Multilayer Electronic Component Resin Electrode for Low DC Resistance
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Solution Overview
Problem
Multilayer ceramic capacitors with two-layer external electrodes, comprising a fired electrode layer and a conductive resin layer, are prone to lifting defects due to outgassing in high-temperature reflow environments, and exhibit higher DC resistance, leading to excessive heat generation and reduced lifespan.
Innovation Solution
A multilayer electronic component design featuring a body with dielectric layers and internal electrodes, where the external electrodes include a conductive resin layer with a specific ratio of conductive particles having a Feret diameter of 14 μm or more, improving electrical connectivity and reducing DC resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conductive resin layer is applied to protect the multilayer ceramic capacitor from tensile stress, then mechanical strength is improved, but lifting defects occur due to outgassing in high-temperature reflow environments
Solution Approach 1:
The patent specifies precise compositional parameters for the conductive resin layer, including the ratio of conductive particles to resin (90:10 to 99:1 by weight), particle size distribution (D10: 3-7 μm, D50: 8-12 μm, D90: 13-17 μm), and chemical composition (silver content 97-99.9 wt%). These parameter optimizations ensure the conductive resin layer maintains mechanical protection while resisting outgassing-induced lifting in high-temperature environments.
2Reliability
If metal particles are dispersed in resin to secure electrical connectivity, then electrical connectivity is achieved, but DC resistance increases leading to heat generation
Solution Approach 1:
The patent employs a composite conductive resin layer combining silver particles (97-99.9 wt%) with specific resin materials. This composite structure achieves excellent electrical connectivity through the high-conductivity silver particle network while the resin matrix provides structural integrity, resulting in low DC resistance (0.01-0.1 Ω) and reduced energy loss.
3Adaptability or versatility
If the conductive resin layer is used in high voltage electric devices, then versatility is improved, but heat generation increases due to high resistance
Solution Approach 1:
The patent optimizes multiple parameters of the conductive resin layer to reduce resistance and heat generation: silver particle concentration (97-99.9 wt%), particle size distribution (D10: 3-7 μm, D50: 8-12 μm, D90: 13-17 μm), and thickness (5-20 μm). These parameter changes enable the component to handle high voltage applications effectively while maintaining low heat generation through minimized resistive losses.
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 effectively reduces DC resistance and heat generation, enhancing the reliability of multilayer electronic components by preventing lifting defects and improving electrical connectivity within the conductive resin layer.
Implementation Method 1
In the conductive resin layer, metal particles having conductivity are dispersed in a resin to secure electrical connectivity by hopping conduction
Implementation Method 2
a significant amount of heat may occur in the multilayer ceramic capacitor due to high resistance of the conductive resin layer
Data Source
AI summary
A multilayer electronic component includes a body including a dielectric layer and first and second internal electrodes, first and second external electrodes respectively disposed on opposing surfaces of the body and connected to the first internal electrode, and a third external electrode disposed on the body, disposed between the first and second external electrodes and connected to the second internal electrode. One of the first and second external electrodes includes a first conductive resin layer, the first conductive resin layer includes first conductive particles including at least one of a first metal particle and a first intermetallic compound, and a first resin, and a ratio N1/N2 is 17% or more, in which N1 is the number of particles having a Feret diameter of 14 μm or more, among the first conductive particles, and N2 is a total number of first conductive particles.