Resin Electrode Porosity Reduction in Multilayer Ceramic Capacitors
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Solution Overview
Problem
Multilayer ceramic electronic components often crack due to high porosity in electrically conductive resin electrode layers, which decreases relaxation properties and increases the likelihood of ceramic base body cracking.
Innovation Solution
Incorporating an alkyl-based silane coupling agent in the electrically conductive paste for the resin electrode layer improves dispersibility and reduces porosity, enhancing the relaxation properties of the resin and preventing ceramic base body cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stearic acid is used for surface treatment of metal powder in electrically conductive resin paste, then electrical resistivity is reduced, but porosity increases and relaxation properties decrease
Solution Approach 1:
The patent changes the chemical parameter of the surface treatment agent from stearic acid (fatty acid) to alkyl-based silane coupling agent. This parameter change fundamentally alters the interaction between metal powder particles and resin, reducing porosity while maintaining electrical conductivity. The silane coupling agent creates stronger chemical bonds and better dispersion, eliminating the porosity issue that occurs with fatty acid treatment.
Solution Approach 2:
The alkyl-based silane coupling agent acts as an intermediary substance between the metal powder and the resin matrix. It provides both electrical conductivity (like the metal) and chemical bonding capability (like the resin), creating a bridge that improves overall composite structure. This intermediary reduces interfacial porosity and enhances stress transfer, preventing ceramic cracking while maintaining electrical pathways.
2Ease of manufacture
If electrically conductive resin electrode layer has high porosity, then manufacturing is easier, but relaxation properties decrease and ceramic base body cracks
Solution Approach 1:
The patent changes the chemical composition parameter of the resin paste by incorporating alkyl-based silane coupling agent. This parameter change fundamentally alters the curing behavior and final structure of the resin electrode layer, achieving low porosity without compromising manufacturability. The silane-modified resin maintains good processability while forming a denser, more reliable final structure that prevents ceramic cracking.
3Stability of the object's composition
If porosity of resin external electrode layer is decreased, then relaxation properties improve, but dispersibility of metal powder and resin must be improved
Solution Approach 1:
The alkyl-based silane coupling agent serves as an intermediary that simultaneously improves both dispersibility and reduces porosity. It coats the metal powder surface, preventing aggregation and ensuring uniform distribution within the resin matrix. This intermediary function eliminates the need for complex dispersing mechanisms while achieving the desired low-porosity structure.
Solution Approach 2:
The patent creates a composite material system where the silane coupling agent forms a bridge between metal powder and resin phases. This composite approach combines the electrical conductivity of metal, the binding properties of resin, and the surface-modifying capabilities of silane, achieving superior dispersibility and reduced porosity through material composition rather than complex processing.
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 an alkyl-based silane coupling agent in the resin external electrode layer significantly decreases porosity and improves the relaxation properties of the resin, reducing the likelihood of ceramic base body cracking and lowering equivalent series resistance (ESR).
Implementation Method 1
The dispersibility of the metal powder and the resin in the resin external electrode layer significantly improves and the porosity of the resin external electrode layer decreases
Data Source
AI summary
A multilayer ceramic capacitor includes a ceramic base body including ceramic layers and internal electrode layers, which are stacked on each other, and a pair of external electrodes provided on the end surfaces of the ceramic base body and electrically connected to the internal electrode layers. Each of the external electrodes includes an underlying electrode layer and a resin external electrode layer stacked on the underlying electrode layer. The resin external electrode layer includes a thermosetting resin, a metal powder, and an alkyl-based silane coupling agent.