Multilayer Filter Resistance Control via Through-Hole Conductor

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Solution Overview

Problem

Existing multilayer filters face challenges in accurately controlling the resistance of the resistance component, particularly when setting it to a large value, due to difficulties in adjusting the compounding ratio of dielectric powder in resistive pastes.

Innovation Solution

The multilayer filter design includes a capacitor element body with laminated insulator layers and internal electrodes, where signal internal electrodes are connected through a through-hole conductor, allowing for precise control of resistance by adjusting the number and location of connected electrodes, and optionally using meander-shaped electrodes to increase resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the compounding ratio of dielectric powder in resistive paste is adjusted to control resistance, then the resistance value can be modified, but it becomes extremely difficult to accurately control the resistance, especially setting it to a large value

Engineering Contradiction:

Improveresistance control accuracyVSAvoidresistance adjustment difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent divides the resistance control function into separate segments: the resistive paste provides base resistance, while additional discrete resistors are added to achieve the desired total resistance value. This segmentation allows independent optimization of each component and enables precise resistance control without relying solely on difficult-to-control paste composition ratios.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces an intermediary element (discrete resistor) between the resistive paste and the final resistance requirement. This intermediary allows the system to achieve precise resistance values by combining the paste's inherent resistance with the discrete resistor's known resistance, avoiding the need to precisely control the paste's compounding ratio alone.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Quantity of substance

If the lamination number of insulator layers and internal electrodes is increased to achieve larger capacitance, then the capacitance value increases, but the combined resistance of signal internal electrodes decreases

Engineering Contradiction:

Improvecapacitance valueVSAvoidresistance value

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent merges two independent resistance control mechanisms: the resistive paste's resistance and discrete resistors. This combination allows the system to simultaneously achieve large capacitance (through increased lamination) and large resistance values (through the series combination of paste resistance and discrete resistors), resolving the trade-off between capacitance and resistance.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent performs preliminary resistance adjustment by selecting appropriate discrete resistor values before final assembly. This preliminary action allows the designer to predict and control the total resistance (paste resistance plus discrete resistor) while independently optimizing the capacitance through lamination, avoiding the need to increase lamination number for resistance control.

Inventive Principle:

Principle #10Preliminary action

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

This configuration enables accurate control of the resistance component, allowing for larger capacitance and resistance values, effectively addressing the challenge of setting resistance to desired levels while maintaining high capacitance.

Implementation Method 1

the first signal internal electrode is connected through a through-hole conductor to only the second signal internal electrode

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

a capacitance is generated between the first and second conductor electrodes

Methodology Applied

Scientific EffectCapacitance: Capacitance

Implementation Method 3

the resistance of the resistor is adjusted by changing a compounding ratio of a dielectric powder in a resistive paste for formation of the resistor

Methodology Applied

Scientific EffectElectrical resistance: Electrical Resistance

Data Source

PatentUS7786824B2Multilayer filter

Publication Date: 2010.08.31 TDK CORP

AI summary

A multilayer filter has a capacitor element body, at least two signal terminal electrodes, and at least one grounding terminal electrode. The capacitor element body has a plurality of laminated insulator layers, a first signal internal electrode and a grounding internal electrode arranged to be opposed to each other with at least one insulator layer out of the plurality of insulator layers in between, and a second signal internal electrode arranged to be opposed to either one internal electrode of the first signal internal electrode and the grounding internal electrode with at least one insulator layer out of the plurality of insulator layers in between. The second signal internal electrode is connected to the at least two signal terminal electrodes. The first signal internal electrode is connected through a through-hole conductor to only the second signal internal electrode. The grounding internal electrode is connected to the at least one grounding terminal electrode.