Plated External Electrode Adhesion via Composite Layer
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Solution Overview
Problem
Multilayer electronic components with plated external electrodes tend to peel off from the laminate due to lack of adhesion, as they do not contain glass, which is a key adhesive component in other electronic components.
Innovation Solution
Incorporating a second electroconductive layer made of metal and glass or resin over the plated external electrodes to enhance adhesion and prevent peeling, while maintaining the plated material's conductivity and structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the external electrode is formed by plating only, then the manufacturing process is simple and productivity is high, but the adhesion strength to the laminate is insufficient causing peeling
Solution Approach 1:
The external electrode is constructed as a composite structure with a plated material layer (providing conductivity and ease of manufacture) and a paste material layer containing glass or resin (providing adhesion). This composite approach combines the advantages of both materials to achieve both high productivity and reliable adhesion.
Solution Approach 2:
The external electrode is divided into two distinct functional layers: a first layer made of plated material for electrical conductivity and a second layer made of paste material for adhesion. This segmentation allows each layer to perform its specific function optimally without compromising the other.
2Ease of manufacture
If the external electrode is formed by plating only, then the manufacturing cost is low, but the external electrode peels off from the laminate
Solution Approach 1:
The external electrode combines plated material (low cost, easy to manufacture) with paste material containing glass or resin (high adhesion). This composite structure maintains cost-effectiveness while significantly improving peeling resistance through the adhesive properties of the paste material.
Solution Approach 2:
The paste material layer acts as an intermediary between the plated electrode layer and the laminate, providing a bonding interface that enhances adhesion while allowing the plated layer to maintain its electrical functionality.
3Reliability
If glass is added to the external electrode material, then adhesion strength is improved, but the manufacturing complexity increases
Solution Approach 1:
The glass-containing paste material is segregated into a separate second layer, distinct from the plated first layer. This segmentation simplifies the overall structure by assigning specific functions to specific layers, making the complex material composition manageable and manufacturable.
Solution Approach 2:
The glass is incorporated into the paste material matrix in the second layer, creating a composite paste material that provides adhesion while maintaining a relatively simple overall structure that can be manufactured using existing paste coating and firing processes.
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 prevents the external electrodes from peeling off by increasing the adhesion strength to the laminate, ensuring reliable electrical connections and reducing the risk of mechanical stress-induced failures.
Implementation Method 1
an external electrode disposed on a surface of the laminate, the external electrode including a first electroconductive layer disposed on the mounting surface to directly cover the exposed portions and made of a plated material
Implementation Method 2
The glass serves as an adhesive. More specifically, when the external electrode is fired, the glass is softened and then coagulated, whereby the external electrode is fixed to the laminate
Data Source
AI summary
In an electronic component, a laminate includes a plurality of laminated ceramic layers and a mounting surface defined by outer edges of the plurality of laminated ceramic layers, the outer edges being continuously located adjacent to each other. Capacitor conductors are disposed on the ceramic layers and include exposed portions that are exposed at the mounting surface between the ceramic layers. An electroconductive layer defining an external electrode is arranged to directly cover the exposed portions and is formed by plating so as to be made of plated material. Another electroconductive layer covers the above-mentioned electroconductive layer and partially covers surfaces of the laminate, and it is made of a material including metal and one of glass and resin.