI summary
A multi-layer ceramic electronic device includes an element body and terminal electrodes. The terminal electrodes include end electrode parts covering ends of the element body in which internal electrode layers are led and upper electrode parts continuing to the end electrode parts and each partially covering an upper surface of the element body in a lamination direction. An upper-surface cover layer covering the upper surface of the element body located between the upper electrode parts has an external surface substantially flush with external surfaces of the upper electrode parts. The terminal electrodes are not substantially formed on a lower surface of the element body located opposite to the upper surface of the element body in the lamination direction.