Gravure printing plates and methods for manufacturing multilayer electronic components
The cylindrical gravure printing plate with rounded corners and recesses addresses the issue of paste protrusion by enhancing transfer efficiency and preventing leakage, ensuring high-quality laminated electronic component manufacturing.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- MURATA MFG CO LTD
- Filing Date
- 2023-11-10
- Publication Date
- 2026-06-23
AI Technical Summary
The conventional gravure printing plates with rectangular shapes and sharp corners lead to thread-like paste protrusion outside the printing range during the manufacturing of laminated electronic components.
A cylindrical or columnar gravure printing plate with rounded corners and recesses, featuring a relationship R1 > R2 between the radii of curvature of the corners, embankment portions with notches, and a curved bottom surface, which facilitates smooth paste transfer and prevents paste leakage.
The solution effectively suppresses paste leakage outside the printing area, ensuring high transfer efficiency and quality in manufacturing laminated electronic components.
Smart Images
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Abstract
Description
Technical Field
[0001] The present disclosure relates to a gravure printing plate used for gravure printing and a method for manufacturing a laminated electronic component using the gravure printing plate.
Background Art
[0002] Conventionally, as described in Japanese Patent Application Laid-Open No. 2012-66559 (Patent Document 1), when manufacturing a laminated electronic component using a gravure printing plate, the gravure printing plate is immersed in a paste tank in which a conductive paste or a dielectric paste is stored, the paste is filled into recesses provided in the gravure printing plate, and the paste is transferred onto a sheet.
Prior Art Documents
Patent Documents
[0003]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0004] However, the printing pattern of the gravure printing plate described in Patent Document 1 has a rectangular shape with sharp corners. Therefore, when the paste separates from the gravure printing plate, the paste may extend in a thread-like manner from the corners and adhere to areas outside the printing range.
[0005] The present disclosure has been made in view of the above problems, and an object of the present disclosure is to provide a gravure printing plate capable of suppressing the protrusion of a thread-like paste outside the printing range and a method for manufacturing a laminated electronic component using the gravure printing plate.
Means for Solving the Problems
[0006] The gravure printing plate according to this disclosure is a cylindrical or columnar printing plate for printing paste onto a ceramic green sheet. The gravure printing plate has a circumferential surface on which one or more printing patterns are provided. Each of the one or more printing patterns has a plurality of recesses separated by a raised edge. The outer edge of the printing pattern is rectangular in shape, with a first corner having rounded corners.
[0007] In the gravure printing plate based on the above disclosure, the outer edge of the recess that defines the opening surface of the recess may have a rectangular shape with a second corner portion having rounded corners. The relationship R1 > R2 may be satisfied when the radius of curvature of the first corner portion is R1 and the radius of curvature of the second corner portion is R2.
[0008] In the gravure printing plate based on the above disclosure, the embankment portion may be provided with notches that connect adjacent recesses. The corners of the embankment portion facing the notches may be rounded.
[0009] In the gravure printing plate based on the above disclosure, the bottom surface of the recess may be a curved surface.
[0010] In the gravure printing plate based on the above disclosure, the depth of the recess may be greater than the depth of the notch.
[0011] In a gravure printing plate based on the above disclosure, the embankment portion may include an outer embankment portion located on the peripheral edge side of the printing pattern and an inner embankment portion located inside the outer embankment portion.
[0012] A method for manufacturing a multilayer electronic component based on the above disclosure comprises the steps of: transferring a dielectric paste or a conductive paste using the above-mentioned gravure printing plate to form a sheet; forming a laminate including the sheet; and firing the laminate. [Effects of the Invention]
[0013] According to this disclosure, it is possible to provide a gravure printing plate capable of suppressing the leakage of thread-like paste outside the printing area, and a method for manufacturing a stacked electronic component using the gravure printing plate. [Brief explanation of the drawing]
[0014] [Figure 1] This figure shows a gravure printing apparatus equipped with a gravure printing plate according to Embodiment 1. [Figure 2] This is a perspective view showing a gravure printing plate according to Embodiment 1. [Figure 3] This figure shows an enlarged view of the printing pattern of the gravure printing plate according to Embodiment 1. [Figure 4] This is a cross-sectional view along the line IV-IV shown in Figure 3. [Figure 5] This figure shows how paste is peeled off from the recessed areas in the gravure printing plate according to Embodiment 1. [Figure 6] This diagram shows the manufacturing flow for producing stacked electronic components using a gravure printing plate according to Embodiment 1. [Figure 7] This figure shows a cross-section of a recess in a gravure printing plate according to Embodiment 2. [Figure 8] This figure shows an enlarged view of the printing pattern of the gravure printing plate according to Embodiment 3. [Figure 9] This figure shows an enlarged view of the printing pattern of the gravure printing plate according to Embodiment 4. [Modes for carrying out the invention]
[0015] The embodiments of this disclosure will be described in detail below with reference to the drawings. In the embodiments described below, the same or common parts are denoted by the same reference numerals in the drawings, and their descriptions will not be repeated.
[0016] (Embodiment 1) FIG. 1 is a diagram showing a gravure printing apparatus provided with a gravure printing plate according to Embodiment 1. FIG. 2 is a perspective view showing the gravure printing plate according to Embodiment 1. The gravure printing apparatus 10 and the gravure printing plate 12 will be described with reference to FIGS. 1 and 2.
[0017] The gravure printing apparatus 10 includes a backup roll 11, a gravure printing plate 12, a blade 13, and a paste tank 15.
[0018] The backup roll 11 and the gravure printing plate 12 are arranged to face each other so that a nip portion is formed. The green sheet 30 passes between the backup roll 11 and the gravure printing plate 12 so that the green sheet 30 is sandwiched in the nip portion.
[0019] The backup roll 11 has a cylindrical shape or a tubular shape. The backup roll 11 is provided rotatable in the direction of arrow AR1 in FIG. 1.
[0020] As shown in FIG. 2, the gravure printing plate 12 has a cylindrical shape or a tubular shape. The diameter of the gravure printing plate 12 is, for example, about 10 mm to 400 mm. The width parallel to the axial direction CL of the gravure printing plate 12 is, for example, about 150 mm to 300 mm. A plurality of printing patterns 121 are provided on the gravure printing plate 12. Note that one or more printing patterns 121 may be provided.
[0021] As shown in FIG. 1 again, the gravure printing plate 12 is provided rotatable in the direction of AR2 in FIG. 1. The gravure printing plate 12 is provided rotatable in the opposite direction to the backup roll 11.
[0022] The conductive paste 14 is stored in the paste tank 15. A part of the gravure printing plate 12 is immersed in the conductive paste 14, and when gravure printing is performed, by rotating in the direction of AR2 in the figure, the conductive paste 14 is filled into a plurality of recesses 42 (see FIG. 3) described later.
[0023] The blade 13 is positioned downstream of the paste tank 15 and is in contact with the gravure printing plate 12 at a predetermined pressure. The blade 13 scrapes off excess conductive paste 14 that is adhering to the gravure printing plate 12.
[0024] Next, as the gravure printing plate 12 holding an appropriate amount of conductive paste 14 passes through the nip section, an electrode pattern 31 corresponding to the printing pattern 121 is printed on the green sheet 30.
[0025] Figure 3 is an enlarged view showing the printing pattern of the gravure printing plate according to Embodiment 1. Figure 4 is a cross-sectional view along the line IV-IV shown in Figure 3. More specifically, Figure 4 is a cross-section of the gravure printing plate 12 parallel to the axial direction CL and passing through the central portions C1 and C2 in the circumferential direction of each of the adjacent recesses 42 in a direction parallel to the axial direction CL. The detailed structure of the gravure printing plate 12 will be described with reference to Figures 3 and 4.
[0026] As shown in Figure 3, each of the multiple printed patterns 121 has a roughly rectangular shape. More specifically, the printed pattern 121 has a rectangular shape with rounded first corners 121 at its four corners. However, the printed pattern 121 is not limited to a roughly rectangular shape, and an appropriate shape can be adopted depending on the shape of the electrode pattern 31.
[0027] Each of the multiple printing patterns 121 has multiple recesses 42 separated by a ridge 41. The ridge 41 is arranged in a grid pattern.
[0028] The embankment section 41 includes a plurality of vertical embankment sections 45 and a plurality of horizontal embankment sections 46. Each of the plurality of vertical embankment sections 45 extends in the circumferential direction of the circumferential surface 12p. The plurality of vertical embankment sections 45 are arranged side by side with spacing between them in a direction parallel to the axial direction CL. Each of the plurality of horizontal embankment sections 46 extends in a direction parallel to the axial direction CL. The plurality of horizontal embankment sections 46 are arranged side by side with spacing between them in the circumferential direction.
[0029] The multiple recesses 42 are arranged in a matrix, for example, in a row direction parallel to the circumferential direction and in a column direction parallel to the axial direction. The outer edge of the recess 42 that defines the opening surface of the recess 42 has a rectangular shape with rounded second corners 42c at all four corners.
[0030] When the radius of curvature of the first corner 121C is R1 and the radius of curvature of the second corner 42c is R2, the relationship R1 > R2 holds true. The radius of curvature can be confirmed by peeling off a portion of the circumferential surface 12p of the gravure printing plate 12, cutting the peeled portion, and observing it with an optical microscope.
[0031] As shown in Figures 3 and 4, the embankment portion 41 has a top portion 411 and a wall portion 43. The top portion 411 is substantially flat. The top portion 411 is substantially parallel to the opening surface of the recess 42. The wall portion 43 is connected to the bottom portion 421 of the recess 42 and defines the side surface of the recess 42. The wall portion 43 is connected to the periphery of the bottom portion 421 and has an annular shape. When the recess 42 is viewed along the depth direction of the recess 42, the periphery of the bottom portion 421 is located inward from the outer edge of the opening surface of the recess 42. The wall portion 43 has a curved shape that curves toward the periphery of the bottom portion 421 as it progresses in the depth direction of the recess 42.
[0032] The wall portion 43 has a first wall portion 431 and a second wall portion 432 facing each other in a direction parallel to the axial direction CL, and a third wall portion 433 and a fourth wall portion 434 facing each other in the circumferential direction. Each of the first wall portion 431 and the second wall portion 432 is composed of a curved surface that curves toward the periphery of the bottom portion 421 as it progresses in the depth direction of the recess 42, as described above. Each of the third wall portion 433 and the fourth wall portion 434 is similarly composed of a curved surface that curves toward the periphery of the bottom portion 421 as it progresses in the depth direction of the recess 42.
[0033] The bottom surface 421 of the recess 42 is flat. In a cross section parallel to the radial direction and the axial direction CL of the gravure printing plate 12, passing through the central portions C1 and C2 described above, the bottom surface 421 is located on the extension of the tangent TL1 of the first wall portion 431 at the connection position T1 between the first wall portion 431 and the bottom surface 421. Also, in the above cross section, the bottom surface 421 is located on the extension of the tangent TL2 of the second wall portion 432 at the connection position T2 between the second wall portion 432 and the bottom surface 421.
[0034] In the cross-section of the gravure printing plate 12, which passes through the central portion in a direction parallel to the axial direction CL and perpendicular to the axial direction CL, each of the circumferentially adjacent recesses 42 has, the bottom surface 421 is located on the extension of the tangent to the third wall surface 433 at the connection point between the third wall surface 433 and the bottom surface 421. Also, in the above cross-section, the bottom surface 421 is located on the extension of the tangent to the fourth wall surface 434 at the connection point between the fourth wall surface 434 and the bottom surface 421.
[0035] The shape of the recess 42 described above can be achieved by adjusting the dwell time of the etching solution when etching the peripheral surface 12p of the gravure printing plate 12. For example, one can use a method such as moving the gravure plate diagonally so that the etching solution stays in a predetermined position on the printing pattern 121 for a longer period of time.
[0036] Figure 5 shows how paste is peeled off from the recessed areas in the gravure printing plate according to Embodiment 1.
[0037] As shown in Figure 5, the wall portion 43 is composed of a curved surface, and the bottom portion 421 is located on the extension of the tangent at the connection point between each of the first wall portion 431 and the fourth wall portion 434. Therefore, when transferring the conductive paste 14 in the recess 42, as shown by the arrow in the figure, a smooth and continuous peeling force can be applied to the conductive paste 14 from the bottom portion 421 to the top portion 411. This allows the conductive paste 14 to be smoothly transferred to the green sheet 30. Specifically, more than 60% of the conductive paste 14 filled in the recess 42 can be transferred to the green sheet 30, reducing the amount of conductive paste 14 remaining in the recess 42.
[0038] The remaining amount of paste can be calculated, for example, as follows: First, the shapes of the 10 recesses 42 are measured in advance using a laser displacement meter or the like. Next, paste 14 is filled into the printed pattern 121, and each of the 10 recesses 42 after transfer is measured using a laser displacement meter or the like. By doing so, the remaining amount of paste in each recess 42 is measured, and the remaining amount of paste 14 is calculated by calculating the average value of the 10 values. Furthermore, the amount of paste 14 that has been transferred can also be calculated based on the calculated remaining amount of paste 14.
[0039] As described above, in the gravure printing plate 12 according to Embodiment 1, the first corners 121c located at the four corners of the outer edge of the printing pattern 121 are rounded, so when the gravure printing plate 12 is pulled away from the green sheet 30, the paste can be separated from the gravure printing plate 12 along the outer edge of the printing pattern 121. This prevents the thread-like paste from extending outward from the first corners 121c.
[0040] (Verification experiment) When 100 shots were printed using the gravure printing plate 12 according to Embodiment 1, and the presence or absence of paste adhesion to areas outside the printing range was checked, no paste adhesion to areas outside the printing range was confirmed. On the other hand, as a comparative example, when 100 shots were printed using a gravure printing plate having angular corners at the four corners of the outer edge of the printing pattern 121, paste adhesion to areas outside the printing range was confirmed in the 13th shot.
[0041] (Manufacturing method for multilayer electronic components) Figure 6 is a diagram showing the manufacturing flow for manufacturing a multilayer electronic component using a gravure printing plate according to Embodiment 1. The manufacturing method for a multilayer electronic component according to Embodiment 1 will be described with reference to Figure 6.
[0042] As shown in Figure 6, when manufacturing a multilayer ceramic capacitor as a multilayer electronic component, first, in process (S1), a green sheet 30 and a conductive paste for the internal electrodes are prepared. The green sheet 30 is formed from a dielectric paste made by kneading ceramic powder, such as barium titanate, a binder, a dispersant, and a plasticizer. The conductive paste 14 is made by kneading conductive powder, a solvent, a binder, and ceramic powder. Known materials can be used for the green sheet 30 and the conductive paste 14.
[0043] Next, in step (S2), as shown in Figure 1, the conductive paste 14 for the internal electrodes is transferred onto the green sheet 30 in a predetermined pattern using the gravure printing plate 12. This forms a dielectric sheet 25 on which the electrode pattern 31 is formed. The gravure printing plate 12 may also be used when transferring the dielectric paste.
[0044] Next, in step (S3), multiple dielectric sheets are stacked to produce a laminated sheet. Specifically, a predetermined number of outer layer dielectric sheets without electrode patterns are stacked, dielectric sheets 25 with electrode patterns 31 printed on them are sequentially stacked on top of them, and a predetermined number of the outer layer dielectric sheets are stacked on top of them.
[0045] Next, in step (S4), a laminated block is manufactured. Specifically, the laminated sheets are pressed in the lamination direction using a press device such as a hydrostatic press.
[0046] Next, in step (S5), the laminated chips are manufactured. Specifically, the laminated block is cut to a predetermined size using a cutting blade to cut out the laminated chips. At this time, the corners and edges of the laminated chips may be rounded by barrel polishing or the like.
[0047] Next, in step (S6), the stacked chip is fired. The firing temperature depends on the dielectric and electrode pattern materials, but is typically around 900°C to 1300°C.
[0048] Next, in step (S7), external electrodes are formed. For example, conductive paste for external electrodes is applied to both ends of the multilayer chip and baked to form a baked layer on both ends. The baking temperature at this time is, for example, 700°C to 900°C. Subsequently, a plating layer is provided on the surface of the baked layer as needed. Through the above steps, a multilayer electronic component can be manufactured.
[0049] (Embodiment 2) Figure 7 is a diagram showing a cross-section of the recess of the gravure printing plate according to Embodiment 2. The gravure printing plate 12A according to Embodiment 2 will be described with reference to Figure 7.
[0050] As shown in Figure 7, the gravure printing plate 12A according to Embodiment 2 differs from the gravure printing plate 12 according to Embodiment 1 in the shape of the recess 42 (more specifically, the bottom surface portion 421). The other configurations are substantially the same.
[0051] In Embodiment 2, in addition to the wall portion 43, the bottom portion 421 is also made of a curved surface. The bottom portion 421 has a shape that curves toward the center of the recess 42 as it goes in the depth direction. The radius of curvature of the bottom portion 421 may be larger than the radius of curvature of the wall portion 43. The radius of curvature can be confirmed by peeling off a part of the peripheral surface 12p of the gravure printing plate 12, cutting the peeled-off part, and observing it with an optical microscope.
[0052] Even in this configuration, the gravure printing plate 12A according to Embodiment 2 provides substantially the same effects as that of Embodiment 1. Because the bottom surface 421 is made of a curved surface, the conductive paste 14 is more easily separated from the gravure printing plate 12A during transfer.
[0053] Furthermore, by making the radius of curvature of the bottom portion 421 larger than that of the wall portion 43, the peeling force can be applied to the conductive paste 14 more smoothly. As a result, the conductive paste 14 can be transferred to the green sheet 30 more smoothly.
[0054] (Embodiment 3) Figure 8 is a magnified view of the printing pattern of the gravure printing plate according to Embodiment 3. The gravure printing plate according to Embodiment 3 will be described with reference to Figure 8.
[0055] As shown in Figure 8, the gravure printing plate according to Embodiment 3 differs from the gravure printing plate 12 according to Embodiment 1 in its printing pattern 121. The other configurations are substantially the same.
[0056] In Embodiment 3, the embankment portion 41 is provided with a plurality of notches 47, 48. The notches 47, 48 are provided so that adjacent recesses 42 are in communication with each other. The depth of the recesses 42 is greater than the depth of the notches 47, 48. The corners 46c, 47c of the embankment portion facing the notches 47, 48 are rounded.
[0057] Multiple notches 47 are provided in each vertical embankment section 45. However, each vertical embankment section 45 may have only one notch 47 instead of multiple notches.
[0058] The notches 47 are provided in the portion of the vertical embankment 45 located between adjacent recesses 42 in a direction parallel to the axial direction CL. Each notch 47, provided in the portion located between each of the multiple recesses 42 aligned in the axial direction CL, may be arranged in line with the axial direction CL, or it may be arranged offset in the circumferential direction.
[0059] Multiple notches 48 are provided in each horizontal embankment section 46. Alternatively, each horizontal embankment section 46 may have only one notch 47 instead of multiple notches.
[0060] The notches 48 are provided in the portion of the lateral embankment 46 located between adjacent recesses 42 in a direction parallel to the axial direction CL. Each notch 48, provided in the portion located between each of the multiple recesses 42 arranged in the circumferential direction, may be arranged in a circumferential direction or may be offset in the direction parallel to the axial direction CL.
[0061] Even when configured as described above, the gravure printing plate according to Embodiment 3 provides substantially the same effects as that of Embodiment 1. The provision of multiple notches 47, 48 improves the fluidity of the conductive paste 14.
[0062] Since the transfer of the conductive paste 14 is performed starting from the ridge, the number of transfer starting points can be increased by providing notches 47 and 48. This ensures that the transfer is performed evenly within the printed pattern 121, improving printability.
[0063] Furthermore, by rounding the corners 46c and 47c of the embankment portion facing the notches 47 and 48, stringing can be suppressed at these corners 46c and 47c when separating the transferred gravure printing plate 12 from the sheet.
[0064] (Embodiment 4) Figure 9 is a magnified view of the printing pattern of the gravure printing plate according to Embodiment 4. The gravure printing plate according to Embodiment 4 will be described with reference to Figure 9.
[0065] As shown in Figure 9, the gravure printing plate according to Embodiment 4 differs from the gravure printing plate according to Embodiment 3 in its printing pattern 121. The other configurations are substantially the same. In Embodiment 4, the multiple notches 47 and 48 may be omitted.
[0066] In Embodiment 4, the embankment portion 41 includes an outer embankment portion located on the peripheral edge side of the printed pattern 121 and an inner embankment portion located inside the outer embankment portion, and the thickness (width) of the outer embankment portion is thinner than the thickness (width) of the inner embankment portion.
[0067] Specifically, for example, the outer embankment is the portion of the embankment 41 that is located outside the virtual line VL in the figure. The outer embankment is composed of, for example, both ends 451 of each vertical embankment 45A in the circumferential direction and both ends 461 of each horizontal embankment 46A in the direction parallel to the axial direction CL.
[0068] The width (W1) of both ends 451 of the vertical embankment section 45A is smaller than the width (W3) of the portion 452 located between the ends 451 of the vertical embankment section 45A. Similarly, the width (W2) of both ends 461 of the horizontal embankment section 46A is smaller than the width (W4) of the portion 462 located between the ends 461 of the horizontal embankment section 46A.
[0069] Even in this configuration, the gravure printing plate according to Embodiment 4 provides substantially the same effects as the gravure printing plate according to Embodiment 3. Furthermore, because the thickness of the outer ridge portion is thinner than the thickness of the inner ridge portion, transfer is promoted at the edges of the electrode pattern 31 during transfer, and blurring of the print can be suppressed.
[0070] (Other variations) Furthermore, grooves with a width of 0.01 μm or more and 1 μm or less may be formed on the top 411 of the embankment portion 41 and / or on the circumferential surface 12p of the gravure printing plate. The grooves may extend in a direction parallel to the axial direction CL or in the circumferential direction. The presence of grooves makes it easier to scrape off excess conductive paste 14 with the blade 13.
[0071] Furthermore, the size of the recesses 42 located on the inside of the printed pattern 121 may be smaller than the size of the recesses 42 located on the outside of the printed pattern 121. By making the inner recesses 42 smaller, more ridges 41 can be formed. Since the conductive paste 14 is transferred starting from the ridges 41, the transfer efficiency of the conductive paste 14 can be improved by arranging more ridges 41.
[0072] The embodiments disclosed herein are illustrative and not restrictive in all respects. The scope of the present invention is defined by the claims, and all modifications are made in the sense and scope equivalent to the claims. [Explanation of Symbols]
[0073] 10 Gravure printing apparatus, 11 Backup roll, 12,12A Gravure printing plate, 12p Peripheral surface, 13 Blade, 14 Conductive paste, 15 Paste tank, 25 Dielectric sheet, 30 Green sheet, 31 Electrode pattern, 41 Embankment, 42 Recess, 42c Second corner, 43 Wall, 45,45A Vertical embankment, 46,46A Horizontal embankment, 47,48 Notch, 47c,48C Corner, 121 Printing pattern, 121c First corner, 411 Top, 421 Bottom, 431 First wall, 432 Second wall, 433 Third wall, 434 Fourth wall, 451,461 Both ends, C1,C2 Center, CL Axial direction, T1,T2 Connection position, TL1,TL2 Tangent line, VL virtual line.
Claims
1. A cylindrical or columnar gravure printing plate for printing paste onto a ceramic green sheet, It has a peripheral surface on which one or more printed patterns are provided, Each of the one or more printing patterns has a plurality of recesses separated by a raised edge. A gravure printing plate in which the outer edge of the aforementioned printing pattern is rectangular in shape, with the four corners having rounded first corners.
2. The outer edge of the recess that defines the opening surface of the recess has a rectangular shape with rounded second corners at all four corners. The gravure printing plate according to claim 1, wherein the relationship R1 > R2 is satisfied when the radius of curvature of the first corner is R1 and the radius of curvature of the second corner is R2.
3. The aforementioned embankment section is provided with notches that connect adjacent recesses, The gravure printing plate according to claim 1, wherein the corner of the embankment portion facing the notch is rounded.
4. The gravure printing plate according to claim 3, wherein the bottom surface of the recess is formed of a curved surface.
5. The gravure printing plate according to claim 3, wherein the depth of the recess is greater than the depth of the notch.
6. The aforementioned embankment portion includes an outer embankment portion located on the peripheral edge side of the printed pattern and an inner embankment portion located inside the outer embankment portion. The gravure printing plate according to claim 1, wherein the thickness of the outer embankment portion is thinner than the thickness of the inner embankment portion.
7. A step of forming a sheet by transferring a dielectric paste or conductive paste using a gravure printing plate according to any one of claims 1 to 6, A step of forming a laminate including the aforementioned sheet, A method for manufacturing a laminated electronic component, comprising the step of firing the laminated body.