Method for manufacturing ceramic sheet laminate and method for manufacturing laminated ceramic electronic component

Abstract

A method for manufacturing a ceramic sheet laminate, comprising: a step for forming a first ceramic sheet on a carrier film; a step in which a plurality of first electrode patterns and a plurality of first positioning patterns are sequentially intaglio-printed on the first ceramic sheet; a step for drying the first electrode pattern; forming a second ceramic sheet; and a step for sequentially gravure printing a plurality of second electrode patterns and a plurality of second positioning patterns on the second ceramic sheet, in which, on the basis of the first positioning pattern, or the first positioning pattern and the second positioning pattern, alignment is performed between the second electrode pattern to be printed and the first electrode pattern overlapping the second electrode pattern.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a ceramic laminate and a method for manufacturing a multilayer ceramic electronic component. Background Art

[0002] A method for manufacturing a ceramic laminate and a method for manufacturing a multilayer ceramic electronic component in the prior art are described, for example, in Patent Document 1.

[0003] Prior Art Documents

[0004] Patent Documents

[0005] Patent Document 1: Japanese Unexamined Patent Application Publication No. 2001-85271 Summary of the Invention

[0006] The method for manufacturing a ceramic laminate of the present disclosure includes: a first forming step of applying a ceramic slurry to a first surface of a strip-shaped carrier film to form a first ceramic sheet;

[0007] a first printing step of sequentially printing a plurality of first electrode patterns and a plurality of first positioning patterns on a second surface of the first ceramic sheet, which is opposite to the carrier film side, using an intaglio roll engraved with an electrode pattern and a positioning pattern and a conductive paste;

[0008] a first drying step of drying the plurality of first electrode patterns;

[0009] a second forming step of applying the ceramic slurry to an area of the second surface where the plurality of first electrode patterns and the plurality of first positioning patterns are not printed, the plurality of first electrode patterns, and the plurality of first positioning patterns to form a second ceramic sheet;

[0010] a second drying step of drying the second ceramic sheet;

[0011] a second printing step of sequentially printing a plurality of second electrode patterns and a plurality of second positioning patterns on a third surface of the second ceramic sheet, which is opposite to the carrier film side, using the intaglio roll and the conductive paste, wherein alignment of a second electrode pattern to be printed next with a first electrode pattern overlapping the second electrode pattern is performed based on at least one of the first positioning patterns, or at least one of the first positioning patterns and at least one of the second positioning patterns.

[0012] The method for manufacturing a multilayer ceramic electronic component of the present disclosure includes: a step of cutting a ceramic laminate manufactured by the method for manufacturing a ceramic laminate described above to produce a plurality of ceramic laminate sheets;

[0013] a step of laminating the plurality of ceramic laminate sheets with each other to produce a mother laminate;

[0014] A process of cutting the mother laminate to produce a green body component;

[0015] A process of firing the green body component;

[0016] A process of forming an external electrode on the fired green body component. Description of the Drawings

[0017] The objectives, features, and advantages of the present disclosure will become clearer from the following detailed description and the drawings.

[0018] Figure 1 It is a top view of a ceramic laminate manufactured by the manufacturing method of the ceramic laminate of the present disclosure.

[0019] Figure 2 It is from Figure 1 A cross-sectional view taken along the section line II-II.

[0020] Figure 3 It is a top view showing the first electrode pattern and the first positioning pattern printed on the first ceramic sheet.

[0021] Figure 4 It is an enlarged top view showing Figure 3 Part IV in an enlarged manner.

[0022] Figure 5 It is a top view showing the shape of the first electrode pattern after the first drying process.

[0023] Figure 6 It is a top view for explaining the control of the shape of the first electrode pattern in the second printing process.

[0024] Figure 7 It is a perspective view showing the structure of the gravure printing apparatus used in the first printing process and the second printing process.

[0025] Figure 8 It is a top view for explaining an example of alignment in the second printing process.

[0026] Figure 9 It is a perspective view showing the manufacturing process of the temporary laminate.

[0027] Figure 10 It is a perspective view showing the mother laminate.

[0028] Figure 11 It is a perspective view showing a plurality of green body components obtained by cutting the mother laminate.

[0029] Figure 12 It is a perspective view showing a laminated ceramic electronic component. Detailed Description of the Invention

[0030] A multilayer ceramic capacitor as an example of a multilayer ceramic electronic component includes a laminate formed by alternately laminating a plurality of dielectric layers and a plurality of internal electrode layers. When manufacturing a multilayer ceramic capacitor, a ceramic sheet laminate in which ceramic sheets and electrode patterns are alternately laminated is prepared in advance, and the ceramic sheet laminate is laminated, whereby a multilayer ceramic capacitor can be efficiently manufactured.

[0031] In Patent Document 1, a method of manufacturing a ceramic sheet laminate by repeatedly performing a step of forming a ceramic sheet on the surface of a carrier film and a step of printing an electrode pattern on the surface of the ceramic sheet is disclosed. In Patent Document 1, the first layer of electrode pattern is formed by gravure printing, and the electrode patterns after the second layer are formed by screen printing.

[0032] In the conventional method of manufacturing a ceramic sheet laminate, since the printing speed of screen printing (for example, 10 m / min or less) is lower than the printing speed of gravure printing (for example, about 50 to 200 m / min), it is difficult to improve the manufacturing efficiency of the ceramic sheet laminate. In addition, in the conventional method of manufacturing a ceramic sheet laminate, since the printing method of the first layer of electrode pattern is different from the printing method of the electrode patterns after the second layer, misalignment between the electrode patterns is likely to occur, and the reliability of the multilayer ceramic capacitor may be reduced.

[0033] Hereinafter, embodiments of a method for manufacturing a ceramic sheet laminate and a method for manufacturing a multilayer ceramic electronic component according to the present disclosure will be described with reference to the drawings. The drawings referred to hereinafter are schematic, and the dimensional ratios and the like shown in the drawings are not necessarily accurately illustrated. In this specification, in some of the drawings, an orthogonal coordinate system xyz is defined for convenience.

[0034] Figure 1 is a plan view of a ceramic sheet laminate manufactured by the method for manufacturing a ceramic sheet laminate according to the present disclosure; Figure 2 is from Figure 1 a cross-sectional view taken along the section line II-II; Figure 3 is a plan view showing a first electrode pattern and a first positioning pattern printed on a first ceramic sheet; Figure 4 is an enlarged view showing Figure 3 an enlarged plan view of part IV; Figure 5 is a plan view showing the shape of the first electrode pattern after the first drying process; Figure 6 is a plan view for explaining the control of the shape of the first electrode pattern in the second printing process; Figure 7 is a perspective view showing the structure of a gravure printing apparatus used in the first printing process and the second printing process. In addition, in Figure 1In [the figure], the first ceramic sheet, the second ceramic sheet, and the first positioning pattern are omitted, and hatching is given to the island electrodes of the first electrode pattern for illustration. In Figure 5 In [the figure], the second ceramic sheet is omitted, and the first electrode pattern before the first drying process and the first electrode pattern after the first drying process are schematically shown. In Figure 6 In [the figure], the second ceramic sheet is omitted, and the first electrode pattern after the first drying process and the first electrode pattern deformed by controlling the tension applied to the thin film are schematically shown. Figure 7 A gravure printing apparatus for performing the second printing process is shown. In Figure 7 In [the figure], the first ceramic sheet and the second ceramic sheet are omitted for illustration, and hatching is given to the first electrode pattern and the second electrode pattern to schematically show the first electrode pattern and the second electrode pattern. In Figure 8 In [the figure], hatching is given to the first alignment mark and the second alignment mark of the first positioning pattern for illustration.

[0035] The method for manufacturing a ceramic sheet laminate according to an embodiment of the present disclosure includes: a first forming process, a first printing process, a first drying process, a second forming process, a second drying process, and a second printing process. As Figure 1 , 2 shown, the ceramic sheet laminate 1 manufactured by the manufacturing method of the present disclosure includes: a first ceramic sheet 3, a plurality of first electrode patterns 4, a second ceramic sheet 7, and a plurality of second electrode patterns 8. In addition, as Figure 1 , 3 shown, the ceramic sheet laminate 1 includes a plurality of first positioning patterns 5 and a plurality of second positioning patterns 9, and the plurality of first positioning patterns 5 and the plurality of second positioning patterns 9 are used for alignment of the plurality of first electrode patterns 4 and the plurality of second electrode patterns 8. As Figure 2 shown, the ceramic sheet laminate 1 is manufactured on a carrier film (hereinafter also simply referred to as a film) 2.

[0036] (First Forming Process)

[0037] As Figure 2 shown, the first forming process is a process of coating a ceramic slurry on the first surface 2a of the film 2 to form the first ceramic sheet 3.

[0038] First, a mixed powder of dielectric ceramic powder, rare earth elements, and glass powder is wet-crushed and mixed using a bead mill, and then an organic carrier is mixed to prepare a ceramic slurry. As the dielectric ceramic powder, powders of ceramic materials such as barium titanate (BaTiO3), calcium titanate (CaTiO3), strontium titanate (SrTiO3), and barium zirconate (BaZrO3) can be used, for example. As the rare earth elements, yttrium (Y), dysprosium (Dy), holmium (Ho), terbium (Tb), ytterbium (Yb), etc. can be used, for example. As the glass powder, SiO2-BaO-CaO-based glass powder can be used, for example. As the organic carrier, an organic carrier in which a resin such as a butyral resin is dissolved in a solvent composed of a mixture of ethanol and toluene can be used, for example.

[0039] As Figure 1 shown, the thin film 2 is in a long strip shape and has a long side direction and a short side direction. The long side direction and the short side direction of the thin film 2 are also referred to as the first direction (x-axis direction) and the second direction (y-axis direction), respectively. The size of the thin film 2 is not particularly limited. The thin film 2 can have a length of, for example, about 1000 to 20000 m in the long side direction, a length of, for example, about 200 to 500 mm in the short side direction, and a thickness of, for example, about 5 to 100 μm. The thin film 2 can be made of a resin material such as polyethylene terephthalate (PET), polyethylene naphthalate (PEN), or polypropylene (PP), for example.

[0040] Next, the prepared ceramic slurry is coated on the first surface 2a of the thin film 2 to form a first ceramic sheet 3. The first ceramic sheet 3 becomes the dielectric layer of the multilayer ceramic electronic component. As a forming method of the first ceramic sheet 3, known forming methods such as a die coating method and a doctor blade method can be used, for example. The thickness of the first ceramic sheet 3 can be, for example, about 0.5 to 2.0 μm.

[0041] (First printing process)

[0042] The first printing process is a process of gravure printing a plurality of first electrode patterns 4 and a plurality of first positioning patterns 5 in sequence on the second surface 3a of the first ceramic sheet 3. The second surface 3a is the surface of the first ceramic sheet 3 on the side opposite to the carrier thin film 2 side. The plurality of first electrode patterns 4 and the plurality of first positioning patterns 5 are formed of a conductive paste.

[0043] First, a gravure roll (also referred to as a gravure cylinder) 6 for gravure printing and a conductive paste are prepared. The gravure roll 6 is in a cylindrical shape (refer to Figure 7), a printing pattern corresponding to the graphic pattern to be printed (i.e., the first electrode pattern 4 and the first positioning pattern 5) is engraved on the outer peripheral surface of the gravure roll 6. The conductive paste is prepared by mixing metal powder with an organic carrier. As the metal powder, for example, powders of metal materials such as nickel (Ni), palladium (Pd), copper (Cu), silver (Ag), etc. can be used. The metal powder can have Ni as the main component. As the organic carrier mixed in the metal powder, for example, an organic carrier in which a resin such as ethyl cellulose is dissolved in a solvent obtained by mixing a dihydroterpineol-based solvent and butyl cellosolve can be used.

[0044] Gravure printing of the plurality of first electrode patterns 4 and the plurality of first positioning patterns 5 can be performed using the gravure printing apparatus 100 described later. The printing speed of the gravure printing can be, for example, about 50 to 200 m / minute.

[0045] The first electrode pattern 4 becomes the internal electrode layer of the multilayer ceramic electronic component. As Figure 3 shown, in the present embodiment, the first electrode pattern 4 is composed of a plurality of island-shaped electrodes 4a arranged in a staggered pattern. The size of each island-shaped electrode 4a can be appropriately set according to the specifications of the multilayer ceramic electronic component. In addition, the arrangement of the plurality of island-shaped electrodes 4a is not limited to the staggered arrangement. For example, elongated island-shaped electrodes 4a can be arranged along the first direction (x-axis direction) in the second direction (y-axis direction). As Figure 3 shown, in a top view perspective, the first electrode pattern 4 can be printed at the central portion of the first ceramic sheet 3 in the second direction (y-axis direction).

[0046] The first positioning pattern 5 is used for alignment of the first electrode pattern 4 and the second electrode pattern (described later). As Figure 3 shown, in the present embodiment, the first positioning pattern 5 includes an alignment mark 5a and a positioning line 5b.

[0047] As Figure 4 shown, the alignment mark 5a can also be composed of a circular first alignment mark 5aa and an annular second alignment mark 5ab. When the pitch of the plurality of island-shaped electrodes 4a in the first direction is set to P, the centroid of the first alignment mark 5aa and the centroid of the second alignment mark 5ab can be spaced apart by a natural multiple of P / 2 in the first direction. The centroid of the first alignment mark 5aa and the centroid of the second alignment mark 5ab can be spaced apart by P / 2 in the first direction.

[0048] The plurality of positioning lines 5b are linear or strip-shaped and extend along the first direction. As Figure 3 shown, one positioning line 5b can be connected to the positioning line 5b adjacent to the one positioning line 5b. In other words, the plurality of positioning lines 5b can continuously extend along the first direction.

[0049] AsFigure 3 As shown, the alignment mark 5a can be printed near one end of the second surface 3a in the second direction (y-axis direction), and the positioning line 5b can be printed near the other end of the second surface 3a in the second direction (y-axis direction).

[0050] (First drying process)

[0051] The first drying process is a process of drying a plurality of first electrode patterns 4. The drying of the first electrode patterns 4 can be performed using a drying furnace (not shown).

[0052] The film 2 holding the first ceramic sheet 3 printed with the first electrode patterns 4 is carried into the furnace of the drying furnace, and the first electrode patterns 4 are heated to a first temperature to dry the first electrode patterns 4. Therefore, in the first drying process, the film 2 is also heated to the first temperature. The first temperature can be above the softening point of the film 2. In this case, when the film 2 is taken out of the furnace of the drying furnace and cooled, it deforms to shrink in the first direction (x-axis direction) and elongate in the second direction (y-axis direction). As the film 2 deforms, the first electrode patterns 4 also deform to shrink in the first direction and elongate in the second direction. Therefore, as Figure 5 shown, the shape of the first electrode patterns 4 deforms from the shape of the first electrode patterns 4A before the first drying process (i.e., the shape corresponding to the printing pattern engraved on the gravure roll 6), but in the second printing process, as Figure 6 shown, by applying a tension T in the first direction to the film 2, the film 2 and the second electrode patterns 8 are deformed to elongate in the first direction and shrink in the second direction (i.e., make the shape of the first electrode patterns 4 close to the shape of the first electrode patterns 4A), so that the alignment of the first electrode patterns 4 and the second electrode patterns can be performed.

[0053] In addition, the film 2 that has undergone the first forming process (i.e., the film 2 holding the first ceramic sheet 3) can be conveyed to the second forming process as the next process without being rewound onto the roll or fed out from the roll after the first printing process and the first drying process. In this case, the ceramic sheet laminate 1 can be manufactured efficiently.

[0054] (Second forming process)

[0055] In the second forming process, ceramic slurry is coated on the regions of the second surface 3a of the first ceramic sheet 3 where a plurality of first electrode patterns 4 and a plurality of first positioning patterns 5 are not printed, the plurality of first electrode patterns 4, and the plurality of first positioning patterns 5 to form as Figure 2The second ceramic sheet 7 shown. As the ceramic slurry, the ceramic slurry used for forming the first ceramic sheet 3 can be used. As the forming method of the second ceramic sheet 7, the same forming method as that of the first ceramic sheet 3 can be used. The thickness of the second ceramic sheet 7 can be the same as that of the first ceramic sheet 3.

[0056] (Second drying process)

[0057] The second drying process is a process of drying the second ceramic sheet 7. In the second drying process, similar to the first drying process, the film 2 holding the first ceramic sheet 3 printed with the first electrode pattern 4 and the second ceramic sheet 7 is carried into the furnace of the drying furnace, and the second ceramic sheet 7 is heated to the second temperature to dry the second ceramic sheet 7. Therefore, in the second drying process, the film 2 is also heated to the second temperature. The second temperature can be lower than the softening point of the film 2. In this case, the deformation of the film 2 holding the first ceramic sheet 3 printed with the first electrode pattern 4 and the second ceramic sheet 7 can be reduced. As a result, the undesired deformation of the first electrode pattern 4 (for example, the deformation of the first electrode pattern 4 stretching in the first direction) can be reduced. Thus, in the second printing process, by applying the tension T in the first direction to the film 2, the alignment of the first electrode pattern 4 and the second electrode pattern 8 can be performed.

[0058] In addition, the film 2 that has undergone the first drying process (i.e., the film 2 holding the first ceramic sheet printed with the first electrode pattern 4) is not rewound onto the roller or fed out from the roller after undergoing the second forming process and the second drying process, but is conveyed to the second printing process as the next process. In this case, since the conveying direction of the film 2 in the second printing process can be the same as the conveying direction of the film 2 in the first printing process, it is easy to make the printing position of the second electrode pattern in the second printing process coincide with the printing position of the first electrode pattern 4 in the short side direction of the film 2.

[0059] (Second printing process)

[0060] As shown in Figure 1 、 2 , the second printing process is a process of intaglio printing a plurality of second electrode patterns 8 and a plurality of second positioning patterns 9 on the third surface 7a of the second ceramic sheet 7 in sequence. The third surface 7a is the surface of the second ceramic sheet 7 on the side opposite to the carrier film 2 side. The plurality of second electrode patterns 8 and the plurality of second positioning patterns 9 are printed using the gravure roll 6 used in the first printing process. The plurality of second electrode patterns 8 and the plurality of second positioning patterns 9 are formed of the conductive paste used in the first printing process.

[0061] In the second printing process, the gravure roll 6 used in the first printing process is employed to print a plurality of second electrode patterns 8 and a plurality of second positioning patterns 9. Accordingly, the second electrode pattern 8 is the same pattern as the first electrode pattern 4 and is composed of a plurality of island-shaped electrodes 8a arranged in a staggered manner. In addition, similar to the first positioning pattern 5, the second positioning pattern 9 includes an alignment mark 9a and a positioning line 9b. As Figure 1 shown, the alignment mark 9a may also be composed of a circular first alignment mark 9aa and an annular second alignment mark 9ab.

[0062] In the second printing process, when printing a plurality of second electrode patterns 8 and a plurality of second positioning patterns 9 in sequence, alignment (hereinafter, also simply referred to as "alignment") is performed between the second electrode pattern 8 to be printed next and the first electrode pattern 4 that overlaps with the second electrode pattern 8. In the second printing process, alignment is performed based on at least one first positioning pattern 5, or at least one first positioning pattern 5 and at least one second positioning pattern 9.

[0063] In the manufacturing method of the ceramic laminate of the present embodiment, since the gravure printing method with a relatively high printing speed (higher than screen printing) is adopted for both the printing of the first electrode pattern 4 and the printing of the second electrode pattern 8, the ceramic laminate 1 can be manufactured efficiently.

[0064] In addition, in the manufacturing method of the ceramic laminate of the present embodiment, since the second electrode pattern 8 is printed using the gravure roll 6 for printing the first electrode pattern 4, the misalignment between the first electrode pattern 4 and the second electrode pattern 8 due to manufacturing tolerances of the gravure roll 6 and the like can be reduced. As a result, a laminated ceramic electronic component with improved reliability can be manufactured efficiently.

[0065] In addition, in the manufacturing method of the ceramic laminate of the present embodiment, since the second electrode pattern 8 is printed while performing alignment, the misalignment between the first electrode pattern 4 and the second electrode pattern 8 can be further reduced. As a result, a laminated ceramic electronic component with further improved reliability can be manufactured efficiently.

[0066] Next, with reference to Figure 7 , a gravure printing apparatus (hereinafter, simply referred to as the printing apparatus) 100 used in the first printing process and the second printing process will be described. Hereinafter, the operation of the printing apparatus 100 in the second printing process will be described, but the operation of the printing apparatus 100 in the first printing process is the same except that the object to be printed is different and alignment is not required.

[0067] The printing device 100 includes: a supply roller 101, a guide roller 102, an intaglio roller 6, a first pinch roller 103, a second pinch roller 104, a line sensor 105, and a camera 106. The printing device 100 may also include guide rollers, a take-up roller, a drive unit, a control unit, etc. that are not shown. The drive unit drives each roller member of the printing device 100. The control unit controls each roller member of the printing device 100 and the drive unit.

[0068] A film 2 is wound around the supply roller 101, and the film 2 holds a first ceramic sheet 3 printed with a first electrode pattern 4 and a first positioning pattern 5, and a second ceramic sheet 7. Hereinafter, the first ceramic sheet 3 printed with the first electrode pattern 4 and the first positioning pattern 5, and the second ceramic sheet 7 are also collectively referred to as a first precursor. During the second printing process, the film 2 holding the first precursor is fed out from the supply roller 101.

[0069] The guide roller 102 is located between the supply roller 101 and the intaglio roller 6 in the conveying direction D1 of the film 2 holding the first precursor. The guide roller 102 is configured such that its center line (rotation axis) can be displaced, and by displacing the center line of the guide roller 102, the position of the film 2 holding the first precursor in the second direction can be adjusted.

[0070] The line sensor 105 is configured to detect the position of the positioning line 5b of the first positioning pattern 5. The line sensor 105 is located between the guide roller 102 and the intaglio roller 6 in the conveying direction D1.

[0071] The camera 106 is configured to detect the alignment mark 5a of the first positioning pattern 5 and the alignment mark 9a of the second positioning pattern 9. The camera 106 is located downstream of the intaglio roller 6 in the conveying direction D2 of the film 2 holding the first precursor printed with the second electrode pattern 8 and the second positioning pattern 9. Hereinafter, the first precursor printed with the second electrode pattern 8 and the second positioning pattern 9 is also referred to as a second precursor.

[0072] The first pinch roller 103 is located between the supply roller 101 and the intaglio roller 6 in the conveying direction D1. Figure 7 An example is shown where the first pinch roller 103 is located upstream of the guide roller 102 and the line sensor 105 in the conveying direction D1, but the position of the first pinch roller 103 relative to the guide roller 102 and the line sensor 105 can be set appropriately. The second pinch roller 104 is located downstream of the intaglio roller 6 in the conveying direction D2. Figure 7 An example is shown where the second pinch roller 104 is located downstream of the camera 106 in the conveying direction D2, but the position of the second pinch roller 104 relative to the camera 106 can be set appropriately. At least one of the first pinch roller 103 and the second pinch roller 104 can be replaced with a suction roller.

[0073] The printing apparatus 100 may include a take-up roller (not shown) located downstream of the camera 106 and the second nip roller 104 in the conveying direction D2. The take-up roller takes up and recovers the film 2 holding the second precursor. The take-up roller may be configured to take up the film 2 holding the second precursor before the second drying process, or may be configured to take up the film 2 holding the second precursor after the second drying process.

[0074] Alignment in the second printing process will be described. First, alignment based on at least one first alignment pattern 5 will be described. As the first alignment pattern 5 (hereinafter also referred to as the first reference pattern) for alignment, an alignment line 5b located on the side in the second direction of the first electrode pattern 4B (see Figure 7 ) that overlaps the second electrode pattern 8 to be printed next can be used.

[0075] In alignment, the first reference pattern is detected by the line sensor 105, and the position of the first reference pattern is made to coincide with the position of the alignment line 9b printed by the printing apparatus 100 in the second direction. Thereby, alignment in the second direction between the second electrode pattern 8 to be printed next and the first electrode pattern 4 that overlaps the second electrode pattern 8 can be performed. Alignment can be performed by adjusting the position of the film 2 holding the first precursor in the second direction. Adjustment of the position of the film 2 holding the first precursor in the second direction can be performed by changing the direction of the center line (rotation axis) of the guide roller 102. In this way, alignment in the second direction between the second electrode pattern 8 to be printed next and the first electrode pattern 4 that overlaps the second electrode pattern 8 can be performed.

[0076] In the case of alignment based on the first alignment pattern 5, as the first reference pattern, an alignment line 5b located on the side in the second direction of the first electrode pattern 4 that overlaps the second electrode pattern 8 to be printed next can also be used. Alternatively, as the first reference pattern, an alignment line 5b located on the side in the second direction of the first electrode pattern 4 that overlaps the second electrode pattern 8 to be printed next and an alignment line 5b located on the side in the second direction of the first electrode pattern 4 that overlaps the second electrode pattern 8 to be printed next can also be used. In this case, alignment in the second direction between the first electrode pattern 4 and the second electrode pattern 8 can be performed with high precision.

[0077] Next, alignment based on at least one first alignment pattern 5 and at least one second alignment pattern 9 will be described. As the first alignment pattern 5 and the second alignment pattern 9 (hereinafter also referred to as the second reference pattern) for alignment, an alignment line 5b located on the side in the second direction of the first electrode pattern 4B (see Figure 7) the alignment marks 9a on the side in the second direction, and the alignment marks 5a on the side in the second direction of the first electrode pattern 4 overlapped by the second electrode pattern 8A.

[0078] In alignment, the second reference pattern is detected by the camera 106, and the misalignment amount between the centroid of the second alignment mark 9ab of the alignment mark 9a and the centroid of the first alignment mark 5aa of the alignment mark 5a is measured. Then, based on the measured misalignment amount, the centroid of the second alignment mark 9ab on the side in the second direction of the second electrode pattern 8 to be printed next is made to coincide with the centroid of the first alignment mark 5aa on the side in the second direction of the first electrode pattern 4 overlapped by the second electrode pattern 8 to be printed next (see Figure 8 ), a tension T is applied to the film 2 holding the first precursor. Thereby, alignment in the first direction between the second electrode pattern 8 to be printed next and the first electrode pattern 4 overlapped by the second electrode pattern 8 can be performed, and the second electrode pattern 8 and the first electrode pattern 4 can be overlapped with a prescribed misalignment amount (P / 2) for manufacturing the multilayer ceramic electronic component offset in the first direction. Alignment can be performed by adjusting the conveyance speed of the first pinch roller 103 and the conveyance speed of the second pinch roller 104. Alignment can be performed by making the conveyance speed of the second pinch roller 104 greater than the conveyance speed of the first pinch roller 103 and applying a tension T in the first direction to the film 2 holding the first precursor.

[0079] In the manufacturing method of the present embodiment, since by performing the first drying process, the film 2 holding the first precursor and the first precursor are deformed to shrink in the first direction and elongate in the second direction compared to the shape of the first electrode pattern 4A before the first drying process (i.e., the shape corresponding to the printing pattern engraved on the gravure roll 6), the adjustment range when applying the tension T in the first direction for alignment is larger. Therefore, the second electrode pattern 8 and the first electrode pattern 4 can be overlapped with high precision in the first direction. In addition, since by applying the tension T in the first direction to the film 2 holding the first precursor, the size of the first precursor in the second direction can be changed (reduced), alignment in the second direction between the second electrode pattern 8 to be printed next and the first electrode pattern 4 overlapped by the second electrode pattern 8 can also be performed. Further, in the case of alignment based on the first positioning pattern 5 and the second positioning pattern 9, as described above, the second direction alignment can be further performed using the first reference pattern. In this case, alignment in the first direction and the second direction between the second electrode pattern 8 to be printed next and the first electrode pattern 4 overlapped by the second electrode pattern 8 can be performed.

[0080] In the case of alignment based on the first alignment pattern 5 and the second alignment pattern 9, as the second reference pattern, alignment marks 9a located on the side in the second direction of the second electrode pattern 8A, alignment marks 9a located on the side in the second direction of the second electrode pattern 8B (refer to Figure 7 ) printed before the second electrode pattern 8A, alignment marks 5a located on the side in the second direction of the first electrode pattern 4 overlapping the second electrode pattern 8A, and alignment marks 5a located on the side in the second direction of the first electrode pattern 4 overlapping the second electrode pattern 8B can be used. In this case, alignment in the first direction and the second direction between the second electrode pattern 8 to be printed next and the first electrode pattern 4 overlapping the second electrode pattern 8 can be performed with high precision.

[0081] In addition to the alignment marks 5a, 9a and the alignment lines 5b, 9b, the first alignment pattern 5 and the second alignment pattern 9 may also have stacked alignment marks (not shown). The stacked alignment marks can be used for alignment of a plurality of ceramic laminate sheets 10 in the stacking direction when manufacturing a temporary laminate (refer to Figure 9 ).

[0082] After the second printing process, a third drying process for drying a plurality of second electrode patterns 8 can be performed. In addition, in the above, a method for manufacturing a ceramic laminate 1 having two ceramic sheets (the first ceramic sheet 3 and the second ceramic sheet 7) and two electrode patterns (the first electrode pattern 4 and the second electrode pattern 8) has been described, but a ceramic laminate having three or more ceramic sheets and three or more electrode patterns can also be manufactured by repeatedly performing the second forming process, the second drying process, and the second printing process.

[0083] Next, a method for manufacturing a stacked ceramic electronic component will be described. Figure 9 is a perspective view showing a process of manufacturing a temporary laminate, Figure 10 is a perspective view showing a mother laminate, Figure 11 is a perspective view showing a plurality of green body components obtained by cutting the mother laminate, Figure 12 is a perspective view showing a stacked ceramic electronic component.

[0084] First, the ceramic laminate 1 is cut along the short side direction (y-axis direction) of the carrier film 2 to separate a plurality of ceramic laminate sheets 10. Each of the plurality of ceramic laminate sheets 10 may include an entire first electrode pattern 4 and an entire second electrode pattern 8.

[0085] Next, as shown in Figure 9As shown, a plurality of ceramic laminate sheets 10 are stacked to produce a temporary laminate. One or more ceramic sheets 11 without electrode patterns may be disposed at both ends of the temporary laminate in the stacking direction. Next, the temporary laminate is pressed in the stacking direction to produce Figure 10 the mother laminate 12 shown. Pressurization of the temporary laminate can be performed, for example, using a hydrostatic press device. When producing the temporary laminate, alignment in the stacking direction of a plurality of ceramic laminate sheets 10 can be performed based on the stacking alignment marks of the first positioning pattern 5 and the second positioning pattern 9. In this case, a plurality of ceramic laminate sheets 10 can be stacked with high precision, and as a result, a stacked ceramic electronic component with improved reliability can be manufactured.

[0086] Next, the mother laminate 12 is cut along the imaginary dividing line 13 to produce a plurality of unburned green body components 14. Cutting of the mother laminate 12 can be performed, for example, using a press cutter, a cutting saw device, a laser cutter, etc. As Figure 11 shown, the green body component 14 has a first end face and a second end face that face each other, a part of the first electrode pattern 4 is exposed on the first end face, and a part of the second electrode pattern 8 is exposed on the second end face.

[0087] Next, in an air atmosphere, an inert gas atmosphere, or a reducing atmosphere, after subjecting the unburned green body component 14 to a debinding treatment at atmospheric pressure or reduced pressure, firing is performed in a reducing atmosphere. The firing temperature can be, for example, about 1100°C to 1300°C. Next, a reoxidation treatment is performed on the fired green body component 14 in a nitrogen atmosphere. By placing the reoxidized green body component 14 in a tank containing abrasive powder, abrasive media, etc. and rotating it to perform grinding, the corners and burrs of the green body component 14 are removed. By forming an external electrode 15 on the green body component 14 from which the corners and burrs have been removed, a stacked ceramic electronic component as Figure 12 shown, 16 can be manufactured. The external electrode 15 can be formed, for example, by coating a base layer made of a metal material such as copper (Cu) on the surfaces of the green body component 14 including the first end face and the second end face and sintering, and sequentially plating nickel (Ni) and tin (Sn) on the base layer.

[0088] In the method for manufacturing a stacked ceramic electronic component of the present disclosure, since the stacked ceramic electronic component is manufactured using the ceramic laminate 1, a stacked ceramic electronic component with improved reliability can be manufactured.

[0089] Examples

[0090] As an example, a ceramic sheet laminate 1 (specimen Nos. 1 to 3 in Table 1) was fabricated by the above-described method for manufacturing a ceramic sheet laminate. As the carrier film 2, a PET film with a width of 400 mm and a thickness of 31 μm was used. In a region of 8000 m in length of the carrier film 2, 20,000 first electrode patterns 4, first positioning patterns 5, second electrode patterns 8, and second positioning patterns 9 were respectively printed by the gravure printing method. The printing speed of the gravure printing was set at 100 m / min. The "printing method" in Table 1 indicates the printing method of the second electrode pattern 8. The first temperature was set at 80 to 90 °C, which is above the softening point (74 °C) of PET, and the second temperature was set at 70 °C, which is lower than the softening point of PET. Further, based on the first positioning pattern 5 and the second positioning pattern 9, alignment of the first electrode pattern 4 and the second electrode pattern 8 was performed in the first direction and the second direction.

[0091] For each pair of the first positioning pattern 5 and the second positioning pattern 9, the amount of misalignment of the centroid of the first alignment mark 5aa of the first positioning pattern 5 with respect to the centroid of the second alignment mark 9ab of the second positioning pattern 9 was respectively measured, and 3σ (three times the standard deviation) of the distribution of the amount of misalignment in the first direction and 3σ of the distribution of the amount of misalignment in the second direction were calculated. The "variation width" and "variation length" in Table 1 show the results. The "variation width" indicates 3σ of the amount of misalignment in the second direction, and the "variation length" indicates 3σ of the amount of misalignment in the first direction.

[0092] Further, using the ceramic sheet laminate 1, 300 multilayer ceramic electronic components 16 were fabricated by the above-described method for manufacturing a multilayer ceramic capacitor. The multilayer ceramic electronic component 16 was a 1005-type multilayer ceramic capacitor with a length, width, and height of 1.0 mm, 0.5 mm, and 0.5 mm, respectively. A high-temperature and high-humidity test was performed on the 300 multilayer ceramic electronic components 16, and the number of defective multilayer ceramic capacitors among the 300 multilayer ceramic capacitors was measured. In the high-temperature and high-humidity test, after applying a voltage of 6.3 V between the external electrodes and leaving it for 48 hours in an environment of a temperature of 85 °C and a humidity of 85%, a multilayer ceramic capacitor with an insulation resistance value of 1 MΩ or less was determined to be defective. The "high-temperature and high-humidity test" in Table 1 shows the results.

[0093] As a comparative example, specimens No. 4 to 6 in Table 1 were fabricated. Similar to the examples, the variation width and variation length were calculated, and a high-temperature and high-humidity test was conducted to measure the number of defective multilayer ceramic capacitors. Specimen No. 4 was the same as specimens No. 1 to 3 except that both the first temperature and the second temperature were set to be lower than the softening point of the thin film 2. Specimen No. 5 was a specimen in which both the first temperature and the second temperature were set to be higher than the softening point of the thin film 2. For specimen No. 5, after the second drying process, the thin film of the ceramic laminate and the ceramic laminate were maintained, and compared with the shape of the first electrode pattern 4A before the first drying process (i.e., the shape corresponding to the printing pattern engraved on the gravure roll 6), it elongated in the first direction, and thus alignment by applying tension in the second printing process could not be performed. Specimen No. 6 was the same as specimen No. 2 except that the second electrode pattern was screen-printed. The printing speed of the gravure printing was set at 7.5 m / min.

[0094] [Table 1]

[0095]

[0096] In specimens No. 1 to 3, the variation width was 10 μm or less and the variation length was 15 μm or less, and the first positioning pattern 5 and the second positioning pattern 9 could be aligned with high precision. In other words, in specimens No. 1 to 3, the first electrode pattern 4 and the second electrode pattern 8 could be overlapped with high precision in the second direction and overlapped with a specified misalignment amount (P / 2) in the first direction, so that no defective multilayer ceramic electronic components were confirmed in the high-temperature and high-humidity test.

[0097] Compared with specimens No. 1 to 3, specimen No. 4 had a larger variation width and variation length, and 1 defective multilayer ceramic electronic component was confirmed in the high-temperature and high-humidity test. It is considered that in specimen No. 4, since the first temperature was lower than the softening point of the PET thin film, the first electrode pattern did not deform as Figure 5 shown, and as a result, the adjustment range when aligning by applying the tension T in the first direction in the second printing process became smaller, and the variation width and variation length became larger. In addition, it is considered that in specimen No. 4, since the variation width and variation length were larger, poor formation of the internal electrode layer of the multilayer ceramic capacitor was likely to occur.

[0098] In Specimen No. 6, compared with Specimens No. 1 to 3, the variation width and the variation length are larger, and nine defective multilayer ceramic electronic components were confirmed in the high-temperature and high-humidity test. It can be considered that in Specimen No. 6, since screen printing was used in the second printing process, the alignment of the first electrode pattern and the second electrode pattern cannot be performed by controlling the tension applied to the thin film, and the variation width and the variation length become larger. In addition, it can be considered that in Specimen No. 6, since the variation width and the variation length are larger, the formation defect of the internal electrode layer of the multilayer ceramic capacitor is likely to occur.

[0099] According to the method for manufacturing a ceramic laminate of the present disclosure, a ceramic laminate with reduced misalignment between the first electrode pattern and the second electrode pattern can be efficiently manufactured. According to the method for manufacturing a multilayer ceramic electronic component of the present disclosure, since a ceramic laminate manufactured by the method for manufacturing a ceramic laminate described above is used to manufacture a multilayer ceramic electronic component, a multilayer ceramic electronic component with improved reliability can be efficiently manufactured.

[0100] The present disclosure may be the following embodiments (1) to (8).

[0101] (1) A method for manufacturing a ceramic laminate, comprising: a first forming step of coating a ceramic slurry on a first surface of a strip-shaped carrier film to form a first ceramic sheet;

[0102] a first printing step of sequentially printing a plurality of first electrode patterns and a plurality of first positioning patterns on a second surface of the first ceramic sheet, which is opposite to the carrier film side, using an intaglio roll engraved with the electrode pattern and the positioning pattern and a conductive paste;

[0103] a first drying step of drying the plurality of first electrode patterns;

[0104] a second forming step of coating the ceramic slurry on an area of the second surface where the plurality of first electrode patterns and the plurality of first positioning patterns are not printed, and the plurality of first electrode patterns and the plurality of first positioning patterns to form a second ceramic sheet;

[0105] a second drying step of drying the second ceramic sheet;

[0106] a second printing step of sequentially printing a plurality of second electrode patterns and a plurality of second positioning patterns on a third surface of the second ceramic sheet, which is opposite to the carrier film side, using the intaglio roll and the conductive paste, wherein the alignment of the second electrode pattern to be printed next and the first electrode pattern overlapping the second electrode pattern is performed based on at least one of the first positioning patterns, or at least one of the first positioning patterns and at least one of the second positioning patterns.

[0107] (2) According to the method for manufacturing a ceramic laminate described in (1) above, the first positioning pattern and the second positioning pattern include alignment marks and positioning lines.

[0108] (3) According to the method for manufacturing a ceramic laminate described in (2) above, in the second printing process, based on the positioning lines of at least one of the first positioning patterns, alignment is performed in the short side direction of the carrier film between the second electrode pattern to be printed next and the first electrode pattern overlapping the second electrode pattern.

[0109] (4) According to the method for manufacturing a ceramic laminate described in (2) or (3) above, in the second printing process, based on the alignment marks of at least one of the first positioning patterns and the alignment marks of at least one of the second positioning patterns, alignment is performed in the long side direction of the carrier film between the second electrode pattern to be printed next and the first electrode pattern overlapping the second electrode pattern.

[0110] (5) According to the method for manufacturing a ceramic laminate described in (4) above, in the second printing process, by applying tension in the long side direction to the carrier film, alignment is performed in the long side direction of the carrier film between the second electrode pattern to be printed next and the first electrode pattern overlapping the second electrode pattern.

[0111] (6) According to the method for manufacturing a ceramic laminate described in any one of (1) to (5) above, the carrier film is made of a resin material;

[0112] In the first drying process, the plurality of first electrode patterns are dried at a peak temperature above the softening point of the carrier film.

[0113] (7) According to the method for manufacturing a ceramic laminate described in (6) above, in the second drying process, the second ceramic sheet is dried at a peak temperature lower than the softening point.

[0114] (8) A method for manufacturing a multilayer ceramic electronic component, comprising: a step of cutting a ceramic laminate manufactured by the method for manufacturing a ceramic laminate described in any one of (1) to (7) above to produce a plurality of ceramic laminate sheets;

[0115] A step of laminating the plurality of ceramic laminate sheets with each other to produce a mother laminate;

[0116] A step of cutting the mother laminate to produce a green body component;

[0117] A step of firing the green body component;

[0118] A step of forming external electrodes on the fired green body component.

[0119] The embodiments of the present disclosure have been described in detail above, but the present disclosure is not limited to the above embodiments, and various changes, improvements, etc. can be made without departing from the spirit of the present disclosure. In addition, the present disclosure is not limited to the above examples.

[0120] Symbol Description

[0121] 1 Ceramic laminate

[0122] 2 Carrier film

[0123] 2a First side

[0124] 3 First ceramic sheet

[0125] 3a Second side

[0126] 4, 4A, 4B First electrode pattern

[0127] 4a Island electrode

[0128] 5 First positioning pattern

[0129] 5a Alignment mark

[0130] 5aa First alignment mark

[0131] 5ab Second alignment mark

[0132] 5b Positioning line

[0133] 6 Gravure roll

[0134] 7 Second ceramic sheet

[0135] 7a Third side

[0136] 8, 8A, 8B Second electrode pattern

[0137] 8a Island electrode

[0138] 9 Second positioning pattern

[0139] 9a Alignment mark

[0140] 9aa First alignment mark

[0141] 9ab Second alignment mark

[0142] 9b Positioning line

[0143] 10 Ceramic laminate sheet

[0144] 11 Ceramic sheet

[0145] 12 Mother laminate

[0146] 13 Imaginary dividing line

[0147] 14 green body component

[0148] 15 external electrode

[0149] 16 multilayer ceramic electronic component

[0150] 100 gravure printing apparatus

[0151] 101 supply roller

[0152] 102 guide roller

[0153] 103 first clamping roller

[0154] 104 second clamping roller

[0155] 105 line sensor

[0156] 106 camera.

Claims

1. A method for manufacturing a ceramic laminate, comprising: A first forming step of applying a ceramic slurry onto a first surface of a strip-shaped carrier film to form a first ceramic sheet; A first printing step of sequentially printing a plurality of first electrode patterns and a plurality of first positioning patterns on a second surface of the first ceramic sheet, which is opposite to the carrier film side, using a gravure roll engraved with an electrode pattern and a positioning pattern and a conductive paste; A first drying step of drying the plurality of first electrode patterns; A second forming step of applying the ceramic slurry onto an area of the second surface where the plurality of first electrode patterns and the plurality of first positioning patterns are not printed, the plurality of first electrode patterns, and the plurality of first positioning patterns to form a second ceramic sheet; A second drying step of drying the second ceramic sheet; A second printing step of sequentially printing a plurality of second electrode patterns and a plurality of second positioning patterns on a third surface of the second ceramic sheet, which is opposite to the carrier film side, using the gravure roll and the conductive paste, wherein alignment of a second electrode pattern to be printed and a first electrode pattern overlapping the second electrode pattern is performed based on at least one of the first positioning patterns, or at least one of the first positioning patterns and at least one of the second positioning patterns.

2. The method for manufacturing a ceramic laminate according to claim 1, wherein the first positioning pattern and the second positioning pattern include alignment marks and positioning lines.

3. The method for manufacturing a ceramic laminate according to claim 2, wherein in the second printing step, alignment of a second electrode pattern to be printed and a first electrode pattern overlapping the second electrode pattern in the short side direction of the carrier film is performed based on the positioning line of at least one of the first positioning patterns.

4. The method for manufacturing a ceramic laminate according to claim 2 or 3, wherein in the second printing step, alignment of a second electrode pattern to be printed and a first electrode pattern overlapping the second electrode pattern in the long side direction of the carrier film is performed based on the alignment marks of at least one of the first positioning patterns and the alignment marks of at least one of the second positioning patterns.

5. The method for manufacturing a ceramic laminate according to claim 4, wherein in the second printing step, alignment of a second electrode pattern to be printed and a first electrode pattern overlapping the second electrode pattern in the long side direction of the carrier film is performed by applying a tension in the long side direction to the carrier film.

6. The method for manufacturing a ceramic laminate according to any one of claims 1 to 5, wherein the carrier film is made of a resin material; In the first drying step, the plurality of first electrode patterns are dried at a peak temperature above the softening point of the carrier film.

7. The method for manufacturing a ceramic laminate according to claim 6, wherein in the second drying step, the second ceramic sheet is dried at a peak temperature lower than the softening point.

8. A method for manufacturing a multilayer ceramic electronic component, comprising: A step of cutting a ceramic laminate manufactured by the manufacturing method of any one of claims 1 to 7 to produce a plurality of ceramic laminate sheets; A step of laminating the plurality of ceramic laminate sheets on each other to produce a mother laminate; A step of cutting the mother laminate to produce a green body component; A step of firing the green body component; A step of forming an external electrode on the fired green body component.

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