Patent Publication Number: US-10319530-B2

Title: Electronic component and manufacturing method thereof

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application is based on and claims the benefit of priority to Korean Patent Application No. 10-2017-0081008 filed on Jun. 27, 2017 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference in its entirety. 
     TECHNICAL FIELD 
     The present disclosure relates to an electronic component and a manufacturing method thereof. 
     BACKGROUND 
     As high capacitance, high voltage, and high reliability are required for capacitors used in electric components of vehicles, and the like, an electrolytic condenser, a film condenser, or the like, has been used. 
     However, a separate cooling device is required in the electrolytic condenser, the film condenser, or the like, due to their low thermal stability, thereby increasing cost of such electric components. 
     In order to solve this problem, a method of replacing the electrolytic condenser, the film condenser, or the like, by bonding several tens to several hundreds of multilayer capacitors that are thermally stable, but have low capacitance, to each other to obtain high capacitance may be considered. 
     As a method of binding the multilayer capacitors according to the related art, there is a method of binding two or three multilayer capacitors to each other using a thermal treatment after applying a binder such as high-temperature solder, or the like, to the multilayer capacitors or a metal frame. 
     However, this method according to the related art has a problem in that, in order to bind several tens to several hundreds of multilayer capacitors, several processes such as the application of the binder to the multilayer capacitors, stacking of the multilayer capacitors, thermal treatment, and the like, should be undertaken. 
     SUMMARY 
     An aspect of the present disclosure may provide an electronic component in which a plurality of capacitors are reliably bonded to each other in a simple manner without any binding means such as high-temperature solder, or the like, and a manufacturing method thereof. 
     According to an aspect of the present disclosure, an electronic component may include: a capacitor array having a structure in which a plurality of capacitors are arranged; a pair of metal frames disposed on side surfaces of the capacitor array, connected to external electrodes of the plurality of capacitors, and including penetration portions formed in positions in which the pair of metal frames are connected to the external electrodes; and a plating member filling the penetration portions. 
     Each of the plurality of capacitors may include a ceramic body and first and second external electrodes, wherein the ceramic body includes dielectric layers and a plurality of first and second internal electrodes alternately disposed with each of the dielectric layers interposed therebetween. 
     The capacitor array may have a structure in which the plurality of capacitors are stacked in a column or in a row. 
     The capacitor array may have a structure in which the plurality of capacitors are stacked both in a column and in a row. 
     An area of the penetration portions may be 50% or more of an area of the external electrodes that comes in contact with the pair of metal frames. 
     The plating member may have a thickness of 10 μm or more. 
     The metal frames may come in direct contact with the external electrodes. 
     A plating member may be further formed on portions of an outer surface of the capacitor array on which the pair of metal frames are disposed except for portions of the capacitor array where ceramic bodies of the plurality of capacitors are exposed to outside. 
     According to another aspect of the present disclosure, a manufacturing method of an electronic component may include: preparing a capacitor array having a structure in which a plurality of capacitors are arranged; disposing a pair of metal frames, connected to external electrodes of the plurality of capacitors and including penetration portions formed in positions in which the pair of metal frames are connected to the external electrodes, on side surfaces of the capacitor array; and plating the capacitor array on which the pair of metal frames are disposed. 
     Each of the plurality of capacitors may include a ceramic body and first and second external electrodes, wherein the ceramic body includes dielectric layers and a plurality of first and second internal electrodes alternately disposed with each of the dielectric layers interposed therebetween. 
     The capacitor array may have a structure in which the plurality of capacitors are stacked in a column or in a row. 
     The capacitor array may have a structure in which the plurality of capacitors are stacked both in a column and in a row. 
     An area of the penetration portions may be 50% or more of an area of the external electrodes that comes in contact with the pair of metal frames. 
     A plating member formed in the plating of the capacitor array may have a thickness of 10 μm or more. 
     In the disposing of a pair of metal frames, the pair of metal frames may be disposed to come in direct contact with the external electrodes. 
     In the plating of the capacitor array, a plating member may be formed on portions of an outer surface of the capacitor array on which the pair of metal frames are disposed except for portions of the capacitor array where ceramic bodies of the plurality of capacitors are exposed to outside. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       The above and other aspects, features, and advantages of the present disclosure will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  is a perspective view schematically illustrating a structure of an electronic component according to an exemplary embodiment in the present disclosure; 
         FIG. 2  is a cross-sectional view taken along line I-I′ of  FIG. 1 ; 
         FIG. 3  is a perspective view schematically illustrating a structure of an electronic component according to an exemplary embodiment in the present disclosure; 
         FIG. 4  is a perspective view schematically illustrating a structure of the electronic component according to an exemplary embodiment in the present disclosure; 
         FIG. 5  is a perspective view illustrating a capacitor array in which a pair of metal frames are disposed in a process of manufacturing the electronic component according to an exemplary embodiment in the present disclosure; and 
         FIG. 6  is a perspective view illustrating plating of the capacitor array in which the pair of metal frames are disposed in the process of manufacturing the electronic component according to an exemplary embodiment in the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Hereinafter, exemplary embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. 
       FIG. 1  is a perspective view schematically illustrating a structure of an electronic component according to an exemplary embodiment in the present disclosure, and  FIG. 2  is a cross-sectional view taken along line I-I′ of  FIG. 1 . However, in order to clearly describe the structure of the electronic component according to the present exemplary embodiment, a plating member is not illustrated in  FIG. 1 . 
     Directions of a ceramic body will be defined in order to clearly describe exemplary embodiments in the present disclosure. X, Y, and Z illustrated in the accompanying drawings refer to a length direction, a width direction, and a thickness direction of the ceramic body, respectively. Here, the thickness direction may be the same as a stacking direction in which dielectric layers are stacked. 
     Referring to  FIGS. 1 and 2 , an electronic component  100  according to an exemplary embodiment in the present disclosure may include a capacitor array having a structure in which a plurality of capacitors  101  are arranged; a pair of metal frames  143  and  144  disposed on side surfaces of the capacitor array, connected to external electrodes  131  and  132  of the plurality of capacitors  101 , and having penetration portions  141  and  142  formed in positions in which the metal frames  143  and  144  are connected to the external electrodes  131  and  132 ; and plating members  151   a  and  152   a  filling the penetration portions  141  and  142 . 
     The plurality of capacitors  101  may be a multilayer capacitor each including a ceramic body  110  and first and second external electrodes  131  and  132 , wherein the ceramic body  110  includes a plurality of dielectric layers  111  and a plurality of first and second internal electrodes  121  and  122  alternately disposed in the Z direction with each of the dielectric layers  111  interposed therebetween and having different polarities from each other. limited, but may be a hexahedral shape, and the ceramic body  110  may have first and second surfaces opposing each other in the Z direction, third and fourth surfaces connected to the first and second surfaces and opposing each other in the X direction, and fifth and sixth surfaces connected to the first and second surfaces and the third and fourth surfaces and opposing each other in the Y direction. 
     Further, covers  112  and  113  may be formed on uppermost and lowermost portions of the ceramic body  110  in the Z direction. Here, the covers  112  and  113  may be formed of the same material as that of the dielectric layers  111 , and formed by stacking at least one dielectric layer that does not include internal electrodes on both surfaces of the ceramic body  110  in the Z direction. 
     The dielectric layers may contain a ceramic powder, for example, a BaTiO 3  based ceramic powder, or the like. 
     The BaTiO 3  based ceramic powder may be formed of, for example, (Ba 1-x Ca x )TiO 3 , Ba(Ti 1-y Ca y )O 3 , (Ba 1-x Ca x ) (Ti 1-y Zr y )O 3  or Ba(Ti 1-y Zr y )O 3  in which Ca, Zr, or the like, is partially solid-dissolved in BaTiO 3 , or the like, but an example of the BaTiO 3 -based ceramic powder is not limited thereto. 
     Here, if necessary, the dielectric layer  111  may further contain at least one of a transition metal oxide or carbide, a rare earth element, magnesium (Mg), aluminum (Al), or the like, in addition to the ceramic powder. 
     The first and second internal electrodes  121  and  122  may be formed on the dielectric layer  111 , stacked in the Z direction, and alternately disposed in the ceramic body  110  to face each other in the Z direction with each of the dielectric layers  111  interposed therebetween. 
     Here, one ends of the first and second internal electrodes  121  and  122  may be exposed to the third and fourth surfaces of the ceramic body  110 , respectively. 
     The first and second external electrodes  131  and  132  may be formed on to both end portions of the ceramic body  110  opposing each other in the X direction, respectively. 
     Here, the first and second external electrodes  131  and  132  may include first and second connection portions  131   a  and  132   a  and first and second band portions  131   b  and  132   b , respectively. 
     The first and second connection portions  131   a  and  132   a  may be disposed on the third and fourth surfaces of the ceramic body  110 , respectively, and come in contact with portions of the first and second internal electrodes  121  and  122  exposed to the outside of the ceramic body  110 , respectively, thereby serving to connect the internal electrodes and the external electrodes to each other. 
     The first and second band portions  131   b  and  132   b  may be portions extended from the first and second connection portions  131   a  and  132   a  to portions of the first and second surfaces of the ceramic body  110 , respectively. 
     Here, if necessary, the first and second band portions  131   b  and  132   b  may be extended from the first and second connection portions  131   a  and  132   a  to portions of the fifth and sixth surfaces of the ceramic body  110 , respectively. 
     The first and second band portions  131   b  and  132   b  may serve to improve bonding strength of the first and second external electrodes  131  and  132 . 
       FIGS. 3 and 4  are perspective views schematically illustrating a structure of the electronic component  100  according to an exemplary embodiment in the present disclosure. However, in order to clearly describe the structure of the electronic component  100  according to the present exemplary embodiment, the plating member is not illustrated in  FIGS. 3 and 4 . 
     Referring to  FIGS. 3 and 4 , the capacitor array may have a structure in which the plurality of capacitors  101  are disposed in a column as illustrated in  FIG. 3 . Alternatively, the capacitor array may have a structure in which the plurality of capacitors  101  are disposed in a row as illustrated in  FIG. 4 . 
     Alternatively, the capacitor array may have a structure in which the plurality of capacitors  101  are stacked in the columns and the rows as illustrated in  FIG. 1 . 
     The pair of metal frames may be first and second metal frames  143  and  144 , respectively, and may be disposed on the side surfaces of the capacitor array and electrically connected to the first and second external electrodes  131  and  132 , respectively, to thereby serve as common electrodes. Further, the first and second penetration portions  141  and  142  may be formed at the positions at which the pair of the metal frames  143  and  144  are connected to the first and second external electrodes  131  and  132 . The first and second metal frames  143  and  144  may come into direct contact with the first and second external electrodes  131  and  132 , respectively. 
     In this case, areas of the first and second penetration portions  141  and  142  may be 50% or more of areas of the external electrodes  131  and  132  that come in contact with each other so that the metal frames  143  and  144  and the capacitor array may be sufficiently adhered to each other. That is, the areas of the first and second penetration portions  141  and  142  may be 50% or more of areas of the first and second connection portions  131   a  and  132   a  on the third and fourth surfaces. 
     In this case, a material of the first and second metal frames  143  and  144  may be a material that is not deformed and/or properties thereof are not changed at a soldering temperature, and it may be preferable to select a material having sufficient wetting properties. 
     Here, the first and second metal frames  143  and  144  may include first and second horizontal portions  145  and  146  and have an L shape so that the first and second metal frames  143  and  144  may be easily mounted on a board. 
     The plating members  151   a  and  152   a  filling the first and second penetration portions  141  and  142  may allow the metal frames  143  and  144  and the plurality of capacitors  101  to be bonded to each other, and the plurality of capacitors  101  may be reliably bonded to the metal frames  143  and  144  in a simple manner without any separate binding means such as high-temperature solder, or the like. The plating members  151   a  and  152   a  may come into direct contact with the first and second external electrodes  131  and  132 . 
     In this case, the plating members  151   a  and  152   a  may have a thickness of 10 μm or more so that the first and second metal frames  143  and  144  and the capacitor array may be sufficiently adhered to each other. 
     Here, the plating members may be further formed on portions  151   b ,  152   b ,  151   c , and  152   c  of outer surfaces of the capacitor array on which the first and second metal frames  143  and  144  are disposed, except for portions on which the ceramic bodies  110  of the capacitors  101  are disposed. Since plating is performed on the capacitor array on which the metal frames  143  and  143  are disposed, the plating member may be formed on exposed portions  151   b  and  152   b  of the metal frames exposed to the outside and portions  151   c  and  152   c  thereof exposed to the outside of the external electrodes. The plating member may be formed of Ni/Sn, and serve to improve binding strength between the metal frames and the capacitors or serve as an adhesive with a solder at the time of mounting the electronic component  100  on a board. 
     According to the present exemplary embodiment, since the plurality of capacitors may be reliably bonded to each other in a simple manner without any binding means such as high-temperature solder, or the like, defamation or damage of the capacitors due to thermal or mechanical causes may be prevented, and high capacitance may be achieved without having a separate cooling device. 
     Particularly, even if the number of capacitors to be bonded is increased, the capacitors may be bonded to each other at once by a plating method. Therefore, the larger the number of capacitors to be bonded, the higher the efficiency as compared to a binding method using the binding means such as the high-temperature solder, or the like. 
     Hereinafter, a manufacturing method of an electronic component according to an exemplary embodiment of the present disclosure will be described. 
     A capacitor array in which a plurality of capacitors  101  are arranged may be prepared. 
     Here, the capacitors  101  may be prepared by forming first and second external electrodes on both surfaces of a ceramic body  110  opposing each other, respectively. 
     In this case, the ceramic body  110  may have a structure in which a plurality of dielectric layers  111  and a plurality of first and second internal electrodes  121  and  122  are included by preparing a plurality of ceramic sheets, printing a conductive paste on the ceramic sheets to form first and second internal electrodes  121  and  122 , and stacking and compressing the plurality of ceramic sheets. 
     Next, as illustrated in  FIG. 5  showing an exemplary embodiment of the present disclosure, first and second metal frames  143  and  144 , that are connected to first and second external electrodes  131  and  132  of a plurality of capacitors  101  of a capacitor array  300  and that include first and second penetration portions  141  and  142  formed in positions in which the first and second metal frames  143  and  144  are connected to the first and second external electrodes  131  and  132 , may be disposed on side surfaces of the capacitor array  300 . 
     Here, first and second support portions  201  and  202  may be formed in the first and second metal frames  143  and  144  so that the first and second metal frames  143  and  144  and the capacitor array  300  may be compressed and attached to each other, and the first and second support portions  201  and  202  may be connected to each other using a connection member  301 . 
     Then, as illustrated in  FIG. 6  showing an exemplary embodiment of the present disclosure, a capacitor array  300  including the first and second metal frames  143  and  144  may be dipped in a plating bath and plating may be performed thereon to be connected to electrodes  410  and  420 , such that the plurality of capacitors may be reliably bonded to each other in a simple manner without any binding means such as high-temperature solder, or the like. 
     Here, in performing the plating, a plating member may have a thickness of 10 μm or more in order to allow the first and second metal frames  143  and  144  and the capacitor array  300  to be sufficiently adhered to each other. 
     Further, after the plating is completed, the first and second support portions  201  and  202  may be removed, and first and second horizontal portions  145  and  146  may be formed in the first and second metal frames  143  and  144  so that the electronic component may be easily mounted on a board. 
     As set forth above, according to exemplary embodiments of the present disclosure, since the plurality of capacitors may be reliably bonded to each other in a simple manner without any binding means such as high-temperature solder, or the like, deformation or damage due to thermal or mechanical causes may be prevented, and high capacitance may be achieved without a separate cooling device. 
     While exemplary embodiments have been shown and described above, it will be apparent to those skilled in the art that modifications and variations could be made without departing from the scope of the present invention as defined by the appended claims.