Multilayer Capacitor Electrode Structure for Flexural Shock Resistance
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Solution Overview
Problem
Multilayer capacitors for automotive and electronic applications require enhanced flexural strength to withstand physical impacts, but existing structures and materials fall short in providing the necessary reliability.
Innovation Solution
A multilayer capacitor design featuring external electrodes with a conductive resin layer containing metal particles, elastic fine powder particles with a metal film, and a plating layer, which enhances flexibility and durability by buffering external shocks while maintaining electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional external electrode structure is used, then the manufacturing process is simple, but the flexural strength and reliability against physical impacts are insufficient
Solution Approach 1:
The external electrode uses a composite conductive resin layer containing metal particles (silver, copper, or aluminum) dispersed in a resin matrix. This composite structure provides both mechanical strength to withstand flexural stress and electrical conductivity to maintain electrical connection, resolving the contradiction between strength and structural simplicity.
Solution Approach 2:
The patent applies different materials and structures to different regions of the external electrode. The conductive resin layer with metal particles provides localized reinforcement at the electrode-body interface to enhance flexural strength, while the overall electrode structure maintains electrical connectivity. This localized quality enhancement allows improved strength without requiring complete structural redesign.
2Reliability
If the external electrode is made more robust to withstand impacts, then reliability improves, but the electrical conductivity and flexibility may deteriorate
Solution Approach 1:
The conductive resin layer combines resin material (providing mechanical robustness and impact resistance) with metal particles (providing electrical conductivity). This composite approach ensures that the electrode can withstand physical impacts while maintaining adequate electrical conductivity, preventing energy loss in both mechanical and electrical domains.
Solution Approach 2:
The patent optimizes the concentration, size, and distribution of metal particles within the conductive resin layer. By adjusting these parameters, the electrode achieves the right balance between mechanical strength for impact resistance and electrical conductivity for signal integrity, ensuring reliability without compromising electrical performance.
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 proposed design significantly improves flexural strength and durability, preventing cracks and detachment during impact tests, and maintains electrical performance without compromising conductivity.
Implementation Method 1
a plurality of elastic fine powder particles each having an elastic powder particle and a metal film plated on a surface of the elastic powder particle
Implementation Method 2
the metal film may react with the metal particles to form an alloy
Implementation Method 3
a conductive resin surrounding the plurality of metal particles and the plurality of elastic fine powder particles and contacting the conductive layer
Data Source
AI summary
A multilayer capacitor includes a capacitor body including a dielectric layer and a plurality of internal electrodes, and external electrodes disposed on both ends of the capacitor body and connected to exposed portions of the plurality of internal electrodes, respectively. Each of the external electrodes includes a conductive layer disposed on the capacitor body to be connected to one or more of the plurality of internal electrodes, a conductive resin layer covering the conductive layer, and including a plurality of metal particles, a plurality of elastic fine powder particles each having an elastic powder particle and a metal film plated on a surface of the elastic powder particle, and a conductive resin surrounding the plurality of metal particles and the plurality of elastic fine powder particles and contacting the conductive layer, and a plating layer covering the conductive resin layer.