PDMS Conductive Resin for MLCC External Electrode Flexure
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Solution Overview
Problem
Multilayer ceramic capacitors face issues with crack formation in external electrodes due to external impacts and plating liquid permeation, limiting their reliability and flexure strength, especially when using epoxy-based conductive resin compositions.
Innovation Solution
A conductive resin composition comprising 10 to 50 wt % gel-type silicon rubber, such as polydimethylsiloxane (PDMS), and 50 to 90 wt % conductive metal powder particles, including copper or silver, is used to form soft-termination layers in multilayer ceramic capacitors, enhancing moisture resistance and flexure strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If epoxy is used as the resin component of the conductive resin composition, then the material properties provide basic structural support, but the flexure strength of the external electrode is limited and cannot be sufficiently improved
Solution Approach 1:
The patent changes the material parameter from epoxy to gel-type silicon rubber, which fundamentally alters the mechanical properties of the conductive resin composition. This parameter change enables the external electrode to achieve both high flexure strength and high reliability under external impact, resolving the technical contradiction between strength improvement and reliability maintenance.
Solution Approach 2:
The patent creates a composite material by combining gel-type silicon rubber with conductive metal powder particles. This composite structure provides both the flexibility and strength needed for the external electrode, while maintaining electrical conductivity. The composite material approach allows simultaneous improvement of flexure strength and impact resistance, resolving the contradiction between strength enhancement and reliability preservation.
2Productivity
If the multilayer ceramic capacitor is microminiaturized with thinner dielectric layers and internal electrodes, then the capacitance density increases, but the occurrence of cracks in external electrodes due to external impact increases
Solution Approach 1:
The patent changes the resin material parameter from epoxy to gel-type silicon rubber, which has superior flexibility and shock absorption properties. This parameter change allows the external electrode to withstand external impacts without cracking, even in microminiaturized capacitors with thinner dielectric layers and internal electrodes, thus resolving the contradiction between increased capacitance density and reduced crack formation.
3Ease of manufacture
If the external electrode structure is simplified without the conductive resin layer, then the manufacturing process is simpler, but the plating liquid permeation into the ceramic body occurs
Solution Approach 1:
The patent introduces a conductive resin layer made of gel-type silicon rubber as an intermediary between the external electrode and the plating layer. This intermediary layer effectively blocks plating liquid permeation into the ceramic body while maintaining electrical conductivity. The use of gel-type silicon rubber specifically provides excellent barrier properties, resolving the contradiction between manufacturing simplicity and permeation resistance.
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 use of the PDMS-based conductive resin composition significantly improves the flexure strength and moisture resistance of multilayer ceramic capacitors, providing a more reliable and durable external electrode structure.
Implementation Method 1
a resin composition including a conductive material is coated between the external electrode and the plating layer, thereby absorbing the external impact
Implementation Method 2
effectively blocking permeation of the plating liquid
Data Source
AI summary
There is provided a conductive resin composition including 10 to 50 wt % of a gel type silicon rubber such as polydimethylsiloxane (PDMS), and 50 to 90 wt % of conductive metal powder particles.