Multilayer Ceramic Component Silane Coating Thermal Shock

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Solution Overview

Problem

Multilayer ceramic electronic components face challenges in mechanical strength against thermal shock, external moisture, surface discharge, and electric field concentration, which affect their lifespan and reliability, especially in miniaturized high-capacity forms.

Innovation Solution

A multilayer ceramic electronic component is developed with a silane coating layer and a polyxylene polymer film on the ceramic surface, along with a metal epoxy electrode layer, to enhance mechanical strength, fracture characteristics, and moisture resistance, while minimizing surface discharge and electric field concentration, thereby improving reliability and enabling operation at high voltages.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the ceramic layers are thinned to achieve miniaturization, then the component size is reduced, but the mechanical strength and lifespan are reduced due to increased influence of external moisture

Engineering Contradiction:

Improvecomponent sizeVSAvoidlifespan and mechanical strength

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

A coating layer comprising a silane coating layer and a polyxylene polymer film is formed on the ceramic body to provide protective functionality. This thin film structure protects the miniaturized ceramic component from external moisture while maintaining the reduced size, resolving the contradiction between miniaturization and reliability.

Inventive Principle:

Principle #30Flexible shells and thin films

2Volume of moving object

If the ceramic layers are thinned for miniaturization, then the component size is reduced, but the fracture characteristics by thermal shock are worsened

Engineering Contradiction:

Improvecomponent sizeVSAvoidfracture characteristics by thermal shock

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The coating layer with silane coating layer and polyxylene polymer film acts as a protective shell that improves fracture characteristics by thermal shock while maintaining the miniaturized form factor, resolving the contradiction between size reduction and thermal shock resistance.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If the ceramic surface is coated to improve moisture resistance, then the lifespan is extended, but the surface discharge and electric field concentration problems are exacerbated

Engineering Contradiction:

ImprovelifespanVSAvoidsurface discharge and electric field concentration

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The coating layer is designed to be transparent or have low dielectric constant to minimize electric field concentration and surface discharge while providing moisture protection, thus extending lifespan without exacerbating electrical harmful factors.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The dielectric properties of the coating layer are carefully controlled by selecting materials with appropriate dielectric constants and designing optimal thickness parameters to balance moisture protection with electrical performance, preventing excessive electric field concentration.

Inventive Principle:

Principle #35Parameter changes

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 effectively improves the lifespan and reliability of the components by enhancing moisture resistance, mechanical strength, and fracture characteristics, while allowing for high-voltage applications by reducing surface discharge and electric field concentration, and improving bending strength.

Implementation Method 1

a silane coating layer uniformly formed on the outer surface of the element unit

Methodology Applied

Scientific EffectSilane coating: Deposition (physical)

Implementation Method 2

a polyxylene polymer film formed on the silane coating layer

Methodology Applied

Scientific EffectPolymer film formation: Deposition (physical)

Implementation Method 3

providing a metal epoxy electrode layer in an external electrode

Methodology Applied

Scientific EffectMetal epoxy bonding: Adhesive

Data Source

PatentUS11469050B2Multilayer ceramic electronic component and manufacturing method thereof

Publication Date: 2022.10.11 SAMHWA CAPACITOR

AI summary

Provided is a multilayer ceramic electronic component and a manufacturing method thereof, the component comprising: an element unit including a ceramic body, and a plurality of first internal electrodes and second internal electrodes alternately positioned inside the ceramic body to be spaced apart from each other; an external electrode unit including a first external electrode electrically communicating with the first internal electrodes and a second external electrode electrically communicating with the second internal electrodes, which are positioned to surround both sides of the element unit and to be spaced apart from each other; a silane coating layer uniformly formed on an outer surface of the element unit to expose part of an outer surface of the external electrode unit; and a plating layer formed on the exposed area of the external electrode unit.