Four-Layer Multilayer Capacitor Electrode for Bending Strength
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Solution Overview
Problem
Multilayered capacitors face challenges in balancing mechanical reliability and electrical connectivity, particularly in automotive applications, where resin-based external electrodes improve ductility but compromise electrical characteristics and bending strength.
Innovation Solution
A multilayered capacitor design with a four-layer external electrode structure, comprising a sintered metal layer, conductive resin layers, and a plating layer, enhances bonding strength, moisture resistance, and electrical connectivity by optimizing the area ratios and lengths of these layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If resin-based external electrodes are applied to improve ductility, then bending strength is improved, but electrical connectivity deteriorates
Solution Approach 1:
The external electrode is divided into multiple functional layers: a sintered external electrode layer (first layer) for electrical connectivity, and a resin-based external electrode layer (second layer) for mechanical strength and ductility. This segmentation allows each layer to perform its specialized function without compromising the other.
Solution Approach 2:
The invention uses composite material structures where the sintered metal layer provides electrical conductivity while the resin-based layer provides mechanical flexibility. The combination creates an external electrode system that simultaneously achieves both electrical connectivity and bending strength.
2Reliability
If metal content in resin-based external electrodes is increased to improve electrical characteristics, then electrical connectivity improves, but ductility deteriorates
Solution Approach 1:
The external electrode is segmented into a sintered metal layer (first layer) that provides electrical connectivity and a resin-based layer (second layer) that provides ductility. This eliminates the need to balance metal content in a single-layer resin-based electrode, as each layer has its optimized composition.
Solution Approach 2:
Different regions of the external electrode have different material compositions optimized for their specific functions: the sintered metal layer has high metal content for electrical conductivity, while the resin-based layer has high resin content for ductility and bending strength.
3Reliability
If sintered external electrodes are used to ensure electrical connectivity, then electrical characteristics improve, but mechanical reliability deteriorates
Solution Approach 1:
The external electrode is segmented into a sintered metal layer (first layer) for electrical connectivity and a resin-based layer (second layer) for mechanical reliability. The resin-based layer covers portions of the sintered layer, providing mechanical protection and flexibility while allowing electrical connections through exposed regions.
Solution Approach 2:
The invention creates a composite external electrode structure combining sintered metal and resin-based materials. The sintered metal provides electrical conductivity while the resin matrix provides mechanical strength, ductility, and stress relief capabilities.
Data Source
AI summary
Disclosed is a multilayered capacitor that includes a capacitor body including a dielectric layer and an internal electrode, and an external electrode outside the capacitor body, wherein the external electrode includes a first layer connected to the internal electrode, a second layer covering a portion of the first layer and exposing another portion, a third layer covering the second layer and including a resin and a conductive metal, and a fourth layer covering the first and third layers, and an area ratio of the resin included in the second layer is greater than an area ratio of the resin included in the third layer.