3D printing-based MLCC green body and manufacturing method therefor

Abstract

A 3D printing-based MLCC green body and a manufacturing method therefor. The 3D printing-based MLCC green body at least comprises five printing unit layers, which are successively a first structural layer (5), a second structural layer (4), a third structural layer (3), a fourth structural layer (2) and an upper sealing layer (1) from bottom to top; the fourth structural layer (2) at least comprises a fourth-layer inner electrode (203), a fourth-layer ceramic filling part (202) and two fourth-layer outer electrodes (201); the second structural layer (4) at least comprises a second-layer inner electrode (403), a second-layer ceramic filling part (402) and two second-layer outer electrodes (401), the fourth-layer inner electrode (203) being offset with respect to the second-layer inner electrode (403). For each layer of the structure, segmentation planning is further performed to form printing sub-areas and a printing sequence is designed, so as to fit the operating mode of 3D printing technology, thus achieving production and manufacturing of MLCC green bodies by using 3D printing technology, efficiently simplifying the production process for MLCC green bodies, and achieving higher production efficiency.

Description

A MLCC blank based on 3D printing and its manufacturing method Technical Field

[0001] The present invention belongs to the technical field of MLCC preparation, and specifically relates to an MLCC blank based on 3D printing and a manufacturing method thereof. Background Art

[0002] The traditional MLCC blank manufacturing process is the tape casting-lamination process, that is, the ceramic slurry is pre-made into ceramic green sheets through the tape casting technology, and then the internal electrode pattern is printed on the ceramic green sheets. Finally, the multiple layers of green sheets are pressed together through staggered lamination to obtain the MLCC green body. Finally, the pressed green body needs to be cut and divided into multiple individual MLCC green bodies.

[0003] The tape casting-lamination process for manufacturing MLCC blanks requires multiple precisely controlled steps and a variety of precision equipment. Problems may occur in each step and lead to failure. 3D printing has the advantages of fast molding speed, high degree of automation, high dimensional accuracy, and excellent surface quality in the preparation of ceramic electronic components.

[0004] The present invention aims to rationally plan and divide the structure of the MLCC blank and design a single-layer printing structure to fit the operating mode of 3D printing technology. Summary of the Invention

[0005] In response to the problems in the related art, the present invention proposes a MLCC blank based on 3D printing and a manufacturing method thereof to overcome the above-mentioned technical problems existing in the existing related art.

[0006] The technical solution of the present invention is achieved as follows:

[0007] A 3D-printed MLCC blank comprises at least five printing unit layers, which are, from bottom to top, the first structural layer, the second structural layer, the third structural layer, the fourth structural layer and the upper sealing layer.

[0008] The first structural layer at least includes a first ceramic dielectric portion and first external electrodes located on the left and right sides of the first ceramic dielectric portion;

[0009] The second structural layer comprises at least a second inner electrode, a second ceramic filling portion, and two second outer electrodes, the two second outer electrodes being located on the left and right sides of the second inner electrode, the right side of the second inner electrode being in contact with the second outer electrode located on the right side, and the ceramic filling portion being filled between the two second outer electrodes and surrounding the second inner electrode;

[0010] The third structural layer at least includes a third ceramic dielectric portion and third external electrodes located on the left and right sides of the third ceramic dielectric portion;

[0011] The fourth structural layer comprises at least a fourth inner electrode, a fourth ceramic filling portion, and two fourth outer electrodes, wherein the two fourth outer electrodes are located on the left and right sides of the fourth inner electrode, the left side of the fourth inner electrode is in contact with the fourth outer electrode located on the left side, and the ceramic filling portion is filled between the two fourth outer electrodes and surrounds the fourth inner electrode;

[0012] The upper sealing layer at least includes an upper sealing layer ceramic dielectric portion and upper sealing layer external electrodes located on the left and right sides of the upper sealing layer ceramic dielectric portion.

[0013] Preferably, the first structural layer, the second structural layer, the third structural layer and the fourth structural layer arranged in sequence from bottom to top are set as a functional group layer;

[0014] A plurality of functional group layers are arranged below the upper sealing layer.

[0015] Preferably, 50-250 groups of the functional group layers are provided below the upper sealing layer.

[0016] Preferably, the shape edges of the first layer external electrode, the second layer external electrode, the third layer external electrode, the fourth layer external electrode and the upper sealing layer external electrode located on the same side are aligned.

[0017] Preferably, the front and rear sides of the first ceramic dielectric portion, the second ceramic filling portion, the third ceramic dielectric portion, the fourth ceramic filling portion and the upper sealing ceramic dielectric portion are aligned.

[0018] The present invention also discloses a method for manufacturing an MLCC blank based on 3D printing, which uses a 3D printer to print the above-mentioned first structural layer, second structural layer, third structural layer, fourth structural layer and upper sealing layer in sequence from bottom to top.

[0019] Preferably, the functional group layers are repeatedly printed from bottom to top until the target number of groups is reached, and finally the upper sealing layer is printed.

[0020] Preferably, when printing the first structural layer, the first layer of external electrodes is printed first, and then the first layer of ceramic dielectric portion is printed;

[0021] When printing the third structural layer, first print the third layer of external electrodes, and then print the third layer of ceramic dielectric portion;

[0022] When printing the upper sealing layer, the outer electrode of the upper sealing layer is printed first, and then the ceramic dielectric portion of the upper sealing layer is printed.

[0023] Preferably, when printing the second structural layer, the two second-layer outer electrodes are printed first, then the second-layer inner electrode is printed, and finally the second-layer ceramic filling portion is printed.

[0024] Preferably, when printing the fourth structural layer, the two fourth-layer outer electrodes are printed first, then the fourth-layer inner electrode is printed, and finally the fourth-layer ceramic filling portion is printed.

[0025] Since ceramic material is the filling medium and is generally printed using a scraping method, the ceramic medium part and the ceramic filling part are printed last to ensure that the space in the unit layer structure except the electrode structure is fully filled.

[0026] First, the present invention rationally plans and divides the structure of the MLCC blank to design the printing unit layer structure. With the top and bottom surfaces of the internal electrode as the dividing interface, it is divided into the first structure layer, the second structure layer, the third structure layer, the fourth structure layer and the upper sealing layer from bottom to top. Each layer structure is further divided and planned to form printing sub-areas and design the printing sequence to fit the operation mode of 3D printing technology, thereby realizing the production and preparation of high-quality MLCC blanks using 3D printing technology.

[0027] Secondly, the conventional casting-lamination process is designed with a "cutting" step after the stack is evenly pressed to cut into the target specification of the blank. The present invention uses 3D printing technology to make MLCC blanks without the need to design plate making, cutting and other steps. After the printing plate surface is reasonably arranged and designed, it can print multiple MLCC blanks of a single specification or multiple MLCC blanks of different specifications (refer to Figure 4);

[0028] Finally, the MLCC blanks made using 3D printing technology are less prone to delamination and cracking during the manufacturing process. At the same time, the conventional casting-lamination process requires end-sealing and end-burning operations to form an external electrode structure after cutting to form a single blank. The present invention also designs the related structures of the external electrode into the printed unit layer structure, and the external electrode structure can be printed together. Therefore, the method of manufacturing MLCC blanks of the present invention does not require the end-sealing and end-burning operations in the traditional process after the blank is sintered, which effectively simplifies the production process and has higher production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] FIG1 is a schematic diagram of the structure decomposition of the present invention (taking five layers as an example);

[0030] Figure 2 is a cross-sectional schematic diagram of the present invention (taking five layers as an example);

[0031] FIG3 is a schematic flow diagram of the manufacturing method of the present invention;

[0032] FIG4 is a schematic diagram showing the arrangement of a printing table for printing a plurality of MLCC blanks of different specifications using the present invention.

[0033] Reference numerals:

[0034] MLCC, MLCC blank;

[0035] A. Functional group layer;

[0036] 1. Upper sealing layer; 101. Upper sealing layer outer electrode; 102. Upper sealing layer ceramic dielectric part;

[0037] 2. Fourth structural layer; 201. Fourth outer electrode; 202. Fourth ceramic filling portion; 203. Fourth inner electrode;

[0038] 3. Third structural layer; 301. Third external electrode; 302. Third ceramic dielectric portion;

[0039] 4. Second structural layer; 401. Second outer electrode; 402. Second ceramic filling portion; 403. Second inner electrode;

[0040] 5. First structural layer; 501. First external electrode; 502. First ceramic dielectric portion. DETAILED DESCRIPTION

[0041] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0042] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like to indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0043] Referring to Figures 1 to 4 , a method for manufacturing an MLCC blank based on 3D printing includes the following steps:

[0044] (1) Design of the printing unit layer structure of the MLCC blank: The MLCC blank based on 3D printing includes five printing unit layers, which are the first structure layer 5, the second structure layer 4, the third structure layer 3, the fourth structure layer 2 and the upper sealing layer 1 from bottom to top.

[0045] The first structural layer 5 includes a first ceramic dielectric portion 502 and first external electrodes 501 located on the left and right sides of the first ceramic dielectric portion 502;

[0046] The second structural layer 4 includes a second inner electrode 403, a second ceramic filling portion 402, and two second outer electrodes 401. The two second outer electrodes 401 are located on the left and right sides of the second inner electrode 403. The right side of the second inner electrode 403 is connected to the second outer electrode 401 located on the right side. The ceramic filling portion is filled between the two second outer electrodes 401 and surrounds the second inner electrode 403.

[0047] The third structural layer 3 includes a third ceramic dielectric portion 302 and third external electrodes 301 located on the left and right sides of the third ceramic dielectric portion 302;

[0048] The fourth structural layer 2 includes a fourth inner electrode 203, a fourth ceramic filling portion 202, and two fourth outer electrodes 201. The two fourth outer electrodes 201 are located on the left and right sides of the fourth inner electrode 203. The left side of the fourth inner electrode 203 is connected to the fourth outer electrode 201 located on the left side. The ceramic filling portion is filled between the two fourth outer electrodes 201 and surrounds the fourth inner electrode 203.

[0049] The upper sealing layer 1 includes an upper sealing layer ceramic dielectric portion 102 and upper sealing layer external electrodes 101 located on the left and right sides of the upper sealing layer ceramic dielectric portion 102 .

[0050] (2) Printing the first structural layer 5 using a 3D printer, first printing the first outer electrodes 501 on the left and right sides, and then printing the first ceramic dielectric layer, which serves as the bottom sealing layer;

[0051] (3) Printing the second structural layer 4 on the top surface of the first structural layer 5 printed in step (2), first printing the two second-layer outer electrodes 401 on the left and right sides, then printing the second-layer inner electrode 403, and finally printing the second-layer ceramic filling portion 402;

[0052] (4) Printing the third structural layer 3 on the top surface of the second structural layer 4 printed in step (3), first printing the third layer external electrodes 301 on the left and right sides, and then printing the third layer ceramic dielectric portion 302;

[0053] (5) When printing the fourth structural layer 2 on the top surface of the third structural layer 3 printed in step (4), first print the two fourth-layer external electrodes 201, then print the fourth-layer internal electrode 203, and finally print the fourth-layer ceramic filling portion 202.

[0054] Repeat the above steps (2) to (5) until the preset number of functional group layers A (100 groups) are completed, and then the capping is completed by printing the upper sealing layer 1. When printing the upper sealing layer 1, the upper sealing layer external electrode 101 is printed first, and then the upper sealing layer ceramic dielectric part 102 is printed, so that the MLCC blank is manufactured.

[0055] The shape edges of the first layer external electrode 501, the second layer external electrode 401, the third layer external electrode 301, the fourth layer external electrode 201 and the upper sealing layer external electrode 101 located on the same side of the MLCC body are aligned; the front and rear sides of the first layer ceramic dielectric part 502, the second layer ceramic filling part 402, the third layer ceramic dielectric part 302, the fourth layer ceramic filling part 202 and the upper sealing layer ceramic dielectric part 102 are aligned.

[0056] First, this embodiment rationally plans and divides the structure of the MLCC body to design the printing unit layer structure. The top and bottom surfaces of the internal electrode are used as the dividing interface, and the structure is divided into the first structure layer 5, the second structure layer 4, the third structure layer 3, the fourth structure layer 2 and the upper sealing layer 1 from bottom to top. Each layer structure is further divided and planned to form a printing sub-area and design a printing sequence to fit the operation mode of 3D printing technology, so as to realize the production and preparation of high-quality MLCC bodies using 3D printing technology.

[0057] Secondly, the conventional casting-lamination process is designed with a "cutting" step after the stack is evenly pressed to cut into the target specification of the blank. This embodiment uses 3D printing technology to make MLCC blanks without the need to design plate making, cutting and other steps. After the printing plate surface is reasonably arranged and designed, it can print multiple MLCC blanks of a single specification or multiple MLCC blanks of different specifications (refer to Figure 4);

[0058] Finally, the MLCC blanks made using 3D printing technology are less prone to delamination and cracking during the manufacturing process. At the same time, the conventional casting-lamination process requires end sealing and end burning operations to form an external electrode structure after cutting to form a single blank. In this embodiment, the relevant structures of the external electrode are also designed into the printed unit layer structure, and the external electrode structure can be printed together. Therefore, the method of manufacturing MLCC blanks in this embodiment does not require the end sealing and end burning operations in the traditional process after the blank is sintered, which effectively simplifies the production process and improves production efficiency.

[0059] Based on the disclosure and teachings of the above description, those skilled in the art may also make changes and modifications to the above embodiments. Therefore, the present invention is not limited to the specific embodiments disclosed and described above, and modifications and variations of the present invention should also fall within the scope of protection of the claims of the present invention. In addition, although certain specific terms are used in this description, these terms are only for convenience of description and do not constitute any limitation to the present invention.

Claims

1. A MLCC blank based on 3D printing, characterized in that: It includes at least five printing unit layers, which are the first structural layer, the second structural layer, the third structural layer, the fourth structural layer and the upper sealing layer from bottom to top. The first structural layer at least includes a first ceramic dielectric portion and a first external electrode located on the left and right sides of the first ceramic dielectric portion; The second structural layer at least includes a second inner electrode, a second ceramic filling portion and two second outer electrodes, the two second outer electrodes are located on the left and right sides of the second inner electrode, the right side of the second inner electrode is connected to the second outer electrode located on the right side, and the ceramic filling portion is filled between the two second outer electrodes and surrounds the second inner electrode; The third structural layer at least includes a third ceramic dielectric portion and a third external electrode located on the left and right sides of the third ceramic dielectric portion; The fourth structural layer at least includes a fourth inner electrode, a fourth ceramic filling portion and two fourth outer electrodes, the two fourth outer electrodes are located on the left and right sides of the fourth inner electrode, the left side of the fourth inner electrode is connected to the fourth outer electrode located on the left side, and the ceramic filling portion is filled between the two fourth outer electrodes and surrounds the fourth inner electrode; The upper sealing layer at least includes an upper sealing layer ceramic dielectric portion and upper sealing layer external electrodes located on the left and right sides of the upper sealing layer ceramic dielectric portion.

2. The MLCC blank according to claim 1, characterized in that: The first structural layer, the second structural layer, the third structural layer and the fourth structural layer arranged in sequence from bottom to top are set as a functional group layer; A plurality of functional group layers are arranged below the upper sealing layer.

3. The MLCC blank according to claim 2, characterized in that: 50-250 groups of the functional group layers are arranged below the upper sealing layer.

4. The MLCC blank according to any one of claims 1 to 3, characterized in that: The shape edges of the first layer external electrode, the second layer external electrode, the third layer external electrode, the fourth layer external electrode and the upper sealing layer external electrode located on the same side are aligned.

5. The MLCC blank according to any one of claims 1 to 3, characterized in that: The front and rear sides of the first ceramic dielectric part, the second ceramic filling part, the third ceramic dielectric part, the fourth ceramic filling part and the upper sealing ceramic dielectric part are aligned.

6. A method for manufacturing an MLCC blank based on 3D printing, characterized in that: The first structural layer, the second structural layer, the third structural layer, the fourth structural layer and the upper sealing layer according to any one of claims 1 to 5 are printed in sequence from bottom to top using a 3D printer.

7. The method for manufacturing an MLCC blank according to claim 6, characterized in that: The functional group layers are repeatedly printed from bottom to top until the target number of groups is reached, and finally the upper cover layer is printed.

8. The method for manufacturing an MLCC blank according to claim 6, characterized in that: When printing the first structural layer, the first layer of external electrodes is printed first, and then the first layer of ceramic dielectric portion is printed; When printing the third structural layer, first print the third layer of external electrodes, and then print the third layer of ceramic dielectric part; When printing the upper sealing layer, the outer electrode of the upper sealing layer is printed first, and then the ceramic dielectric part of the upper sealing layer is printed.

9. The method for manufacturing an MLCC blank according to claim 6, characterized in that: When printing the second structural layer, first print the two second-layer outer electrodes, then print the second-layer inner electrodes, and finally print the second-layer ceramic filling part.

10. The method for manufacturing an MLCC blank according to claim 6, characterized in that: When printing the fourth structural layer, first print the two fourth-layer outer electrodes, then print the fourth-layer inner electrode, and finally print the fourth-layer ceramic filling portion.

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