Multilayered capacitor and manufacturing method thereof

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Solution Overview

Problem

Multilayered capacitors face challenges in achieving high bending strength and electrical connectivity due to the use of resin-based external electrodes, which improve mechanical characteristics but deteriorate electrical connectivity compared to sintered external electrodes.

Innovation Solution

A multilayered capacitor design incorporating a conductive polymer layer with a metal coating on its external electrodes, comprising a first layer connected to internal electrodes and a second layer covering at least a portion of the first layer, improves bending strength and reduces acoustic noise while maintaining electrical connectivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If resin-based external electrodes are used to improve mechanical characteristics, then bending strength is improved, but electrical connectivity deteriorates

Engineering Contradiction:

Improvebending strengthVSAvoidelectrical connectivity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The external electrode is constructed as a composite structure with a first layer (sintered external electrode) and a second layer (resin-based external electrode). The first layer provides excellent electrical connectivity through sintered metal powder and binder, while the second layer provides higher ductility and improved mechanical characteristics. This composite structure resolves the contradiction by combining materials with complementary properties.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The external electrode is divided into two distinct layers with different functions: the first layer is optimized for electrical connectivity and the second layer is optimized for mechanical characteristics. This segmentation allows each layer to perform its specialized function without compromising the other, resolving the contradiction between electrical and mechanical performance.

Inventive Principle:

Principle #1Segmentation

2Reliability

If sintered external electrodes are used to ensure electrical connectivity, then electrical connectivity is improved, but mechanical reliability deteriorates

Engineering Contradiction:

Improveelectrical connectivityVSAvoidmechanical reliability

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The external electrode uses a composite structure where the first layer (sintered external electrode) ensures excellent electrical connectivity through sintered metal powder and binder, while the second layer (resin-based external electrode) provides higher ductility and improved mechanical characteristics. This composite structure resolves the contradiction by combining materials with complementary properties.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Inventive Principle:

Principle #1Segmentation

3Reliability

If a two-layer external electrode structure is implemented, then mechanical and electrical performance is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveoverall performanceVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The first layer (sintered external electrode) is formed and sintered first to establish the base structure with excellent electrical connectivity. Then the second layer (resin-based external electrode) is formed over the first layer to provide improved mechanical characteristics. This sequential preliminary action allows each layer to be optimized independently while simplifying the overall manufacturing process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The external electrode uses a composite structure with a first layer (sintered external electrode) and a second layer (resin-based external electrode). The first layer provides excellent electrical connectivity through sintered metal powder and binder, while the second layer provides higher ductility and improved mechanical characteristics. This composite structure resolves the contradiction by combining materials with complementary properties.

Inventive Principle:

Principle #40Composite materials

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 design enhances bending strength and reduces acoustic noise by utilizing a conductive polymer layer with a metal coating, ensuring improved mechanical reliability and electrical performance without additional processing steps.

Implementation Method 1

the second layer includes resin and conductive polymer particles

Methodology Applied

Scientific EffectConductive polymer:

Implementation Method 2

The conductive polymer particles may further include a metal coating layer on their surfaces

Methodology Applied

Scientific EffectMetal coating: Deposition (physical)

Data Source

PatentUS12525401B2Multilayered capacitor and manufacturing method thereof

Publication Date: 2026.01.13 SAMSUNG ELECTRO MECHANICS CO LTD

AI summary

A multilayered capacitor includes a capacitor body including a dielectric layer and an internal electrode, and an external electrode disposed outside the capacitor body, wherein the external electrode includes a first layer connected to the internal electrode, and a second layer covering at least a portion of the first layer, and the second layer includes resin and conductive polymer particles.