MLCC External Electrode Structure for Uniform Thin Terminations
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Solution Overview
Problem
Multilayer ceramic capacitors (MLCCs) in electronic devices face issues with non-uniform external electrode thickness, leading to decreased mounting density, deteriorated sealing characteristics, and plating defects due to blistering, which compromises their mechanical strength and reliability in harsh environments.
Innovation Solution
A capacitor component design featuring uniform metal and ceramic layers covering the entire surface, with multilayer external electrodes and additional metal layers for enhanced moisture resistance, formed through a process of transferring and sintering these layers to ensure consistent thickness and improved sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If external electrodes are formed by applying and sintering paste in the related art, then the manufacturing process is simple, but the thickness of outer regions becomes lower than central regions causing non-uniformity
Solution Approach 1:
The patent applies a thickness adjustment layer to the outer regions of the external electrodes before sintering, in advance compensating for the expected thickness reduction during the sintering process. This preliminary action ensures uniform final thickness despite the simplification of using paste application instead of complex deposition processes.
2Productivity
If external electrode thickness is reduced, then mounting density improves, but sealing characteristics deteriorate
Solution Approach 1:
The patent applies different thicknesses of the thickness adjustment layer to different regions: a first thickness to outer regions and a second thickness (different from the first) to other regions. This local differentiation allows the outer regions to have sufficient thickness for sealing while maintaining reduced overall electrode thickness for high mounting density.
3Ease of manufacture
If external electrode thickness is non-uniform, then manufacturing is easier, but plating defects occur due to blistering
Solution Approach 1:
The thickness adjustment layer is applied in advance to compensate for expected thickness variations during sintering, ensuring uniform final thickness and preventing plating defects. This preliminary compensation maintains manufacturing simplicity while eliminating blistering issues.
4Reliability
If uniform thickness is achieved through additional layers, then sealing characteristics improve, but device complexity increases
Solution Approach 1:
The patent controls the thickness parameters of the adjustment layer (first thickness for outer regions, second thickness for other regions) to optimize the balance between sealing characteristics and structural simplicity. By carefully selecting these parameters, the patent achieves improved sealing without excessive 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 solution achieves reduced external electrode thickness, enhanced sealing characteristics, and improved moisture resistance, addressing the issues of non-uniformity and mechanical strength in MLCCs, particularly in environments with vibrations, impacts, and varying temperatures.
Implementation Method 1
forming first and second metal layers on surfaces of the body on which the first and second internal electrodes are exposed, respectively, forming first and second ceramic layers to cover the first and second metal layers
Implementation Method 2
formed through a process of transferring and sintering these layers to ensure consistent thickness and improved sealing
Data Source
AI summary
A capacitor component includes a body having a first surface and a second surface opposing each other and including a multilayer structure in which a plurality of dielectric layers are stacked and first and second internal electrodes are alternately disposed with respective dielectric layers interposed therebetween and exposed to the first surface and the second surface, respectively, first and second metal layers covering the first surface and the second surface and connected to the first and second internal electrodes, respectively, first and second ceramic layers covering the first and second metal layers, and first and second external electrodes covering the first and second ceramic layers and connected to the first and second metal layers to be electrically connected to the first and second internal electrodes, respectively.