U.S. patent application number 09/740870 was filed with the patent office on 2001-05-17 for ceramic capacitor.
This patent application is currently assigned to TDK Corporation. Invention is credited to Aiba, Yuji, Ishigaki, Takaya, Ishikawa, Masatoshi, Itakura, Shunji, Kamiya, Takashi, Yamamoto, Masanori.
Application Number | 20010001258 09/740870 |
Document ID | / |
Family ID | 27453500 |
Filed Date | 2001-05-17 |
United States Patent
Application |
20010001258 |
Kind Code |
A1 |
Ishigaki, Takaya ; et
al. |
May 17, 2001 |
Ceramic capacitor
Abstract
The present invention relates to a ceramic capacitor having
metal plate terminals that absorb thermal stress and mechanical
stress caused by flexure of the substrate. A ceramic capacitor
element is provided with terminal electrodes at the two side end
surfaces facing opposite each other. The metal plate terminals are
each connected to one of the terminal electrodes at one end
thereof, are each provided with a folded portion in a middle area
and a terminal portion to be connected to the outside toward the
other end from the folded portion.
Inventors: |
Ishigaki, Takaya;
(Honjo-shi, JP) ; Ishikawa, Masatoshi; (Yuri-gun,
JP) ; Kamiya, Takashi; (Yuri-gun, JP) ;
Itakura, Shunji; (Yotsukaido-shi, JP) ; Aiba,
Yuji; (Yuri-gun, JP) ; Yamamoto, Masanori;
(Yuri-gun, JP) |
Correspondence
Address: |
OBLON SPIVAK MCCLELLAND MAIER & NEUSTADT PC
FOURTH FLOOR
1755 JEFFERSON DAVIS HIGHWAY
ARLINGTON
VA
22202
US
|
Assignee: |
TDK Corporation
13-1, Nihonbashi 1-chome Chuo-ku
Tokyo
JP
103-0027
|
Family ID: |
27453500 |
Appl. No.: |
09/740870 |
Filed: |
December 21, 2000 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09740870 |
Dec 21, 2000 |
|
|
|
09226918 |
Jan 5, 1999 |
|
|
|
Current U.S.
Class: |
361/502 |
Current CPC
Class: |
H01F 2027/295 20130101;
Y02P 70/613 20151101; Y02P 70/50 20151101; Y10T 29/435 20150115;
H01G 4/232 20130101; Y10T 29/43 20150115; H05K 3/3426 20130101;
H01G 4/38 20130101; Y10T 29/49149 20150115; Y10T 29/49144
20150115 |
Class at
Publication: |
361/502 |
International
Class: |
H01G 009/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 7, 1998 |
JP |
10-1884 |
Jan 29, 1998 |
JP |
10-17565 |
Feb 9, 1998 |
JP |
10-27629 |
May 8, 1998 |
JP |
10-142226 |
Claims
What is claimed is:
1. A ceramic capacitor comprising: at least one ceramic capacitor
element having terminal electrodes at two side end surfaces facing
opposite each other; and at least a pair of metal plate terminals
each connected to one of said terminal electrodes at the front end
thereof and each provided with a folded portion in a middle area
thereof and a terminal portion to be connected to the outside to
the rear of said folded portion.
2. The ceramic capacitor of claim 1, wherein: said folded portion
of each of said metal plate terminals includes at least one bent
portion; and said metal plate terminals are each connected to one
of said terminal electrodes at an area between a first bent portion
of said folded portion and said front end.
3. The ceramic capacitor of claim 2, wherein: said folded portion
of each of said metal plate terminals includes two bent
portions.
4. The ceramic capacitor of claim 3, wherein: said folded portion
of each of said metal plate terminals includes a first bent portion
and a second bent portion; and said folded portion is bent away
from said terminal electrode at said first bent portion and, at
said second bent portion, is bent so as to face opposite said end
surfaces over a distance from said first bent portion.
5. The ceramic capacitor of claim 2, wherein: said folded portion
of each of said metal plate terminals is constituted of one bent
portion and is bent at an acute angle.
6. The ceramic capacitor of claim 5, wherein: the maximum distance
between two portions facing opposite each other formed through
bending at each of said metal plate terminals is 300 .mu.m or
less.
7. The ceramic capacitor of claim 2, wherein: said folded portion
of each of said metal plate terminals is bent in an arc.
8. The ceramic capacitor of claim 1, wherein: said terminal portion
is provided with at least one hole.
9. The ceramic capacitor of claim 1, wherein: said metal plate
terminals are each connected to one of said terminal electrodes at
said front end and provided with a folded portion in a middle area
thereof and a terminal portion to be connected to the outside to
the rear of said folded portion, with a coefficient of average
linear expansion .alpha. thereof over a range of -55.degree. C. to
125.degree. C. set at 13.times.10.sup.-6 or lower.
10. The ceramic capacitor of claim 9, wherein: said metal plate
terminals are constituted of an alloy with Fe accounting for 55 wt
% to 70 wt % and Ni accounting for 30 wt % to 45 wt %.
11. The ceramic capacitor of claim 1, wherein: said metal plate
terminals and said terminal electrodes are connected via a
solder.
12. The ceramic capacitor of claim 11, wherein: said solder has a
melting point within the range of 200.degree. C. or higher and
400.degree. C. or lower.
13. The ceramic capacitor of claim 1, wherein said terminal portion
is located under a ceramic capacitor element positioned at a
lowermost layer among said ceramic capacitor elements over a
distance.
14. The ceramic capacitor of claim 1, wherein: the length of a path
in each of said metal plate terminals extending from said terminal
portion to a mounting portion at which said terminal electrode is
mounted is larger than a component height relative to said terminal
portion.
15. The ceramic capacitor of claim 1, wherein: the apex of said
folded portion is located at a position that is lower than the apex
of said ceramic capacitor element.
16. The ceramic capacitor of claim 1, wherein: said metal plate
terminals are each provided with a bent portion between said folded
portion and said terminal portion; and each of said metal plate
terminals is bent between said folded portion and said terminal
portion in a direction such that said terminal portion approaches
said ceramic capacitor element.
17. The ceramic capacitor of claim 1, wherein: said metal plate
terminals are each provided with another bent portion in an area
extending from said front end thereof to a first bent portion of
said folded portion, with a portion extending from said another
bent portion to said first bent portion facing opposite said side
end surface over a distance and a portion between said front end
and said another bent portion connected to said terminal
electrode.
18. The ceramic capacitor of claim 1, wherein: a plurality of said
ceramic capacitor elements are sequentially laminated, with said
terminal electrodes thereof connected in parallel.
19. The ceramic capacitor of claim 18, wherein: said metal plate
terminals are each connected to at least one of said terminal
electrodes of said plurality of ceramic capacitor elements.
20. The ceramic capacitor of claim 19, wherein: a portion between
said front end and said another bent portion is located between two
terminal electrodes of two ceramic capacitor elements and is
connected to said two terminal electrodes.
21. The ceramic capacitor of claim 20, wherein: a portion between
said front end and said another bent portion is provided to support
a terminal electrode of a ceramic capacitor element at a lowermost
layer among said plurality of ceramic capacitor elements and is
connected to said terminal electrode.
22. The ceramic capacitor of claim 1, provided with a plurality of
internal electrodes inside a ceramic dielectric base body, wherein:
said internal electrodes are each connected to one of said terminal
electrodes at one end, with another end thereof set at a distance
from said other terminal electrode and said distance set at a
length that ensures that a vertical line drawn from said other end
in a direction of the thickness of said ceramic dielectric base
body does not intersect said terminal electrode.
23. The ceramic capacitor of claim 1, wherein: said terminal
electrodes are formed only at said side end surfaces.
24. The ceramic capacitor of claim 1, wherein: said ceramic
capacitor element satisfies .alpha..sub.1<.alpha..sub.2 with
.alpha..sub.1 representing a coefficient of average linear
expansion thereof over a temperature range of 25.degree. C. to
-55.degree. C. and .alpha..sub.2 representing a coefficient of
average linear expansion thereof over a temperature range of
25.degree. C. to 125.degree. C.; and said metal plate terminals
satisfy .beta.<1.3 .alpha..sub.2 and .beta.>0.7 .alpha..sub.1
with .beta. representing a coefficient of average linear expansion
thereof over a temperature range of -55.degree. C. to 125.degree.
C.
25. The ceramic capacitor of claim 24, wherein: said ceramic
capacitor element, with a main constituent of a dielectric body
thereof constituted of barium titanate, satisfies
.alpha..sub.1.ltoreq.7.times.10.sup.-6 and
.alpha..sub.2.gtoreq.9.times.10.sup.-6.
26. The ceramic capacitor of claim 24, wherein: said ceramic
capacitor element, with a main constituent of a dielectric body
thereof constituted of lead type combined perovskite, satisfies
.alpha..sub.1.ltoreq.2.times.- 10.sup.-6 and
.alpha..sub.2.gtoreq.3.times.10.sup.-6.
27. The ceramic capacitor of claim 1, wherein: a plurality of said
ceramic capacitor elements are laminated while maintaining a
distance of 20 .mu.m or smaller between individual ceramic
capacitor elements, with said terminal electrodes soldered onto
said metal plate terminals.
28. A method for manufacturing a ceramic capacitor comprising a
plurality of ceramic capacitor elements and at least a pair of
metal plate terminals, with said ceramic capacitor elements each
having terminal electrodes at two side end surfaces facing opposite
each other, said ceramic capacitor elements laminated sequentially,
and said metal plate terminals each soldered onto one of said
terminal electrodes at a front end thereof and each provided with a
folded portion in a middle area thereof and a terminal portion to
be connected to the outside to the rear of said folded portion,
wherein: said plurality of ceramic capacitor elements are assembled
by maintaining gaps therebetween at 20 .mu.m or smaller; a solder
paste constituted of solder particles 90% or more of which have
particle sizes ranging between 35 .mu.m and 55 .mu.m and a
rosin-type resin is applied to surfaces of individual terminal
electrodes of said ceramic capacitor elements and surfaces of said
metal plate terminals that face opposite each other; and a
soldering process is implemented in a reflow furnace with an oxygen
content at 100 ppm or less.
29. The manufacturing method of claim 28, wherein: said solder
paste is constituted of solder particles and a rosin-type resin
applied at an application quantity of 0.02 mg/mm.sup.2 to 0.06
mg/mm.sup.2; the content of said solder particles is within the
range of 70 wt % to 75 wt %; the content of said rosin-type resin
is within the range of 25 wt % to 30 wt %; and said soldering
process in said reflow furnace is implemented within a temperature
range of 250.degree. C. to 350.degree. C.
Description
BACKGROUND OF THE INVENTION
1. 1. Field of the Invention
2. The present invention relates to a ceramic capacitor, and more
specifically it relates to a ceramic capacitor employed as a
smoothing capacitor for a switching source.
3. 2. Discussion of Background
4. Up to the present time, most smoothing capacitors for switching
sources have been constituted of aluminum electrolytic capacitors.
However, as the demand for both miniaturization and improved
reliability have increased in the market, the need for a compact
ceramic capacitor assuring a high degree of reliability has also
increased.
5. Generally speaking, since a great deal of heat is generated in
the vicinity of a source, substrates are normally constituted of an
aluminum having a high heat discharge capacity. However, since the
temperature in the vicinity of the source changes greatly when the
source is turned on and off, a great deal of thermal stress occurs
at a ceramic capacitor mounted on the aluminum substrate, which has
a high coefficient of thermal expansion. This thermal stress causes
cracking to occur at the ceramic capacitor, which, in turn, may
induce problems such as shorting defects and arcing.
6. In order to prevent problems such as arcing, it is crucial that
the thermal stress occurring at the ceramic capacitor be reduced.
As a means for reducing the thermal stress, Japanese Examined
Utility Model Publication No. 46258/1993, Japanese Unexamined
Patent Publication No. 171911/1992, Japanese Unexamined Patent
Publication No. 259205/1992 and the like disclose a structure
achieved by soldering a metal plate onto a terminal electrode of
the ceramic capacitor and mounting the metal plate onto the
aluminum substrate to prevent the ceramic capacitor from being
soldered directly onto the aluminum substrate.
7. Under normal circumstances, it is necessary to set the length of
the leg portion of the metal plate extending from the terminal
portion to be soldered onto the aluminum substrate to the portion
where it is connected to the ceramic capacitor as large as possible
in order to ensure that the thermal stress caused by the expansion
and contraction of the aluminum substrate is absorbed to a
sufficient degree. However, since products in the prior art adopt a
structure in which the height of the ceramic capacitor is bound to
increase if the legs of the metal plate are lengthened, the length
of the leg of the metal plate must be restricted to ensure that it
is less than the allowable height that is permitted on the
substrate.
8. Because of this, the length of the legs of the metal plate
cannot be set at a large value in the products in the prior art
and, consequently, if the ceramic capacitor is continuously
operated over an extended period of time in an environment where
the temperature changes drastically (-55.degree. C. to 120.degree.
C.), as in the vicinity of a source, cracks will occur near the
ends of the ceramic capacitor, presenting a high risk of arcing.
This gravely compromises the reliability of the ceramic capacitor
and has been a obstacle to the wider use of ceramic capacitors.
9. In addition, the metal plate in the prior art is constituted of
phosphor bronze, silver, copper, stainless steel, aluminum, nickel
silver or the like. However, these metals all have a coefficient of
average linear expansion that is markedly higher than the
coefficient of average linear expansion of the ceramic dielectric
material constituting the ceramic capacitor. Thus, if any of them
is employed to constitute a component to be mounted in the vicinity
of a source where the temperature changes greatly, a great deal of
stress is applied to, in particular, the area where the metal plate
is connected due to the difference between the coefficient of
average linear expansion of the ceramic capacitor element and the
coefficient of average linear expansion of the metal plate to
result in cracking occurring near the ends of the ceramic
capacitor, which may lead to problems such as continuity defects,
arcing and the like.
10. Furthermore, ceramic capacitors achieving a large capacity by
laminating a plurality of laminated ceramic capacitor elements,
soldering metal plate terminals onto terminal electrodes of the
individual laminated ceramic capacitor elements and electrically
connecting in parallel the plurality of laminated ceramic capacitor
elements have been proposed (e.g., Japanese Unexamined Patent
Publication No. 188810/1992, Japanese Unexamined Patent Publication
No. 17679/1996).
11. Normally, soldering paste containing solder particulates,
rosin-type resin, an actuator and the like is employed to solder
and secure metal plate terminals onto the terminal electrodes of
laminated ceramic capacitor elements. The activator is constituted
of a halogen compound containing chlorine and the like. The
particle size of the solder particulate is set at approximately 1
.mu.m to 50 .mu.m. The rosin-type resin content is set within the
range of 50 wt % to 55 wt %. The content of the activator which is
constituted of a halogen compound containing chlorine and the like
is set at approximately 1%. In addition, the distance formed
between the individual capacitor elements when combining the
laminated ceramic capacitor elements is maintained within a range
of 10 .mu.m to 20 .mu.m.
12. However, when soldering the metal plate terminals onto the
individual terminal electrodes of the laminated ceramic capacitor
elements, the solder particles and the flux contained in the
soldering paste enter the gaps between the laminated ceramic
capacitor elements to result in buildup occurring due to the solder
balls and the flux, presenting problems such as shorting defects
between the terminals and deteriorated insulation.
SUMMARY OF THE INVENTION
13. It is an object of the present invention to provide a ceramic
capacitor in which cracks, damage and the like can be prevented
from occurring at the ceramic capacitor element with a high degree
of reliability.
14. It is a further object of the present invention to provide a
ceramic capacitor in which the thermal stress and the mechanical
stress occurring at the ceramic capacitor element can be
reduced.
15. It is a still further object of the present invention to
provide a ceramic capacitor in which the length of the metal plate
terminal extending from the terminal portion located toward the
substrate to the ceramic capacitor element is increased without
increasing its height.
16. It is a still further object of the present invention to
provide a ceramic capacitor in which cracks, damage and the like
can be prevented from occurring at the ceramic capacitor element
with a high degree of reliability within a temperature range of
-55.degree. C. to 125.degree. C.
17. It is a still further object of the present invention to
provide a ceramic capacitor achieving an improvement in reliability
by preventing solder particles and soldering flux from entering
gaps between the ceramic capacitor elements.
18. In order to achieve the objects described above, the present
invention discloses a structure of metal plate terminals, the
material that should be selected to constitute the metal plate
terminals, the correlation between the coefficient of linear
expansion of the ceramic capacitor elements and the coefficient of
linear expansion of the metal plate terminals and the soldering
requirements to be fulfilled when soldering the ceramic capacitor
elements and the metal plate terminals.
19. In regard to the structure of the metal plate terminals, the
ceramic capacitor according to the present invention includes at
least one ceramic capacitor element and at least a pair of metal
plate terminals. Terminal electrodes are provided at the two
diametrical side end surfaces of the ceramic capacitor element.
20. The metal plate terminals are each connected to one of the
terminal electrodes at one end, and are each provided with a folded
portion in the middle, with a terminal portion to be connected to
an external conductor such as a substrate provided toward the other
end of the folded portion.
21. In the metal plate terminals structured as described above, the
folded portions increase the lengths which extend from the terminal
portions to the ends that are connected to the terminal electrodes
of the ceramic capacitor element. In addition, the folded portions
achieve a spring-like effect. This ensures that the flexure and the
thermal expansion of the substrate are absorbed with a high degree
of reliability to reduce the mechanical stress and the thermal
stress occurring at the ceramic capacitor element so that cracks
can be prevented from occurring at the ceramic capacitor element.
Consequently, even when the ceramic capacitor according to the
present invention is employed as a smoothing capacitor for a
switching source that is often mounted at an aluminum substrate,
cracks can be prevented from occurring so that the risk of arcing
can be eliminated.
22. In addition, by providing the folded portion at the metal plate
terminal, the flexure and the thermal expansion of the substrate
are absorbed to prevent mechanical stress and thermal stress from
occurring at the ceramic capacitor element, and an increase in the
height is prevented. Thus, the length of the metal plate terminal
extending from the terminal portion located toward the substrate to
the ceramic capacitor element mounting portions can be increased
without increasing its height, to improve the absorbing effect with
respect to flexure and the thermal expansion of the substrate so
that the mechanical stress and the thermal stress occurring at the
ceramic capacitor element can be reduced.
23. The metal plate terminals are each constituted of a metal
material having a coefficient of average linear expansion .alpha.
of 13.times.10.sup.-6 or lower over the range of -55.degree. C. to
125.degree. C. It has been learned that by constituting the metal
plate terminals with a metal material achieving such a coefficient
of average linear expansion .alpha., cracks do not occur and the
risk of arcing is eliminated even when it is used continuously over
an extended period of time in an environment where the temperature
changes drastically over the range of -55.degree. C. to 125.degree.
C. Consequently, even when the ceramic capacitor according to the
present invention is employed as a smoothing capacitor in a
switching source that is turned on/off frequently and may
experience a temperature fluctuation within the range of -55
.degree. C. to 125.degree. C., a sufficient degree of reliability
is assured. The coefficient of average linear expansion a as
referred to in the present invention refers to the average value of
coefficients of linear expansion measured at a plurality of
different temperatures.
24. In regard to the coefficients of linear expansion of the
ceramic capacitor element and the metal plate terminals,
.alpha..sub.1<.alpha.- .sub.2 is satisfied with .alpha..sub.1
representing the coefficient of average linear expansion of the
ceramic capacitor element over a range of 25.degree. C. to
-55.degree. C. and .alpha..sub.2 representing the coefficient of
average linear expansion of the ceramic capacitor element over a
range of 25.degree. C. to 125.degree. C., and the coefficient of
average linear expansion .beta. of the metal plate terminals over
the range of -55.degree. C. to 125.degree. C. satisfies
.beta.<1.3 .alpha..sub.2 and .beta.>0.7 .alpha..sub.1.
25. It has been confirmed that when the coefficients of average
linear expansion .alpha..sub.1, .alpha..sub.2 and .beta. satisfy
the requirements presented above, cracks, damage and the like are
prevented from occurring at the ceramic capacitor element with a
high degree of reliability over the temperature range of
-55.degree. C. to 125.degree. C.
26. When the main constituent of the dielectric is barium titanate,
the coefficients of average linear expansion of the ceramic
dielectric satisfies .alpha..sub.1.ltoreq.7.times.10.sup.-6 and
.alpha..sub.2.gtoreq.9.times.10.sup.6. When the main constituent of
the ceramic dielectric is a lead type complex perovskite,
.alpha..sub.2.times.10.sup.-6 and
.alpha..sub.2.gtoreq.3.times.10.sup.-6 are satisfied.
27. Consequently, the coefficient of average linear expansion
.beta. of the metal plate terminals must be set by taking into
consideration the different coefficients of average linear
expansion .alpha..sub.1 and .alpha..sub.2 manifesting when the main
constituent of the dielectric is barium titanate and when it is
lead-type complex perovskite so that the requirements described
earlier are satisfied in both cases.
28. The soldering requirements for soldering the ceramic capacitor
element and the metal plate terminals are adopted when producing a
combined ceramic capacitor constituted by combining a plurality of
ceramic capacitor elements. The plurality of ceramic capacitor
elements are each laminated while maintaining a distance of 20
.mu.m or less with their terminal electrodes soldered to the metal
plate terminals. A soldering paste containing solder particles 90%
or more of which achieve a particle size of 35 .mu. m to 55 .mu.m
is used in the soldering process. In the combined ceramic capacitor
achieved in this manner, the solder particles and the soldering
flux do not enter the gaps between the ceramic capacitor elements.
This contributes to an improvement in the reliability.
BRIEF DESCRIPTION OF THE DRAWINGS
29. Other objects, structural features and advantages of the
present invention are explained in further detail by referring to
the attached drawings, provided simply to illustrate examples,
wherein:
30. FIG. 1 is a frontal view of the ceramic capacitor according to
the present invention
31. FIG. 2 is a frontal sectional view of the ceramic capacitor in
FIG. 1;
32. FIG. 3 is a partial sectional view illustrating the ceramic
capacitor shown in FIGS. 1 and 2 mounted on a circuit board;
33. FIG. 4 is an enlarged sectional view illustrating an example of
the metal plate terminals that may be employed in the ceramic
capacitor according to the present invention;
34. FIG. 5 is a frontal view illustrating another embodiment of
ceramic capacitor according to the present invention;
35. FIG. 6 is a frontal view illustrating yet another embodiment of
ceramic capacitor according to the present invention;
36. FIG. 7 is a perspective illustrating yet another embodiment of
the ceramic capacitor according to the present invention;
37. FIG. 8 is a frontal view illustrating yet another embodiment of
the ceramic capacitor illustrated in FIG. 7;
38. FIG. 9 is a perspective illustrating yet another embodiment of
the ceramic capacitor according to the present invention;
39. FIG. 10 is a frontal view of the ceramic capacitor in FIG.
9;
40. FIG. 11 is a frontal view illustrating yet another embodiment
of the ceramic capacitor according to the present invention;
41. FIG. 12 is a perspective illustrating yet another embodiment of
the ceramic capacitor according to the present invention;
42. FIG. 13 is a frontal view illustrating yet another embodiment
of the ceramic capacitor according to the present invention;
43. FIG. 14 is a frontal view illustrating yet another embodiment
of the ceramic capacitor according to the present invention;
44. FIG. 15 is a frontal view illustrating yet another embodiment
of the ceramic capacitor according to the present invention;
45. FIG. 16 is a frontal view illustrating yet another embodiment
of the ceramic capacitor according to the present invention;
46. FIG. 17 is a frontal sectional view illustrating yet another
embodiment of the ceramic capacitor according to the present
invention;
47. FIG. 18 is a frontal sectional view illustrating yet another
embodiment of the ceramic capacitor according to the present
invention;
48. FIG. 19 is a perspective illustrating yet another embodiment of
the ceramic capacitor according to the present invention
49. FIG. 20 is a bottom view illustrating yet another embodiment of
the ceramic capacitor according to the present invention;
50. FIG. 21 is a partial sectional view illustrating an example of
the mounted ceramic capacitor shown in FIG. 20
51. FIG. 22 is a frontal view illustrating yet another embodiment
of the ceramic capacitor according to the present invention;
52. FIG. 23 is a frontal view illustrating yet another embodiment
of the ceramic capacitor according to the present invention;
53. FIG. 24 is a perspective illustrating yet another embodiment of
the ceramic capacitor according to the present invention;
54. FIG. 25 is a frontal view illustrating yet another embodiment
of the ceramic capacitor illustrated in FIG. 7; and
55. FIG. 26 is a frontal view illustrating yet another embodiment
of the ceramic capacitor according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
56. I Metal Plate Terminal Structure
57. In reference to FIGS. 1 and 2, the ceramic capacitor according
to the present invention includes one ceramic capacitor element 1
and a pair of metal plate terminals 2 and 3. The ceramic capacitor
element 1 is provided with terminal electrodes 11 and 12 at the two
side end surfaces facing opposite each other in the direction of
the length L.
58. The ceramic capacitor element 1 is provided with a number of
(e.g., 100 layers) internal electrodes 101 and 102 inside a ceramic
dielectric base body 100. The internal electrodes 101 are each
connected to the terminal electrode 11 at one end, with the other
ends constituting free ends, and the internal electrodes 102 are
each connected to the terminal electrode 12 at one end with the
other ends constituting free ends. The materials to constitute the
terminal electrodes 11 and 12, the internal electrodes 101 and 102
and the ceramic dielectric base body 100, the methods for
manufacturing them and the like are of the known art.
59. It is desirable that each internal electrode 101 be formed to
create a distance .DELTA.L1 between its free end and the terminal
electrode 12. Each internal electrode 102 should be formed to
create a distance A .DELTA.L2 between its free end and the terminal
electrode 11. The distances .DELTA.L1 and .DELTA.L2 are minimum
distances between the free end and terminal electrode 11 and the
free end and the terminal electrode 12. In more specific terms, the
distance .DELTA.L1 is given as the distance between the line S11
drawn in the direction of the thickness of the ceramic dielectric
base body 100 from the front end of a hanging portion 121 of the
terminal electrode 12 deposited onto the front surface and the rear
surface of the ceramic dielectric base body 100 and the line S12
drawn in the direction of the thickness of the ceramic dielectric
base body 100 from the front end of the free ends. The distance
.DELTA. L2 is given as the distance between the line S21 drawn in
the direction of the thickness of the ceramic dielectric base body
100 from the front end of a hanging portion 111 of the terminal
electrode 11 deposited onto the front surface and the rear surface
of the ceramic dielectric base body 100 and the line S22 in the
direction of the thickness of the ceramic dielectric base body 100
drawn from the front end of the free ends.
60. While the ceramic capacitor element 1 in FIG. 2 adopts a
transverse configuration in which the electrode surfaces of the
internal electrodes 101 and 102 extend parallel to the horizontal
surface, a longitudinal configuration achieved by rotating the
ceramic capacitor element 1 by approximately 90.degree. from its
position in FIG. 2 so that the electrode surfaces of the internal
electrodes 101 and 102 extend perpendicular to the horizontal
surface may be adopted, instead.
61. The metal plate terminal 2, one end 21 of which is connected to
the terminal electrode 11, is provided with a folded portion 22 in
the middle area, and a terminal portion 23 to be connected to the
outside toward the other end from the folded portion 22. The metal
plate terminal 3, one end 31 of which is connected to the terminal
electrode 12, too, is provided with a folded portion 32 in its
middle area and a terminal portion 33 to be connected to the
outside toward the other end from the folded portion 32. The metal
plate terminals 2 and 3 should be constituted of a material having
a low electrical resistance and demonstrating outstanding spring
property. Typical examples include a phosphor bronze plate. While
no particular restriction is imposed on its plate thickness, the
plate will be typically 0.1 mm thick.
62. The ends 21 and 31 of the metal plate terminals 2 and 3 are
respectively connected to the terminal electrodes 11 and 12 via
bonding members 4 and 5.
63. FIG. 3 is a partial sectional view illustrating the ceramic
capacitor in FIGS. 1 and 2 mounted on a circuit board. The ceramic
capacitor is mounted on a circuit board 70, with conductor patterns
71 and 72 formed at the surface of the circuit board 70. The
terminal portion 23 of the metal plate terminal 2 provided at the
ceramic capacitor is soldered to the conductor pattern 71 with a
solder 81, whereas the terminal portion 33 of the metal plate
terminal 3 is soldered to the conductor pattern 72 with a solder
82.
64. The metal plate terminals 2 and 3, at least a pair of which are
provided in the ceramic capacitor according to the present
invention, are respectively connected to the terminal electrodes 11
and 12 of the ceramic capacitor element 1 at their ends 21 and 31,
and are provided with the folded portions 22 and 32 respectively in
their middle areas and the terminal portions 23 and 33 respectively
to be connected to the outside toward the other end from the folded
portions 22 and 32. The length (height) of the metal plate
terminals 2 and 3 structured as described above, extending from the
terminal portions to be connected to an external conductor such as
a substrate to the ends connected to the terminal electrodes 11 and
12 of the ceramic capacitor element 1 is extended by the folded
portions 22 and 32 provided in the middle areas.
65. For instance, while in a product in the prior art without the
folding portions 22 and 32, the height from the terminal portions
23 and 33 to the positions at which the metal plate terminals 2 and
3 are connected by using the bonding members 4 and 5 is a component
height H, this height is constituted of the length of the paths h
to the apexes of the folded portions 22 and 32 according to the
present invention achieving a great increase in height dimension.
The length of the paths h can be set smaller than the component
height H that is allowed in a ceramic capacitor whose entire length
is L by adjusting the positions of the apexes of the folded
portions 22 and 32.
66. In addition, a spring-like effect is achieved by the folded
portions 22 and 32. The flexure and the thermal expansion of the
circuit board 70 are thus absorbed through the spring effect
achieved at the folded portions 22 and 32 to reduce the mechanical
stress and the thermal stress occurring at the ceramic capacitor
element 1. By selecting the structure and the shape of the folded
portions 22 and 32 as appropriate, the distance from the terminal
portions 23 and 33 that are mounted at the circuit board 70 to the
portions at which the metal electrodes are mounted to the terminal
electrodes 11 and 12 of the ceramic capacitor element 1 can be
increased by a factor of 2 to 5 compared to the prior art, to
prevent cracks from occurring at the ceramic capacitor element 1.
Thus, even when the ceramic capacitor is employed as a smoothing
capacitor for a switching source that is often mounted at the
aluminum circuit board 70, the occurrence of cracks and the risk of
resultant arcing can be avoided.
67. Furthermore, the folded portions 22 and 32 provided at the
metal plate terminals 2 and 3, which absorb the flexure and the
thermal expansion of the circuit board 70 and prevent an increase
in the height. In the case of the embodiment, the length h of the
path over which the spring effect is achieved can be set smaller
than the component height H of the ceramic capacitor having the
full length L, by adjusting the positions of the apexes of the
folded portions 22 and 32. As a result, the length h of the path
extending from the terminal portions 23 and 33 located toward the
circuit board 70 to the ceramic capacitor element mounting portions
can be increased for the metal plate terminals 2 and 3 without
increasing the component height H, to achieve an improvement in the
absorption of the flexure and the thermal expansion of the circuit
board 70 by the metal plate terminals 2 and 3, which, in turn,
reduces the mechanical stress and the thermal stress occurring at
the ceramic capacitor element 1.
68. The apexes of the folded portions 22 and 32 are set at
positions that are lower than the apex of the ceramic capacitor
element 1. Namely, h<H is satisfied. This structure makes it
possible to keep the component height H at a small value.
69. The bonding members 4 and 5 for bonding the metal plate
terminals 2 and 3 to the terminal electrodes 11 and 12 respectively
may be constituted of a conductive adhesive containing resin or of
solder. In the connecting structure whereby the metal plate
terminals 2 and 3 are connected to the terminal electrodes 11 and
12 via the bonding members 4 and 5 constituted of a conductive
adhesive containing resin, hardly any thermal shock is imparted
and, consequently, there is no risk of cracks occurring at the
ceramic capacitor element 1 before use. This contributes to an
improvement in reliability.
70. It is desirable that the conductive adhesive contain silver
particles as its conductive constituent, since silver particles
will improve conductivity. Flat silver particles having a particle
size of 3 .mu.m or larger are particularly desirable, as silver
particles having such a particle size and shape will achieve an
increase in the quantity of silver particles relative to the resin
to assure good conductivity. However, since, if the particle size
of the silver particles becomes too large, their dispersion in the
resin becomes poor, to lower the adhesive strength, it is necessary
to determine the maximum particle size of the silver particles to
be used by taking into consideration the adhesive strength.
71. Since the ceramic capacitor according to the present invention
is employed over a wide range of temperature of -55.degree. C. to
125.degree. C., the resin constituting the conductive adhesive
should be a thermosetting resin having a stable temperature
resistant property over such a temperature range. Specific examples
of such a resin include epoxy-type thermosetting resin,
urethane-type thermosetting resin, polyimide-type thermosetting
resin and acrylic-type thermosetting resin.
72. The bonding members 4 and 5 for connecting the metal plate
terminals 2 and 3 to the terminal electrodes 11 and 12 may be
constituted of solder instead of the conductive adhesive described
above. A solder having a melting point of 200.degree. C. or higher
and 400.degree. C. or lower is particularly suited for this
application.
73. When soldering the ceramic capacitor onto the circuit board 70,
as illustrated in FIG. 3, the soldering process is implemented at a
temperature of approximately 200.degree. C. During this soldering
process, the bonding members 4 and 5 connecting the metal plate
terminals 2 and 3 to the terminal electrodes 11 and 12 must not
become fused. Thus, it is necessary to use a solder having a
melting point of 250.degree. C. or higher to constitute the bonding
members 4 and 5.
74. However, if a solder having a melting point of 400.degree. C.
or higher is used to constitute the bonding members 4 and 5, heat
exceeding 400.degree. C. will be applied to the ceramic capacitor
element 1 while soldering the metal plate terminals 2 and 3 to the
terminal electrodes 11 and 12, to form thermal cracks at the
ceramic capacitor element 1. Thus, the solder must have a melting
point of 400.degree. C. or lower.
75. When solder is used to constitute the bonding members 4 and 5,
it is desirable that the metal plate terminals 2 and 3 be provided
with a cover film having a non-adhesive property with respect to
the solder at, at least, surfaces facing opposite the external
connection surfaces of the terminal portions 23 and 33. This aspect
is now explained in reference to FIG. 4.
76. In the embodiment illustrated in FIG. 4, a substrate 200 is
formed from a plate material constituted of phosphor bronze,
iron-nickel alloy or the like and a metal film 201 that achieves
good soldering is provided on the side where the external
connection surface that is connected to the outside through
soldering (the outer side) is present, with a cover film 202 to
which the solder does not adhere or adheres less readily is
laminated at the inside on the opposite side. Since the use of such
metal plate terminals 2 and 3 ensures that the solder does not
adhere to the surfaces of the terminal portions 23 and 33 as
illustrated in FIG. 3, the areas between the terminal portions 23
and 33 and the terminal portions 23 and 33 are not filled with the
solder. Thus, the spring property of the metal plate terminals 2
and 3 is not compromised.
77. The cover film 202, to which the solder does not adhere or
adheres less readily, may be laminated over the entire lengths of
the metal plate terminals 2 and 3, or may be partially laminated
including the terminal portions 23 and 33. The cover film 202 may
be constituted of one of the following: a metal oxide film, wax,
resin and silicon oil. As a means for forming the metal oxide film,
a method whereby a metal film such as Ni or Cu, which readily
becomes oxidized is laminated at the surface of the substrate 200
through plating and is left in a natural state to become oxidized
may be employed. The metal film 201 may be constituted as an Sn or
Pb--Sn plated film.
78. Now the explanation is given again in reference to FIGS. 1 and
2. The terminal portions 23 and 33 are provided under the ceramic
capacitor element 1 over a distance. This structure prevents an
increase in the area occupied by the terminal portions 23 and 33 at
the substrate to achieve a capacitor with a minimum mounting
area.
79. In the ceramic capacitor illustrated in FIGS. 1 and 2, the
folded portion 22 of the metal plate terminal 2 includes a first
bent portion 221 and a second bent portion 222. The folded portion
22 is bent to fold away from the terminal electrode 11 at the first
bent portion 221, whereas at the second bent portion 222, it is
bent to extend in a direction parallel to the end surface over a
distance from the first bent portion 221. The metal plate terminal
2 is connected to the terminal electrode 11 at the area extending
from its front end to the first bent portion 221.
80. Likewise, the folded portion 32 of the metal plate terminal 3
includes a first bent portion 321 and a second bent portion 322.
The folded portion 32 is bent to fold in a direction that moves
away from the terminal electrode 12 at the first bent portion 321,
whereas at the second bent portion 322 it is bent to extend in a
direction parallel to the end surface over a distance from the
first bent portion 321. The metal plate terminal 3 is connected to
the terminal electrode 12 at the area extending from its front end
to the first bent portion 321.
81. The structure described above achieves a spring effect in the
areas extending from the first bent portions 221 and 321 and the
second bent portions 222 and 322 to the terminal portions 23 and 33
so that the flexure and the thermal expansion of the substrate can
be absorbed through the spring effect.
82. The metal plate terminal 2 is provided with a third bent
portion 223. The third bent portion 223 partitions the folded
portion 22 from the terminal portion 23. In addition, the metal
plate terminal 3 is provided with a third bent portion 323. The
third bent portion 323 partitions the folded portion 32 from the
terminal portion 33. As a result, a spring effect is achieved in
the areas extending from the first bent portions 221 and 321 to the
third bent portions 223 and 323 so that the flexure and the thermal
expansion of the substrate is absorbed through the spring
effect.
83. The metal plate terminals 2 and 3 are bent at the third bent
portions 223 and 323 respectively in a direction in which their
terminal portions 23 and 33 are placed closer to the ceramic
capacitor element 1. The terminal portions 23 and 33 of the metal
plate terminals 2 and 3 are provided under the ceramic capacitor
element 1 over distances G01 and G02 respectively to minimize the
mounting area by preventing an increase in the area occupied by the
terminal portions 23 and 33 at the substrate.
84. In addition, in the structure achieving the distance .DELTA.L1
formed between the free ends of the internal electrodes 101 and the
terminal electrode 12 and the distance .DELTA.L2 formed between the
free ends of the internal electrodes 102 and the terminal electrode
11, the internal electrodes 101 and the internal electrodes 102 do
not overlap each other at the interfaces of the metal plate
terminals and the conductive adhesive where cracks and damage tend
to occur readily, and near the areas where the conductive adhesive
is applied. Thus, the risks of shorting caused by cracks and of
arcing resulting from shorting are drastically reduced.
85. While the first bent portions 221 and 321 and the second bent
portions 222 and 322 are bent at an angle of approximately
90.degree. in FIGS. 1 and 2, they may be bent at angles other than
90.degree.. Furthermore, the first bent portions 221 and 321 and
the second bent portions 222 and 322 may be bent in a shape without
a clear angle, e.g., in an arc shape, instead.
86. FIG. 5 is a frontal view illustrating another embodiment of the
ceramic capacitor according to the present invention. In the
figure, the same reference numbers are assigned to components
identical to those in FIGS. 1 and 2 to preclude the necessity for
repeated explanation thereof. In this embodiment, the bonding
members 4 and 5 containing resin are partially deposited onto the
terminal electrodes 11 and 12. In this structure, the length of the
paths H where the spring effect is achieved is expressed as a value
achieved by adding a length h1 of the path extending from the
terminal portions 23 and 33 to the second bent portions 222 and 322
and the length h2 of the paths extending from the first bent
portions 221 and 321 to the mounting portions (h=h1+h2). This
length h of the paths is larger than the component height H.
Consequently, the length h of the path extending from the terminal
portions 23 and 33 toward the substrate to the ceramic capacitor
element mounting portions can be increased for the metal plate
terminals 2 and 3 without increasing the component height H to
improve the effect for absorbing the flexure and the thermal
expansion of the substrate.
87. FIG. 6 is a frontal view illustrating another embodiment of the
ceramic capacitor according to the present invention. In the
figure, the same reference numbers are assigned to components
identical to those in FIGS. 1 and 2 to preclude the necessity for
repeated explanation thereof.
88. The metal plate terminal 2 is provided with another bent
portion 224 in the area extending from its front end to the first
bent portion 221, with the portion extending from the other bent
portion 224 to the first bent portion 221 facing opposite a side
end surface of the ceramic capacitor element 1 over a distance G1
and the area between the front end and the other bent portion 224
connected to the terminal electrode 11. The metal plate terminal 3,
too, is provided with another bent portion 324 in the area
extending from its front end to the first bent portion 321, with
the portion extending from the other bent portion 324 to the first
bent portion 321 facing opposite the side end surface over a
distance G2 and the area between the front end and the other bent
portion 324 connected to the terminal electrode 12.
89. In this structure, since a spring effect is achieved in the
areas extending from the other bent portions 224 and 324 to the
third bent portions 223 and 323, the length over which the spring
effect is achieved is increased to further improve the effect for
absorbing the flexure and the thermal expansion of the substrate.
In the embodiment, the length h of the path over which the spring
effect is achieved is expressed as a value achieved by adding the
length h1.ltoreq.H of the path extending from the first bent
portions 23 and 33 to the second bent portions 222 and 322 and the
length h2 of the path extending from the first bent portions 221
and 321 to the mounting portions (h=h1+h2). This length h of the
path is greater than the component height H. As a result, the
length h of the paths extending from the terminal portions 23 and
33 located toward the substrate to the ceramic capacitor element
mounting portions can be increased without having to increase the
component height H, for the metal plate terminals 2 and 3, to
improve the absorption effect through which the flexure and the
thermal expansion of the substrate are absorbed.
90. FIG. 7 is a perspective illustrating yet another embodiment of
ceramic capacitor according to the present invention and FIG. 8 is
a frontal view of the ceramic capacitor in FIG. 7. The ceramic
capacitor in this embodiment is provided with two ceramic capacitor
elements 110 and 120. The ceramic capacitor elements 110 and 120
are laminated sequentially, with the terminal electrodes 11 and 12
connected in parallel via the bonding members 4 and 5. The terminal
portions 23 and 33 of the metal plate terminals 2 and 3 are
provided under the ceramic capacitor element 120 located at the
lowermost layer of the ceramic capacitor elements 110 and 120, over
distances G01 and G02 respectively to minimize the mounting area by
preventing an increase in the area occupied by the terminal
portions 23 and 33 at the substrate.
91. The folded portions 22 and 32 of the metal plate terminals 2
and 3 include the first bent portions 221 and 321 and the second
bent portions 222 and 322 respectively. They are bent away from the
terminal electrodes 11 and 12 at the first bent portions 221 and
321, whereas they are bent at the second bent portions 222 and 322
in a direction extending parallel to the side end surfaces of the
ceramic capacitor elements 110 and 120 over distances from the
first bent portions 221 and 321 respectively.
92. The portions of the metal plate terminals 2 and 3 extending
from their front ends to the first bent portions 221 and 321 are
connected to the terminal electrodes 11 and 12 formed at the side
end surfaces of the ceramic capacitor elements 110 and 120. The
bonding members 4 and 5 constituted of solder or a conductive
adhesive containing resin are employed to connect the metal plate
terminals 2 and 3 to the terminal electrodes 11 and 12 and to
connect the ceramic capacitor elements 110 and 120 to each
other.
93. In the embodiment illustrated in FIGS. 7 and 8, a large
capacitance achieved by adding the capacitances of the two ceramic
capacitor elements 110 and 120 is realized in addition to the
advantages explained earlier in reference to FIGS. 1 and 2.
94. FIG. 9 is a perspective illustrating yet another embodiment of
the ceramic capacitor according to the present invention and FIG.
10 is a frontal view of the ceramic capacitor in FIG. 9. In the
figures, the same reference numbers are assigned to components
identical to those in FIGS. 7 and 8. In this embodiment, the metal
plate terminals 2 and 3 are only connected to the terminal
electrodes 11 and 12 formed at the side end surfaces of the ceramic
capacitor element 120 at the areas extending from their front ends
to the first bent portions 221 and 321. This embodiment achieves
advantages similar to those achieved in the embodiment illustrated
in FIGS. 7 and 8.
95. FIG. 11 is a frontal view illustrating yet another embodiment
of the ceramic capacitor according to the present invention. In the
figure, the same reference numbers are assigned to components
identical to those in FIGS. 7 to 10. In this embodiment, the metal
plate terminals 2 and 3 are only connected to the terminal
electrodes 11 and 12 formed at the side end surfaces of the ceramic
capacitor element 120 at the areas extending from their front ends
to the first bent portions 221 and 321.
96. In this embodiment, the length h of the path over which the
spring effect is achieved is expressed as a value achieved by
adding the length h1 of the paths extending from the terminal
portions 23 and 33 to the second bent portions 222 and 322 and the
length h2 of the paths extending from the first bent portions 221
and 321 to the mounting portions (h=h1+h2). Consequently, the
length h of the paths extending from the terminal portions 23 and
33 located toward the substrate to the ceramic capacitor element
mounting portions is increased for the metal plate terminals 2 and
3 to improve the absorption effect for absorbing the flexure and
the thermal expansion of the substrate so that the mechanical
stress and the thermal stress occurring at the ceramic capacitors
110 and 120 are reduced.
97. FIG. 12 is a perspective illustrating yet another embodiment of
the ceramic capacitor according to the present invention. In the
figure, the same reference numbers are assigned to components
identical to those in FIGS. 8 to 11. In this embodiment, the metal
plate terminals 2 and 3 are respectively provided with notched
portions 225 and 325 in the middle areas of the folded portions 22
and 32 in the widthwise direction. The presence of these notched
portions 225 and 325 reduces heat conduction occurring from the
metal plate terminals 2 and 3 toward the ceramic capacitor elements
110 and 120 to lessen the thermal stress at the ceramic capacitor
elements 110 and 120. In addition, since the rigidity of the metal
plate terminals 2 and 3 is reduced, a spring effect that is suited
for absorbing the flexure and the thermal expansion of the
substrate is achieved.
98. FIG. 13 is a frontal view illustrating yet another embodiment
of the ceramic capacitor according to the present invention. In the
figure, the same reference numbers are assigned to components
identical to those in FIGS. 8 to 12. In this embodiment, the metal
plate terminals 2 and 3 are connected only to the terminal
electrodes 11 and 12 formed at the side end surfaces of the ceramic
capacitor element 110 at the areas extending from their front ends
to the first bent portions 221 and 321. The length h of the paths
over which the spring effect is achieved is the length of the areas
extending from the terminal portions 23 and 33 to the second bent
portions 222 and 322. As a result, relative to the terminal
portions 23 and 33, the length extending to the positions at which
the metal plate terminals 2 and 3 are connected via the bonding
members 4 and 5 is the length h of the paths that is larger than
the height h0 (see FIG. 1 and the like) in the prior art without
the folded portions 22 and 32. Thus, the absorption effect for
absorbing the flexure and the thermal expansion of the substrate is
improved to reduce the mechanical stress and thermal stress
occurring at the ceramic capacitor elements 110 and 120.
99. FIG. 14 is a frontal view illustrating yet another embodiment
of the ceramic capacitor according to the present invention. The
metal plate terminals 2 and 3 are respectively provided with other
bent portions 224 and 324 at the areas extending from the front
ends to the first bent portions 221 and 321, with the portions
extending from the other bent portions 224 and 324 to the first
bent portions 221 and 321 facing opposite the side end surfaces of
the ceramic capacitor elements 110 and 120 over distances G1 and G2
and the areas between the front ends and the other bent portions
224 and 324 connected to the terminal electrodes 11 and 12. To give
further details, at the metal plate terminal 2, the portion between
its front end and the other bent portion 224 is located between the
terminal electrode 11 of the ceramic capacitor element 110 and the
terminal electrode 11 of the ceramic capacitor element 120 and is
connected and secured to the terminal electrodes 11 and 11 via the
bonding member 4 constituted of solder or a conductive adhesive
containing resin. At the metal plate terminal 3, the portion
between its front end and the other bent portion 324 is located
between the terminal electrode 12 of the ceramic capacitor element
110 and the terminal electrode 12 of the ceramic capacitor element
120 and is connected and secured to the terminal electrodes 12 and
12 via the bonding member 5 constituted of solder or a conductive
adhesive containing resin.
100. The length h of the paths over which the spring effect is
achieved is expressed as a value obtained by adding length h1 of
the paths extending from the terminal portions 23 and 33 to the
second bent portions 222 and 322 and the length h2 of the paths
extending from the first bent portions 221 and 321 to the other
bent portions 224 and 324 (h=h1+h2). Consequently, the length of
the paths extending from the terminal portions 23 and 33 located
toward the substrate to the ceramic capacitor element mounting
portions is increased for the metal plate terminals 2 and 3 to
improve the absorption effect for absorbing the flexure and the
thermal expansion of the substrate so that the mechanical stress
and the thermal stress occurring at the ceramic capacitor elements
110 and 120 are reduced.
101. FIG. 15 is a frontal view illustrating yet another embodiment
of the ceramic capacitor according to the present invention. In
this embodiment, the portion between the front end and the other
bent portion 224 at the metal plate terminal 2 is located so that
it receives the terminal electrode 11 of the ceramic capacitor
element 120 at the lowermost layer and is connected and secured to
the terminal electrode 11 by the bonding member 41 constituted of
solder or a conductive adhesive containing resin. The portion
between the front end and the other bent portion 324 at the metal
plate terminal 3 is located so that it receives the terminal
electrode 12 of the ceramic capacitor element 120 at the lowermost
layer and is connected and secured to the terminal electrode 12 by
the bonding member 51 constituted of solder or a conductive
adhesive containing resin.
102. The length h of the paths over which the spring effect is
achieved is expressed as a value achieved by adding the length h1
of the paths extending from the terminal portions 23 and 33 to the
second bent portions 222 and 322 and the length h2 of the paths
extending from the first bent portions 221 and 321 to the other
bent portions 224 and 324 (h=h1+h2). Consequently, the length h of
the paths extending from the terminal portions 23 and 33 located
toward the substrate to the ceramic capacitor element mounting
portions is increased for the metal plate terminals 2 and 3 to
improve the absorption effect for absorbing the flexure and the
thermal expansion of the substrate so that the mechanical stress
and the thermal stress occurring at the ceramic capacitor elements
110 and 120 are reduced.
103. FIG. 16 is a frontal view illustrating yet another embodiment
of the ceramic capacitor according to the present invention. In
this embodiment, four ceramic capacitor elements 110 to 140 are
sequentially laminated, with the areas between the terminal
electrodes 11-11 and the areas between the terminal electrodes
12-12 bonded with the bonding members 41 to 43 and 51 to 53
constituted of solder or a conductive adhesive containing resin. In
addition, at the metal plate terminal 2, the portion between its
front end and the first bent portion 221 is connected and secured
to the terminal electrode 11 by the bonding member 41 constituted
of solder or a conductive adhesive containing resin. At the metal
plate terminal 3, the portion between its front end and the first
bent portion 321 is connected and secured to the terminal electrode
12 by the bonding member 51 constituted of solder or a conductive
adhesive containing resin.
104. The embodiment illustrated in FIG. 16 achieves an even greater
capacitance than those achieved in the embodiments illustrated in
FIGS. 1 to 15. The number of ceramic capacitor elements 110 to 140
may be increased further to achieve the desired capacitance.
105. The length h of the paths over which the spring effect is
achieved is expressed as a value achieved by adding the length h1
of the paths extending from the terminal portions 23 and 33 to the
second bent portions 222 and 322 and the length h2 of the paths
extending from the first bent portions 221 and 321 to the other
bent portions 224 and 324 (h=h1+h2). Consequently, the length h of
the paths extending from the terminal portions 23 and 33 located
toward the substrate to the ceramic capacitor element mounting
portions is increased at the metal plate terminals 2 and 3 to
improve the absorption effect for absorbing the flexure and the
thermal expansion of the substrate so that the mechanical stress
and the thermal stress occurring at the ceramic capacitor elements
110 to 140 are reduced.
106. FIG. 17 is a frontal sectional view illustrating yet another
embodiment of the ceramic capacitor according to the present
invention. In the figure, the same reference numbers are assigned
to components identical to those in FIGS. 1 and 2 and their
explanation is omitted. In this embodiment, the terminal electrodes
11 and 12 are formed only at the side end surfaces. Since this
structure allows the distance .DELTA.L1 between the internal
electrodes 101 and the terminal electrode 12 and the distance
.DELTA.L2 between the internal electrodes 102 and the terminal
electrode 11 to be set in reference to the side end surfaces of the
ceramic dielectric base body 100, the area over which the internal
electrodes 101 and the internal electrodes 102 overlap each other
can be increased to assure an even larger capacity.
107. FIG. 18 is a frontal sectional view illustrating yet another
embodiment of the ceramic capacitor according to the present
invention. In the figure, the same reference numbers are assigned
to components identical to those in FIG. 17 and their explanation
is omitted. In the embodiment illustrated in FIG. 18, two ceramic
capacitor elements 110 and 120 are provided. The ceramic capacitor
elements 110 and 120 are laminated sequentially, with the terminal
electrodes 11 and 12 connected in parallel via the bonding members
4 and 5. The terminal electrodes 11 and 12 are formed only at the
side end surfaces of the ceramic dielectric base body 100. By
adopting this embodiment, an even larger capacitance is obtained
compared to that achieved in FIG. 17.
108. FIG. 19 is a perspective illustrating yet another embodiment
of the ceramic capacitor according to the present invention. In the
figure, the same reference numbers are assigned to components
identical to those in FIGS. 1 and 2 to preclude the necessity for
repeated explanation thereof. In this embodiment, the metal plate
terminal 2 is provided with a punched portion 24. The punched
portion faces opposite the mounting portion at which the terminal
electrode 11 is mounted. Although not shown, the metal plate
terminal 3, too, is provided with a punched portion 34. The punched
portion 34 faces opposite the mounting portion at which the
terminal electrode 12 is mounted.
109. The structure described above allows the connection work for
connecting the metal plate terminals 2 and 3 to the terminal
electrodes 11 and 12 to be carried out with ease by holding the
mounting portions of the metal plate terminals 2 and 3 through the
punched portions 24 and 34 of the metal plate terminals 2 and 3
respectively to place them in contact with the terminal electrode
11 and 12. In addition, through the punched portions 24 and 34, the
mounting portions can be bonded to the terminal electrodes 11 and
12 with a uniform force.
110. FIG. 20 is a bottom view illustrating yet another embodiment
of the ceramic capacitor according to the present invention. In the
figure, the same reference numbers are assigned to components
identical to those in FIGS. 1 and 2 to preclude the necessity for
repeated explanation thereof. In this embodiment, the terminal
portion 23 of the metal plate terminal 2 is provided with two holes
231 and 232. Likewise, the terminal portion 33 of the metal plate
terminal 3 is provided with two holes 331 and 332. The quantities
of holes at the terminal portions are arbitrary.
111. FIG. 21 is a partial sectional view illustrating the ceramic
capacitor shown in FIG. 20 mounted at the circuit board 70. As
illustrated in FIG. 21, when soldering the ceramic capacitor shown
in FIG. 20 to conductor patterns 71 and 72 provided at the circuit
board 70, solders 821 and 811 are charged to fill the holes 231 and
232 and the holes 331 and 332 at the terminal portions 23 and 33
respectively to solder the ceramic capacitor onto the circuit board
70 with a high degree of reliability.
112. FIG. 22 is a frontal view illustrating yet another embodiment
of the ceramic capacitor according to the present invention. In the
figure, the same reference numbers are assigned to components
identical to those in FIGS. 1 and 2 to preclude the necessity for
repeated explanation thereof. In this embodiment, the folded
portion 22 of the metal plate terminal 2 includes an acute angle
bent portion 221 at which the folded portion 22 is bent to fold at
an acute angle in a direction such that it faces roughly opposite
the end surface of the ceramic capacitor element 1. Likewise, the
folded portion 32 of the metal plate terminal 3 includes an
acute-angle bent portion 321 at which the folded portion 32 is bent
at an acute angle in a direction such that it faces roughly
opposite the end surface of the ceramic capacitor element 1.
113. In the structure described above, a spring effect is achieved
in the areas extending from the bending positions 221 and 321 to
the terminal portions 23 and 33, as in the ceramic capacitor
illustrated in FIGS. 1 and 2, so that the flexure and the thermal
expansion of the substrate are absorbed through the spring
effect.
114. It is desirable that the maximum distance d between the two
portions facing opposite each other formed by the bending at each
the metal plate terminals 2 and 3 be set at 300 .mu.m or less. The
smaller the distance d, the further toward the high frequency side
the resonance points of the metal plate terminals 2 and 3 move.
Since there is a likelihood of oscillation or vibration at 20 Hz to
200 Hz occurring at a normal source, it is desirable to set the
distance d at a small value to ensure that the resonance points are
at 200 Hz or higher. This requirement can be satisfied by setting
the distance d at 300 .mu.m or less. Table I presents test data
indicating the crack occurrence rate (%), obtained by performing
excitation for two hours at frequencies ranging from 10 Hz to 500
Hz while varying the distance d in ceramic capacitors structured as
illustrated in FIG. 22. The quantity of ceramic capacitors that
were tested for individual distances d was 100.
1 TABLE I distance d (.mu.m) 70 90 300 370 640 740 crack occurrence
rate (%) 0 0 0 100 85 85
115. As Table I indicates, the crack occurrence rate reaches 85% to
100% when the distance d is at 370 .mu.m or more, well above 300
.mu.m. In contrast, when the distance d (.mu.m) is at or less than
300 .mu.m, i.e., at 70 .mu.m and 90 .mu.m, no cracks occur.
116. FIG. 23 is a frontal view illustrating yet another embodiment
of the ceramic capacitor according to the present invention. In the
figure, the same reference numbers are assigned to components
identical to those in FIGS. 1 and 2 to preclude the necessity for
repeated explanation thereof. The folded portions 22 and 32 on the
metal plate terminals 2 and 3 are bent in an arc. In this
embodiment, too, advantages similar to those achieved in the
embodiment illustrated in FIGS. 1 and 2 are achieved.
117. Although not illustrated to avoid repeated explanation, it is
obvious that the operating modes and the embodiments illustrated in
FIGS. 3 to 21 may be adopted when employing the metal plate
terminals 2 and 3 shown in FIGS. 22 and 23. In addition, although
not illustrated, it goes without saying that there are a number of
ways in which the embodiments may be combined.
118. Next, the crack occurrence rate test data related to specific
embodiments and comparison examples are presented.
Embodiment 1
119. Two ceramic capacitor elements with dimensions of 5.6
mm.times. 5.0 mm.times.2.3 mm and having a capacitance of 22 .mu.F,
temperature characteristics E and a rated voltage of 25V were
prepared.
120. The ceramic capacitor elements described above were each
provided with internal electrodes constituted of Ag--Pd inside a
ceramic dielectric body constituted of lead-type complex perovskite
and terminal electrodes constituted of baked electrodes formed from
an Ag paste containing glass frit at the two side end surfaces of
the ceramic dielectric body facing opposite each other.
121. Two such ceramic capacitor elements were placed one on top of
the other with their terminal electrodes aligned and were bonded
together by applying to the terminal electrodes a conductive
adhesive with silver particles dispersed therein. Next, only the
portions that were bent inward of a metal plate (phosphor bronze)
having a thickness of 0.1 mm which had undergone a silver plating
treatment (the middle layer was constituted of nickel, Ni--Ag) were
pressed onto the side surfaces of the terminal electrodes of the
lower ceramic capacitor of ceramic capacitors that had been stacked
over two levels with a specific pressure. In this state, heat was
applied at 150.degree. C. for 1 hour to thermally harden the
conductive adhesive to prepare a combined ceramic capacitor having
the two ceramic capacitor elements and the metal plate terminals
bonded at the ends. The shape of the metal plate terminals and the
structure through which the metal plate terminals were mounted to
the ceramic capacitor elements adopted the mode illustrated in FIG.
13.
Embodiment 2
122. The shape of the metal plate terminals and the structure with
which the metal plate terminals were mounted at the ceramic
capacitor elements adopted the mode illustrated in FIGS. 7 and 8.
Otherwise, a method similar to that adopted to prepare embodiment 1
was employed to prepare a ceramic capacitor.
Embodiment 3
123. The shape of the metal plate terminals and the structure with
which the metal plate terminals were mounted at the ceramic
capacitor elements adopted the mode illustrated in FIG. 11.
Otherwise, a method similar to that adopted to prepare embodiment 1
was employed to prepare a ceramic capacitor.
Embodiment 4
124. The shape of the metal plate terminals and the structure with
which the metal plate terminals were mounted at the ceramic
capacitor elements adopted the mode illustrated in FIGS. 12 and 13.
Otherwise, a method similar to that adopted to prepare embodiment 1
was employed to prepare a ceramic capacitor.
Comparison Example 1
125. The shape of the metal plate terminals and the structure with
which the metal plate terminals were mounted at the ceramic
capacitor elements adopted a mode in the prior art illustrated in
FIG. 24. Otherwise, a method similar to that adopted to prepare
embodiment 1 was employed to prepare a ceramic capacitor. In FIG.
24, the same reference numbers are assigned to components identical
to those in FIG. 1.
Comparison Example 2
126. A ceramic capacitor was prepared by employing the means for
producing embodiments 1 to 4 without using any metal plate
terminals.
127. Table II presents the states of crack occurrence manifesting
in embodiments 1 to 4 and comparison examples 1 and 2 after a heat
cycle test.
2 TABLE II crack occurrence rate (%) h H after after (mm) (mm) h/L
40 cycles 100 cycles Embodiment 1 (FIG. 15) 9 5.5 1.61 0 0
Embodiment 2 (FIGS. 7, 8) 5 5.5 0.89 0 0 Embodiment 3 (FIG. 11) 3
5.5 0.54 0 0 Embodiment 4 (FIG. 9, 10) 2 5.5 0.36 0 0 Comparison
example 1 1 5.5 0.18 30 100 (FIG. 24) Comparison example 2 0 2.3
0.00 100 100
128. As Table II indicates, no occurrence of cracks was observed in
embodiments 1 to 4 according to the present invention. In
comparison example 1, a crack occurrence rate of 30% and a crack
occurrence rate of 100% resulted after 40 cycles and 100 cycles
respectively. In the case of comparison example 2 with no metal
plate terminals, a 100% crack occurrence rate was observed both
after 40 cycles and 100 cycles.
Embodiments 5 to 7
129. Four ceramic capacitors with dimensions of 3.2 mm.times.2.5
mm.times.1.0 mm and having a capacitance of 6.8 .mu.F, temperature
characteristics E and a rated voltage of 16V were prepared.
130. The ceramic capacitor elements described above were each
provided with internal electrodes constituted of Ag--Pd embedded in
a ceramic dielectric body constituted of lead-type complex
perovskite and terminal electrodes constituted of baked electrodes
formed from an Ag paste containing glass frit at the two side end
surfaces of the ceramic dielectric body facing opposite each
other.
131. Four such ceramic capacitor elements were laminated together
with their terminal electrodes aligned and were bonded by applying
to the terminal electrodes a conductive adhesive with silver
particles dispersed therein. Next, the metal plate terminals were
mounted by adopting the structure and the positional arrangement
illustrated in FIG. 16. A metal plate (phosphor bronze) having a
thickness of 0.1 mm that had undergone a silver plating treatment
(the middle layer was constituted of nickel, Ni--Ag) was used to
constitute the metal plate terminals. The terminal portions located
at the front ends of the metal plate terminals were pressed onto
the side surfaces of the terminal electrodes of the ceramic
capacitor element located at the lowermost layer among the ceramic
capacitor elements that had been stacked over four levels, with a
specific pressure. In this state, heat was applied at 150.degree.
C. for 1 hour to thermally harden the conductive adhesive to
prepare a combined ceramic capacitor having the four ceramic
capacitor elements and the metal plate terminals bonded at the
terminal electrodes.
132. The length h of the paths where the spring effect is achieved
was varied in test pieces prepared through the process described
above. The test pieces thus obtained are embodiments 5 to 7.
Comparison Example 3
133. The shape of the metal plate terminals and the structure with
which the metal plate terminals were mounted at the ceramic
capacitor elements adopted the mode in the prior art illustrated in
FIG. 24. Otherwise, a method similar to that adopted to prepare
embodiments 5 to 7 was employed to prepare a ceramic capacitor.
Comparison Example 4
134. A ceramic capacitor was prepared by employing the means for
producing embodiments 5 to 7 without using any metal plate
terminals.
135. Table III presents the states of crack occurrence manifesting
in embodiments 5 to 7 and comparison examples 3 and 4 after a heat
cycle test.
3 TABLE III crack occurrence rate (%) h H after after (mm) (mm) h/L
40 cycles 100 cycles Embodiment 5 9 5.0 2.81 0 0 Embodiment 6 3 5.0
0.94 0 0 Embodiment 7 1.5 5.0 0.47 0 0 Comparison example 3 1 5.0
0.31 15 100 Comparison example 4 0 1.0 0.00 100 100
136. As Table III indicates, no occurrence of cracks was observed
in embodiments 5 to 7 according to the present invention. In
comparison example 3, a crack occurrence rate of 15% and a crack
occurrence rate of 100% resulted after 40 cycles and 100 cycles
respectively. In the case of comparison example 4 with no metal
plate terminals, a 100% crack occurrence rate was observed both
after 40 cycles and 100 cycles.
Embodiment 8
137. Four ceramic capacitor elements with dimensions of 5.6
mm.times.5.0 mm.times.2.3 mm and having a capacitance of 22 .mu.F,
temperature characteristics E and a rated voltage of 25V were
prepared. The ceramic capacitor elements described above were each
provided with internal electrodes constituted of Ag--Pd embedded in
a ceramic dielectric body constituted of lead-type complex
perovskite and terminal electrodes constituted of baked electrodes
formed from an Ag paste containing glass frit at the two side end
surfaces facing opposite each other.
138. Four such ceramic capacitor elements were laminated together
with their terminal electrodes aligned and bonded by applying to
the terminal electrodes a conductive adhesive with silver particles
dispersed therein. Next, the metal plate terminals were mounted by
adopting the structure and the positional arrangement illustrated
in FIG. 16. A metal plate (phosphor bronze) having a thickness of
0.1 mm that had undergone a silver plating treatment (the middle
layer was constituted of nickel, Ni--Ag) was used to constitute the
metal plate terminals. The terminal portions located at the front
ends of the metal plate terminals were pressed onto the side
surfaces of the terminal electrodes of the ceramic capacitor
element located at the lowermost layer among the ceramic capacitor
elements that had been stacked over four levels, with a specific
pressure. In this state, heat was applied at 150.degree. C. for 1
hour to thermally harden the conductive adhesive to prepare a
combined ceramic capacitor having the four ceramic capacitor
elements and the metal plate terminals bonded at the terminal
electrodes.
Comparison Example 5
139. Two ceramic capacitor elements with dimensions of 5.6
mm.times. 5.0 mm.times.2.3 mm and having a capacitance of 22 .mu.F,
temperature characteristics E and a rated voltage of 25V were
prepared. The ceramic capacitor elements described above were each
provided with internal electrodes constituted of Ag--Pd inside a
ceramic dielectric body constituted of lead-type complex perovskite
and terminal electrodes constituted of baked electrodes formed from
an Ag paste containing glass frit at the two side end surfaces of
the ceramic dielectric body facing opposite each other.
140. Two such ceramic capacitor elements were placed one on top of
the other with their terminal electrodes aligned and a conductive
adhesive with silver particles dispersed therein was applied to the
terminal electrodes. Then, a metal plate (phosphor bronze) having a
thickness of 0.1 mm that had undergone a plating treatment was
pressed in the structure in the prior art illustrated in FIG. 24
with a specific pressure. In this state, heat was applied at
150.degree. C. for 1 hour to thermally harden the conductive
adhesive to prepare a combined ceramic capacitor having the two
ceramic capacitor elements and the metal plate terminals bonded at
the terminal electrodes.
Comparison Example 6
141. Four ceramic capacitor elements with dimensions of 3.2
mm.times.2.5 mm.times.1.0 mm and having a capacitance of 6.8 .mu.F,
temperature characteristics E and a rated voltage of 16V were
prepared. The ceramic capacitor elements described above were each
provided with internal electrodes constituted of Ag--Pd inside a
ceramic dielectric body constituted of lead-type complex perovskite
and terminal electrodes constituted of baked electrodes formed from
an Ag paste containing glass frit.
142. Four such ceramic capacitor elements were placed one on top of
another with their terminal electrodes aligned, a conductive
adhesive with silver particles dispersed therein was applied to the
terminal electrodes and the metal plate terminals were placed on
top by adopting the mode in the prior art illustrated in FIG. 24
and they were pressed together with a specific pressure. The metal
plate terminals were constituted of a metal plate (phosphor bronze)
having a thickness of 0.1 mm that had undergone a plating
treatment.
143. In this state, heat was applied at 150.degree. C. for 1 hour
to thermally harden the conductive adhesive to prepare a combined
ceramic capacitor having the four ceramic capacitor elements and
the metal plate terminals bonded at the terminal electrodes.
144. Each of the test pieces obtained through the methods explained
in reference to embodiment 8 and comparison examples 5 and 6 was
placed in a thermal shock test tank with the terminal portions of
its metal plate terminals soldered onto an aluminum substrate to
undergo thermal shock testing. The thermal shock test was conducted
for 40 cycles and 100 cycles with the temperature changing from
125.degree. C. to -55.degree. C. to 125.degree. C. in a cycle. The
test pieces were inspected to ascertain the presence/absence of
cracks inside the ceramic capacitor elements before and after
testing.
145. While no occurrence of cracks was observed in embodiment 8
according to the present invention, fracture caused by cracks were
found in comparison examples 5 and 6. All the fractures occurred at
the interfaces of the metal plate terminals and the conductive
adhesive and in the vicinity of the areas where the conductive
adhesive was applied.
146. II Metal Plate Terminal Material
147. The metal plate terminals 2 and 3 are each constituted of a
metal material having a coefficient of average linear expansion
.alpha. of 13.times.10.sup.-6 or less over a temperature range of
-50.degree. C. to 125.degree. C. Specific examples of such a metal
material include an Fe--Ni alloy with an Fe content of 55 wt % to
70 wt % and an Ni content of 35 wt % to 45 wt %. In addition, any
of the following metal materials may be employed to constitute the
metal plate terminals 2 and 3 in the ceramic capacitor according to
the present invention.
148. Invar (Fe--Ni alloy)
149. coefficient of linear expansion .alpha.=1 to
2.times.10.sup.-6
150. 42 Alloy (registered trademark) (Fe 58 wt %, Ni 42 wt %)
151. coefficient of linear expansion .alpha.=4 to
5.times.10.sup.-6
152. Ru
153. coefficient of linear expansion
.alpha.=6.8.times.10.sup.-6
154. Nimonic 80 (registered trademark)
155. coefficient of linear expansion
.alpha.=11.7.times.10.sup.-6
156. Pt
157. coefficient of linear expansion .alpha.=9.times.10.sup.-6
158. Pd
159. coefficient of linear expansion
.alpha.=10.6.times.10.sup.-6
160. titanium
161. coefficient of linear expansion .alpha.=9.times.10.sup.-6
162. Carbon copper
163. coefficient of linear expansion .alpha.=10 to
13.times.10.sup.-6
164. It has been confirmed that when the metal plate terminals are
constituted by using any of the metal materials having the
coefficients of average linear expansion a listed above, no cracks
occur and the risk of arcing is thus eliminated as well even if the
ceramic capacitor is continuously operated over an extended period
of time in an environment in which the temperature changes
drastically within the range of -55.degree. C. to 125.degree. C.
Consequently, when it is employed as a smoothing capacitor at a
switching source that is turned on/off frequently to result in a
temperature fluctuation within the range of -55.degree. C. to
125.degree. C., a sufficient degree of reliability is assured.
165. As explained above, according to the present invention, with
the metal plate terminals 2 and 3 each realizing a coefficient of
average linear expansion .alpha. of 13.times.10.sup.-6 or less over
the temperature range of -55.degree. C. to 125.degree. C., a
ceramic capacitor that is free of cracks and also free of risk of
arcing even when it is continuously operated over an extended
period of time in an environment where the temperature changes
drastically over the range of -55.degree. C. to 125.degree. C. is
achieved. Next, this point is further explained in reference to
crack occurrence rate data on specific embodiments and comparison
examples.
Embodiments 11 to 21
166. Two ceramic capacitor elements with dimensions of 5.6
mm.times. 5.0 mm.times.2.3 mm and having a capacitance of 22 .mu.F,
temperature characteristics E and a rated voltage of 25V were
prepared. The ceramic capacitor elements described above were each
provided with internal electrodes constituted of Ag--Pd inside a
ceramic dielectric body constituted of lead-type complex perovskite
and terminal electrodes constituted of baked electrodes formed from
an Ag paste containing glass frit at the two side end surfaces of
the ceramic dielectric body facing opposite each other.
167. Two such ceramic capacitor elements were placed one on top of
the other with their terminal electrodes aligned and were bonded
together by applying to the terminal electrodes a conductive
adhesive with silver particles dispersed therein. Next, metal plate
terminals having a thickness of 0.1 mm that had undergone silver
plating treatment (the middle layer was constituted of nickel,
Ni--Ag) were pressed against the terminal electrode side surfaces
of the two ceramic capacitors that had been stacked over two levels
with a specific pressure. In this state, heat was applied at
150.degree. C. for 1 hour to thermally harden the conductive
adhesive to prepare a ceramic capacitor having the two ceramic
capacitor elements and the metal plate terminals bonded at the
ends. FIG. 24 is a perspective of a ceramic capacitor obtained
through the process described above and FIG. 25 is a frontal view
of the ceramic capacitor illustrated in FIG. 24.
168. In embodiments 11 to 21, the metal plate terminals 2 and 3
(see FIGS. 24 and 25) were constituted by using different metal
materials having a coefficient of average linear expansion at
13.times.10.sup.-6 or lower. In embodiment 11 the metal plate
terminals 2 and 3 were constituted of Inconel X-750 (embodiment
11), in embodiment 12 they were constituted of Nimonic 90, in
embodiment 13 they were constituted of carbon steel, in embodiment
14 they were constituted of stainless 430, in embodiment 15 they
were constituted of Hasteroy B, in embodiment 16 they were
constituted of stainless steel 403, in embodiment 17 they were
constituted of pure titanium, in embodiment 18 they were
constituted of industrial titanium, in embodiment 19 they were
constituted of chromium, in embodiment 20 they were constituted of
42 Alloy and in embodiment 21 they were constituted of Invar.
169. The ceramic capacitors in embodiments 11 to 21 were each
secured to an aluminum substrate through soldering, and were
subjected to thermal shock to evaluate occurrence of cracks. The
thermal shock was applied under the following conditions.
170. (1) 100 ceramic capacitors each were prepared for embodiments
11 to 21 and they were each soldered onto an aluminum substrate and
subjected to thermal shock in a heat test tank.
171. (2) In each heat cycle, the temperature was rapidly lowered
from room temperature (25.degree. C.) to -55.degree. C., was
rapidly raised to 125.degree. C. and then was reset to room
temperature (25.degree. C.).
172. (3) Embodiments 11 to 21 each underwent 400 heat cycles.
173. (4) The products were then evaluated by disengaging them from
the aluminum substrates to examine their appearance and inspect
their electrical characteristics and then by polishing them to
check for internal cracks.
Comparison Examples 11 to 19
174. Next, for purposes of comparison, ceramic capacitors as
illustrated in FIGS. 24 and 25 were manufactured by using metal
materials each having a coefficient of average linear expansion
exceeding 13.times.10.sup.-6 to constitute the metal plate
terminals 2 and 3. In comparison example 11, the metal plate
terminals 2 and 3 were constituted of aluminum, in comparison
example 12, they were constituted of iron, in comparison example
13, they were constituted of silver, in comparison example 14, they
were constituted of phosphor bronze, in comparison example 15, they
were constituted of stainless steel 304, in comparison example 16,
they were constituted of copper, in comparison example 17, they
were constituted of nickel silver, in comparison example 18, they
were constituted of stainless steel 317 and in comparison example
19, they were constituted of nickel.
175. The ceramic capacitors in comparison examples 11 to 19 were
each secured onto an aluminum substrate through soldering to
evaluate occurrence of cracks by applying thermal shock. The
thermal shock was applied under conditions identical to those for
embodiments 11 to 20. Table IV presents occurrence of cracks
observed after the heat cycles in embodiments 11 to 21 and
comparison examples 11 to 19.
4TABLE IV coefficient of -55.degree. C. average linear to
125.degree. C. metal expansion a crack occurrence terminal material
13 .times. 10.sup.-6 rate (%) remarks Inconel X-750 at or lower 0
(Embodiment 11) Nimonic 90 at or lower 0 (Embodiment 12) carbon
steel at or lower 0 (Embodiment 13) stainless steel 430 at or lower
0 (Embodiment 14) Hasteroy B at or lower 0 (Embodiment 15) since
steel 403 at or lower 0 (Embodiment 16) pure titanium at or lower 0
(Embodiment 17) industrial titanium at or lower 0 (Embodiment 18)
chromium at or lower 0 (Embodiment 19) 42 Alloy at or lower 0
(Embodiment 20) Invar at or lower 0 (Embodiment 21) aluminum at or
higher 100 (Comparison example 11) iron at or higher 100
(Comparison example 12) silver at or higher 93 (Comparison example
13) phosphor bronze at or higher 81 (Comparison example 14)
stainless steel 304 at or higher 69 (Comparison example 15) copper
at or higher 57 (Comparison example 16) Silver nickel at or higher
45 (Comparison example 17) stainless steel 317 at or higher 33
(Comparison example 18) nickel at or higher 5 (Comparison example
19)
176. As indicated in Table IV, no occurrence of cracks was observed
in embodiments 11 to 21 according to the present invention, whereas
comparison examples 11 to 19 were all proved to be defective. In
particular, those with metal plate terminals constituted of
aluminum or iron proved to be defective, having a crack occurrence
rate of 100%.
Embodiments 22 to 25
177. Two ceramic capacitor elements with dimensions of 5.6
mm.times. 5.0 mm.times.2.3 mm and having a capacitance of 22 .mu.F,
temperature characteristics E and a rated voltage of 25V were
prepared.
178. The ceramic capacitor elements described above were each
provided with internal electrodes constituted of Ag--Pd inside a
ceramic dielectric body constituted of lead-type complex perovskite
and terminal electrodes constituted of baked electrodes formed from
an Ag paste containing glass frit at the two side end surfaces of
the ceramic dielectric body facing opposite each other.
179. Two such ceramic capacitor elements were placed one on top of
the other with their terminal electrodes aligned and bonded by
applying to the terminal electrodes a conductive adhesive with
silver particles dispersed therein. Next, the metal plate terminals
2 and 3 were secured as illustrated in FIGS. 24 and 25.
180. In embodiments 22 to 25, the metal plate terminals 2 and 3,
prepared by varying the material composition of an Fe--Ni alloy,
were used. In embodiment 22, the metal plate terminals 2 and 3 were
constituted of an Fe--Ni alloy having a composition of Fe 55%-Ni
45%. In embodiment 23, they were constituted of an Fe--Ni alloy
having a composition of Fe 60%-Ni 40%, in embodiment 24, they were
constituted of an Fe--Ni alloy having a composition of Fe 65%-Ni
35% and in embodiment 25 they were constituted of an Fe--Ni alloy
having a composition of Fe 70%-Ni 30%.
181. The ceramic capacitors in embodiments 22 to 25 were each
secured to an aluminum substrate through soldering and were
subjected to thermal shock to evaluate occurrence of cracks. The
thermal shock was applied under the conditions described earlier in
reference to embodiments 11 to 21.
Comparison Examples 20 and 21
182. For purposes of comparison, ceramic capacitors in comparison
examples 20 and 21 constituted by forming the metal plate terminals
2 and 3 with Fe--Ni alloys having different material compositions
were prepared. In comparison example 20, the metal plate terminals
2 and 3 were constituted of an Fe--Ni alloy having a material
composition of Fe 50%-Ni 50% and in comparison example 21, they
were constituted of an Fe--Ni alloy having a material composition
of Fe 75%-Ni 25%. The ceramic capacitors in the comparison examples
were prepared through a process that is otherwise similar to that
adopted to prepare embodiments 22 to 25.
183. The ceramic capacitors in comparison examples 20 and 21 were
each secured to an aluminum substrate through soldering and
subjected to thermal shock to evaluate occurrence of cracks. The
thermal shock was applied under conditions described earlier in
reference to embodiments 11 to 21.
184. Table V presents occurrence of cracks observed in embodiments
22 to 25 and comparison examples 20 and 21 after heat cycles.
5TABLE V metal terminal -55.degree. C. material composition to
125.degree. C. crack Fe--Ni alloy occurrence rate (%) remarks Fe
50%--Ni 50% 8 (comparison example 20) Fe 55%--Ni 45% 0 embodiment
22 Fe 60%--Ni 40% 0 embodiment 23 Fe 65%--Ni 35% 0 embodiment 24 Fe
70%--Ni 30% 0 embodiment 25 Fe 75%--Ni 25% 16 (comparison example
21)
185. As Table V indicates, no occurrence of cracks was observed in
embodiment 22 to 25 according to the present invention. Comparison
examples 20 and 21 both proved to be defective.
186. III Coefficient of Linear Expansion
187. The ceramic capacitor element 1 must satisfy
.alpha..sub.1<.alpha.- .sub.2 with .alpha..sub.1 representing
the coefficient of average linear expansion over a temperature
range of 25.degree. C. to -55.degree. C. and .alpha..sub.2
representing the coefficient of average linear expansion within a
range of 25.degree. C. to 125.degree. C.
188. Of the metal plate terminals 2 and 3, the metal plate terminal
2 is connected to the terminal electrode 11 and the metal plate
terminal 3 is connected to the terminal electrode 12. The metal
plate terminals 2 and 3 must satisfy .beta.<1.3 .alpha..sub.2
and .beta.> 0.7 .alpha..sub.1 with .beta. representing their
coefficient of average linear expansion within a range of
-55.degree. C. to 125.degree. C.
189. Next, these requirements are explained.
190. .beta.<1.3 .alpha..sub.2 (A)
191. An explanation is given on individual cases in which .beta.
.ltoreq..alpha..sub.2 and in which .alpha..sub.2<.beta.<1.3
.alpha..sub.2.
.beta..ltoreq..alpha..sub.2 (A1)
192. When .beta..ltoreq..alpha..sub.2, the ceramic capacitor
element 1 expands to a larger degree than the metal plate terminals
2 and 3 over the temperature range of 25.degree. C. to 125.degree.
C., resulting in a compressive stress occurring at the ceramic
capacitor element 1. Thus, when the individual coefficients are set
to satisfy .beta..ltoreq..alpha..sub.2, no cracks occur at the
ceramic capacitor element 1 over the temperature range of
25.degree. C. to 125.degree. C.
.alpha..sub.2<.beta.<1.3 .alpha..sub.2 (A2)
193. When .beta.>.alpha..sub.2, the ceramic capacitor element 1
expands to a lesser degree than the metal plate terminals 2 and 3
over the temperature range of 25.degree. C. to 125.degree. C.,
resulting in tensile stress occurring at the ceramic capacitor
element 1. As long as .beta.< 1.3 .alpha..sub.2 in this case, no
cracks occur even if tensile stress occurs at the ceramic capacitor
element 1 since the stress is insignificant.
0.7 .alpha..sub.1<.beta. (B)
194. An explanation is given on individual cases in which .beta.
.gtoreq..alpha..sub.1 and in which 0.7
.alpha..sub.1<.beta.<.alpha.- .sub.1.
.beta..gtoreq..alpha..sub.1 (B1)
195. Over the temperature range of -55 to 25.degree. C., both the
ceramic capacitor element 1 and the metal plate terminals 2 and 3
tend to contract proportionally with the temperature relative to
25.degree. C. When .beta..gtoreq..alpha..sub.1, since the ceramic
capacitor element 1 contracts to a lesser degree than the
contraction of the metal plate terminals 2 and 3, compressive
stress occurs at the ceramic capacitor element 1. As a result, no
cracks occur at the ceramic capacitor element 1.
0.7 .alpha.<.beta.<.alpha..sub.1 (B2)
196. When .alpha..sub.1>.beta., the ceramic capacitor element 1
contracts to a greater degree than the metal plate terminals 2 and
3 over the temperature range of -55.degree. C. to 25.degree. C.
resulting in tensile stress occurring at the ceramic capacitor
element 1. As long as 0.7 .alpha..sub.1<.beta. in this case, no
cracks occur even if tensile stress occurs at the ceramic capacitor
element 1 since the stress is low.
197. When the main constituent of the dielectric body is barium
titanate, the ceramic capacitor element 1 satisfies
.alpha..sub.1.ltoreq. 7.times.10.sup.-6 and
.alpha..sub.2.gtoreq.9.times.10.sup.-6. When the main constituent
of the dielectric base body 100 is lead-type complex perovskite,
.alpha..sub.1.ltoreq. 2.times.10.sup.-6 and
.alpha..sub.2.gtoreq.3.times.10.sup.-6 are satisfied. Thus, it is
necessary to set the coefficient of average linear expansion .beta.
of the metal plate terminals 2 and 3 at different values to ensure
that the requirements described earlier are satisfied by taking
into consideration the coefficients of average linear expansion
.alpha..sub.1 and .alpha..sub.2 in the individual cases in which
the main constituent of the dielectric base body 100 is barium
titanate and in which it is a lead-type complex perovskite.
198. A typical example of the lead-type complex perovskite
(relaxor) ceramic dielectric material that may be employed in the
present invention is a substance expressed with a composition
formula Pb (Mg.sub.1/3Nb.sub.2/3) O.sub.3--Pb
(Mg.sub.1/2W/.sub.1/2) O.sub.3--PbTiO.sub.3. This composition
formula is normally expressed as PMN--PMW--PT. Apart from this,
substances expressed through regularized formulae such as
PMN--Pnn--PT, PMN--PZt--PT and PMN-- Pnn--PMW--PT may be used as
well.
199. In each of the embodiments described above, the coefficients
of average linear expansion .beta. of the metal plate terminals 2
and 3 all satisfy .beta.<1.3 .alpha..sub.2 and .beta.>0.7
.alpha..sub.1 over the temperature range of -55.degree. C. to
125.degree. C. Thus, ceramic capacitors that do not form any cracks
and do not present the risk of arcing even when they are
continuously operated over an extended period of time in an
environment in which the temperature changes drastically over the
range of -55.degree. C. to 125.degree. C. are achieved. Next, this
point is explained in reference to crack occurrence rate test
data.
Embodiments 31 to 33
200. A lead-type dielectric body with dimensions of 5.6 mm.times.
5.0 mm.times.2.3 mm and achieving a capacitance of 22 .mu.F and
temperature characteristics E at a rated voltage of 25V was
prepared to constitute a ceramic capacitor element. The ceramic
capacitor element was provided with internal electrodes constituted
of Ag--Pd inside the lead-type ceramic dielectric body and terminal
electrodes constituted of baked electrodes that were formed from an
Ag paste containing glass frit at the two side end surfaces of the
ceramic dielectric body facing opposite each other. The coefficient
of average linear expansion .alpha..sub.1 of the lead-type ceramic
capacitor element over the temperature range of -55.degree. C. to
25.degree. C. was 0.5 to 2.times.10.sup.-6 and its coefficient of
average linear expansion .alpha..sub.2 over the temperature range
of 25.degree. C. to 125.degree. C. was 4.2.times.10.sup.-6.
201. Two such ceramic capacitor elements were placed one on top of
the other with their terminal electrodes aligned and were bonded by
applying to the terminal electrodes a conductive adhesive with
silver particles dispersed therein. Next, only the portions that
were bent inward of a 0.1 mm-thick metal plate that had undergone a
silver plating treatment (the middle layer was constituted of
nickel, Ni--Ag) were pressed onto the side surfaces of the terminal
electrodes of the ceramic capacitor that had been achieved by
stacking the ceramic capacitor elements over two levels with a
specific pressure. In this state, heat was applied for one hour at
150.degree. C. to thermally harden the conductive adhesive to
prepare a combined ceramic capacitor having the two ceramic
capacitor elements and the metal plate terminals bonded at the
ends. The shape of the metal plate terminals and the structure
adopted for mounting the metal plate terminals to the ceramic
capacitor elements assume the mode illustrated in FIGS. 10 and
11.
202. Samples of embodiments 31 to 33 were obtained by using metal
materials having different coefficients of average linear expansion
to constitute the metal plate terminals 2 and 3. In embodiment 31,
the metal plate terminals 2 and 3 were constituted of chromium, in
embodiment 32 they were constituted of 42 Alloy (Fe 58 wt %-Ni 42
wt %) and in embodiment 33 they were constituted of Invar. The
coefficient of average linear expansion .beta. of the chromium used
in embodiment 31 is 4.5.times.10.sup.-6 and the coefficient of
average linear expansion .beta. of the 42 Alloy used in embodiment
32 is 4.4.times.10.sup.-6. Consequently, 0.7
.alpha..sub.1<.beta. and to the <1.3 .alpha..sub.2 are
satisfied in embodiments 31, 32 and 33.
Comparison Examples 31 to 45
203. Ceramic capacitors in comparison examples 31 to 45 were
prepared by using materials different from those used in the
embodiments to constitute the metal plate terminals 2 and 3 through
the process described in reference to embodiments 31 to 33. The
materials used in comparison examples 31 to 45 to constitute their
metal plate terminals 2 and 3 and their coefficients of average
linear expansion .beta. are listed in Table VI. Samples of
embodiments 31, 32 and 33 and comparison examples 31 to 45 were
each secured onto an aluminum substrate through soldering and were
subjected to thermal shock to evaluate occurrence of cracks.
204. The tests were conducted under the following conditions.
205. (1) Thermal shock test on the low temperature side (heat cycle
test over the -55.degree. C. to 25.degree. C. range)
206. (1-1) 100 samples of each embodiment and each comparison
example were soldered onto an aluminum substrate and were subjected
to low-end thermal shock in a low-end thermal shock test tank.
207. (1-2) In each heat cycle, the temperature was rapidly lowered
from 25.degree. C. (room temperature) to -55.degree. C.
(low-temperature thermal shock test tank) and then was reset to
25.degree. C. (room temperature)
208. (1-3) Each test piece underwent 500 heat cycles.
209. (1-4) Each product was evaluated by disengaging it from the
aluminum substrate to examine its appearance and inspect its
electrical characteristics and then by polishing the product to
check for internal cracks.
210. (2) Thermal shock tests on the high temperature side (heat
cycle tests over the 25.degree. C. to 125.degree. C. range)
211. (2-1) 100 samples of each embodiment and each comparison
example were soldered onto an aluminum substrate and were subjected
to high-end thermal shock in a high-temperature thermal shock test
tank.
212. (2-2) In each heat cycle, the temperature was rapidly raised
from 25.degree. C. (room temperature) to 125.degree. C. and then
was rapidly lowered to 25.degree. C. (room temperature)
213. (2-3) Each test piece underwent 500 heat cycles.
214. (2-4) Each product was evaluated by disengaging it from the
aluminum substrate to examine its appearance and inspect its
electrical characteristics and then by polishing the product to
check for internal cracks.
6TABLE VI dielectric material lead type (relaxor type) heat cycle
25.fwdarw.55.degree. C. 25.fwdarw.125.degree. C. coefficient of
linear 0.5 to 2 4.2 expansion of dielectric body (.times.10.sup.-6)
a.sub.1 a.sub.2 metal plate terminals crack occurence rate
coefficient of linear after 500 heat cycles Embodiment/ metal
material expansion .times. 10.sup.-6 % Comparison example aluminum
24.3 0 100 Comparison example 31 iron 22.7 0 100 Comparison example
32 silver 18.8 0 100 Comparison example 33 phosphor bronze 18.1 0
100 Comparison example 34 stainless steel 304 17.3 0 100 Comparison
example 35 copper 16.6 0 100 Comparison example 36 Silver nickel
16.2 0 100 Comparison example 37 stainless steel 317 16.0 0 100
Comparison example 38 Nimonic 90 11.5 0 100 Comparison example 39
carbon steel 10.6 0 100 Comparison example 40 stainless steel 430
10.4 0 97 Comparison example 41 Hasteroy B 10.0 0 91 Comparison
example 42 stainless steel 403 9.9 0 77 Comparison example 43 pure
titanium 9.0 0 68 Comparison example 44 industrial titanium 7.6 0
54 Comparison example 45 chromium 4.5 0 0 Embodiment 31 42 Alloy
4.4 0 0 Embodiment 32 Invar 1.5 0 0 Embodiment 33
215. Table VI presents occurrence of cracks observed in embodiments
31 to 33 and comparison examples 31 to 45 after the heat
cycles.
216. As indicated in Table VI, while the lead-type ceramic
capacitors in comparison examples 31 to 45 were crack-free after
the 25.degree. C..fwdarw.-55.degree. C. low-temperature thermal
shock tests, cracks occurred in them at rates of 54% to 100% in the
25.degree. C..fwdarw.125.degree. C. high-temperature thermal shock
tests. In contrast, no occurrence of cracks was observed in
embodiments 31 to 33 according to the present invention after the
25.degree. C..fwdarw.-55.degree. C. low-temperature thermal shock
tests or after the 25.degree. C..fwdarw.125.degree. C. high
-temperature thermal shock tests.
217. Next, occurrence of cracks in ceramic capacitors constituted
by using regular barium titanate type dielectric materials was
examined in thermal shock tests. Samples that were examined were
embodiments 51 to 59 and comparison examples 51 to 59. The
structure of the samples was the same as that of the lead- type
ceramic capacitors explained above. The results of the tests are
presented in Table VII.
7TABLE VII barium titanate type dielectric material (regular
material) heat cycle 25.fwdarw.55.degree. C. 25.fwdarw.125.degree.
C. coefficient of linear 6.0 11.5 expansion of dielectric body
(.times.10.sup.-6) a.sub.1 a.sub.2 metal plate terminals crack
occurence rate coefficient of linear after 500 heat cycles
Embodiment/ metal material expansion .times. 10.sup.-6 % Comparison
example aluminum 24.3 0 100 Comparison example 51 iron 22.7 0 100
Comparison example 52 silver 18.8 0 100 Comparison example 53
phosphor bronze 18.1 0 100 Comparison example 54 stainless steel
304 17.3 0 100 Comparison example 55 copper 16.6 0 93 Comparison
example 56 Silver nickel 16.2 0 89 Comparison example 57 stainless
steel 317 16.0 0 87 Comparison example 58 Nimonic 90 11.5 0 0
Embodiment 51 carbon steel 10.6 0 0 Embodiment 52 stainless steel
430 10.4 0 0 Embodiment 53 Hasteroy B 10.0 0 0 Embodiment 54
stainless steel 403 9.9 0 0 Embodiment 55 pure titanium 9.0 0 0
Embodiment 56 industrial titanium 7.6 0 0 Embodiment 57 chromium
4.5 0 0 Embodiment 58 42 Alloy 4.4 0 0 Embodiment 59 Invar 1.5 4 0
Comparison example 59
218. The materials constituting the metal plate terminals 2 and 3
and the coefficients of average linear thermal expansion .beta. of
the metal plate terminals 2 and 3 employed in embodiments 51 to 59
are as indicated in Table VII, all satisfying 0.7
.alpha..sub.1<.beta. and .beta.<1.3 .alpha..sub.2.
219. The ceramic capacitors in comparison examples 51 to 59 were
prepared in the process identical to that through which the
embodiments 51 to 59 were prepared except that the materials to
constitute the metal plate terminals 2 and 3 were varied. The
materials constituting the metal plate terminals 2 and 3 and their
coefficients of average linear expansion .beta. in comparison
examples 51 to 59 are listed in Table VII. In none of the
comparison examples is 0.7 .alpha..sub.1<.beta. or .beta.<1.3
.alpha..sub.2 satisfied except for comparison example 59, in which
0.7 .alpha..sub.1<.beta. is satisfied and .beta.<1.3
.alpha..sub.2 is not satisfied.
220. Samples of embodiments 51 to 59 and comparison examples 51 to
59 were each secured onto an aluminum substrate through soldering
and were subjected to thermal shock to evaluate occurrence of
cracks. The thermal shock tests were conducted under the same
conditions as those under which the lead-type ceramic capacitors
described earlier were tested. As indicated in Table VII, while no
cracks occurred in the barium titanate type ceramic capacitors in
comparison examples 51 to 58 in the 25.degree.
C..fwdarw.-55.degree. C. low-temperature thermal shock tests,
cracks occurred in them in the 25.degree. C..fwdarw.125.degree. C.
high-temperature thermal shock tests at rates of 87% to 100%. In
comparison example 59 which satisfies 0.7 .alpha..sub.1<.beta.
is satisfied but not .beta.<1.3 .alpha..sub.2, cracks occurred
at a rate of 4% after the 25.degree. C..fwdarw.-55.degree. C.
low-temperature thermal shock tests.
221. In contrast, no occurrence of cracks was observed in
embodiments 51 to 59 according to the present invention after the
25.degree. C..fwdarw.-55.degree. C. low-temperature thermal shock
tests or in the 25.degree. C..fwdarw.125.degree. C.
high-temperature thermal shock tests.
Other Embodiments
222. Ceramic capacitor elements having internal electrodes whose
main constituent was Ni were adopted in embodiments 31 to 33 and 51
to 59 to conduct a comparative examination of occurrence of cracks.
The results of the examination demonstrate almost no significant
difference for all of the embodiments, i.e., embodiments 31 to 33
and 51 to 59. Thus, by using internal electrodes whose main
constituent is Ni in ceramic capacitor elements, a ceramic
capacitor achieving a high degree of corrosion resistance that does
not change much over time, is inexpensive and achieves a high
degree of reliability.
223. IV Soldering Requirements
224. FIG. 26 illustrates a combined ceramic capacitor constituted
by combining a plurality of ceramic capacitor elements 110 to 150.
In the figure, the same reference numbers are assigned to
components identical to those included in the previous drawings. In
the combined ceramic capacitor in the figure, the shapes and
external dimensions of the plurality of ceramic capacitor elements
110 to 150 are almost the same, with each ceramic capacitor element
provided with terminal electrodes 11 and 12 at the two ends facing
opposite each other. The plurality of ceramic capacitor elements
110 to 150 are combined with their terminal electrodes 11 aligned
with one another and their terminal electrodes 12 aligned with one
another to constitute a capacitor assembly. The metal plate
terminals 2 and 3 are secured onto the terminal electrodes 11 and
12 provided at the two ends of the capacitor assembly via solders 4
and 5 respectively.
225. A solder paste composed of solder particles with 90% or more
of the particles contained having a particle size of 35 .mu.m to 55
.mu.m and a rosin-type resin constituting the flux, which does not
contain an activator constituted of a halogen compound, is used to
constitute the solders 4 and 5. It is desirable to achieve a
composition in which the solder particles account for 70 wt % to 75
wt % of the total weight and the rosin-type resin account for 25 wt
% to 30 wt % of the total weight for this solder paste. Since most
of the solder particles contained in the solder paste have a
particle size of 35 .mu.m to 55 .mu.m and only a small portion of
the flux component is contained in the solder paste, the solder
particles are effectively prevented from entering the gaps between
the electrodes. In addition, since no activator constituted of a
halogen compound of chlorine, bromine or the like is contained, any
degradation of the insulation resistance is prevented as well.
226. In order to achieve the combined ceramic capacitor in the
figure, the ceramic capacitor elements 110 to 150 are assembled by
maintaining gaps g formed between them within a range of
approximately 10 .mu.m to 20 .mu.m. The gaps g may be set at 20
.mu.m or less by combining the ceramic capacitor elements 110 to
150 provided with the terminal electrodes 11 and 12 whose thickness
is set at 20 .mu.m or less.
227. After applying the solder paste through printing or by using a
dispenser or the like to the terminal electrodes 11 and 12 at the
two ends of the capacitor assembly achieved by combining the
ceramic capacitor elements 110 to 150, the metal plate terminals 2
and 3 are mounted to the two ends of the capacitor assembly. It is
desirable to apply the solder paste at an application quantity of
0.02 mg/mm.sup.2 to 0.06 mg/mm.sup.2 to the areas of the terminal
electrodes 11 and 12 and the metal plate terminals 2 and 3 that
face opposite each other. At this application quantity, the metal
plate terminals 2 and 3 can be secured through soldering while
assuring, at least, sufficient mechanical strength. In addition,
any degradation of insulation resistance that would occur when the
application quantity exceeds 0.06 mg/mm.sup.2 can be prevented as
well.
228. After the metal plate terminals 2 and 3 are mounted, the
capacitor assembly is sent into a reflow furnace for a soldering
process. Since the solder paste is composed of the solder particles
accounting for 70 wt % to 75 wt % and the rosin-type resin
accounting for 25 wt % to 30 wt %, this soldering process can be
implemented at 250.degree. C. to 350.degree. C. (temperature rising
rate of 14.degree. C./minute). In addition, since the solder paste
does not contain an activator constituted of a halogen compound,
the soldering process is implemented in a reflow furnace with an
oxygen content of 100 ppm or less. Thus, the solder particles are
prevented from becoming oxidized and they can be fused with a high
degree of reliability even though the solder paste does not contain
an activator to prevent formation of solder balls.
229. By manufacturing a combined ceramic capacitor in this manner,
the solder particles and the flux are prevented from entering the
gaps between the ceramic capacitor elements 110 to 150, and
occurrence of build-up caused by the flux can be prevented.
Consequently, a combined ceramic capacitor that achieves a high
voltage withstand, a large capacity and a high degree of
reliability due to sufficient mechanical strength is realized at
low cost.
230. In order to verify its usability, combined ceramic capacitors
were manufactured through various combinations of the individual
requirements described above as embodiments 61 to 63, together with
an example of the prior art (comparison example 60). In addition,
combined ceramic capacitors that do not satisfy all of the
requirements were manufactured as comparison examples 61 to 63.
8TABLE VIII distance solder rosin clorine application between
particle quantity quantity quantity electrodes Test piece no. size
(.mu.m) (wt %) (%) (mg/mm.sup.2) (.mu.m) comparison 1 to 50 50 to
55 1 0.16 10 to 20 example 60 comparison 20 to 30 50 to 55 0 0.16
10 to 20 example 61 comparison 35 to 55 25 to 30 0.2 0.16 10 to 20
example 62 comparison 35 to 55 25 to 30 0.2 0.06 30 to 50 example
63 embodiment 61 35 to 55 25 to 30 0 0.06 10 to 20 embodiment 62 35
to 55 25 to 30 0 0.04 10 to 20 embodiment 63 35 to 55 25 to 30 0
0.02 10 to 20
231. Each of the test pieces was examined to ascertain the
.times.10.sup.-6 presence/absence of solder particle entry and to
check for any degradation of the insulation resistance. The
presence/absence of solder particle entry was verified using a
microscope with a magnifying power of 20 on 10 pieces each of the
individual comparison examples and the individual embodiments that
were judged to be defective if even one solder particle was found
in a distance between the laminated ceramic capacitor elements. The
insulation resistance was examined through a pressure cooker test
on 30 pieces each of the comparison examples and the embodiments,
conducted at a temperature of 120.degree. C. at a pressure of 2 atm
for a period of 100 hours. Any sample in which the insulation
resistance became reduced to 10.sup.6 .OMEGA. or less was judged to
be defective. The results of the test are presented in Table
IX.
9TABLE IX entry of solder pressure test piece no. particles into
gaps (%) cooker test (%) comparison example 60 100 10 comparison
example 61 10 0 comparison example 62 0 3.4 comparison example 63 0
6.7 embodiment 61 0 0 embodiment 62 0 0 embodiment 63 0 0
232. As the data in Tables VIII and IX indicate, comparison example
60 which is an example of the prior art and was constituted by
using a solder paste containing minute solder particles with their
particle sizes ranging from 1 .mu.m to 50 .mu.m with a rosin
content accounting for 50 wt % to 55 wt %, the solder particles
entered gaps between the laminated ceramic capacitor elements at
the rate of 100% even though the gaps were set at 10 .mu.m to 20
.mu.m. In addition, 10% of comparison example 60, i.e., an example
of the prior art constituted by using the solder paste containing
chlorine at 1% with the application quantity of solder paste set at
0.16 mg/mm.sup.2, manifested a reduction in the insulation
resistance.
233. A solder particle entry occurred in 10% of comparison example
61 that was constituted by using a solder paste containing minute
solder particles with particle sizes ranging from 20 .mu.m to 30
.mu.m with a rosin content of 50 wt % to 55 wt %, even though the
gaps between the laminated ceramic capacitor elements were set at
10 wt % to 20 .mu.m. However, no deterioration of the insulation
resistance was observed in comparison example 61 in which the
solder paste did not contain any chlorine. A reduction in the
insulation resistance was observed in 3.4% of comparison example
62, in which the solder paste contained chlorine at 0.2%, even
though the gaps between the laminated ceramic capacitor elements
were set at 10 .mu.m to 20 .mu.m. In addition, a reduction in the
insulation resistance was observed in 6.7% of comparison example 63
with its solder paste containing chlorine at 0.2% and the gaps
between the laminated ceramic capacitor elements set at 30 .mu.m to
50 .mu.m.
234. In contrast, no entry of solder particles or reduction in the
insulation resistance was observed in any of embodiments 61 to 63
according to the present invention.
* * * * *