Multilayer Ceramic Component Binder Gradient for Bubble Prevention
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Solution Overview
Problem
The existing method for manufacturing multilayer ceramic electronic components often results in bubble trapping due to poor adhesion between ceramic green sheets and supporting materials, leading to defects like short-circuiting and deformation.
Innovation Solution
The method involves forming ceramic green sheets with varying binder concentrations across their thickness, specifically increasing the binder amount at the open surface opposite to the carrier film side, and using sterically hindered dispersing agents to enhance adhesion, preventing bubble trapping and related defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a good quality paper with rough surface is placed on lamination support table for preventing displacement between layers, then displacement prevention is improved, but adhesion between paper and ceramic green sheet becomes insufficient causing bubble trapping
Solution Approach 1:
The patent applies local quality by creating a gradient binder concentration distribution within the ceramic green sheet itself, with higher binder concentration at the surface contacting the supporting member. This local modification of material properties at the adhesion interface improves bonding strength without affecting the overall sheet structure, thereby resolving the contradiction between displacement prevention and adhesion quality.
Solution Approach 2:
The patent changes the binder concentration parameter within the ceramic green sheet, specifically increasing it at the surface layer compared to the internal layers. This parameter modification enhances the adhesion between the green sheet and supporting member, preventing bubble trapping while maintaining the sheet's structural integrity and displacement resistance.
2Ease of manufacture
If carrier film is peeled off after lamination to form first-layer ceramic green sheet, then sheet formation is achieved, but poor adhesion causes peeling and bubble trapping between sheet and supporting member
Solution Approach 1:
The patent modifies the local quality of the ceramic green sheet by concentrating binder material at the surface layer that contacts the supporting member. This localized enhancement ensures strong adhesion during the peeling process and final lamination, preventing defects while maintaining ease of manufacturing through the carrier film method.
Solution Approach 2:
The patent creates a composite structure within the ceramic green sheet by combining ceramic particles with a binder resin, where the binder concentration varies through the thickness. This composite approach with graded composition provides both the mechanical integrity needed for carrier film support and the enhanced surface adhesion required for defect-free lamination.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively prevents bubble trapping and associated defects, ensuring strong adhesion between layers and reducing the occurrence of short-circuiting and solder explosion, while maintaining a particle concentration ratio of 0.45 to 0.90 times within the laminate.
Implementation Method 1
a binder resin, and a dispersing agent... the binder resin and the ceramic particles are not easily mixed with each other, and hence the binder resin adheres the ceramic particles and the internal electrode paste to each other
Implementation Method 2
when a sterically hindered dispersing agent is used, the dispersing agent is dispersed as if to form a network among the ceramic particles, and hence free movement of the binder resin is suppressed, and hence the binder resin and the ceramic particles are not easily mixed with each other
Implementation Method 3
forming first ceramic green sheets supported by carrier films; pressure-bonding one of the first ceramic green sheets to a supporting member and then peeling off its carrier film
Implementation Method 4
pressure-bonding one of the first ceramic green sheets to a supporting member and then peeling off its carrier film to form a first-layer ceramic green sheet; sequentially pressure-bonding the other first ceramic green sheets or the second ceramic green sheets to the first-layer ceramic green sheet
Implementation Method 5
firing the laminate to form a sintered body
Implementation Method 6
forming external electrodes on surfaces of the sintered body
Data Source
AI summary
A method for manufacturing a multilayer ceramic electronic component can prevent the occurrence of bubble trapping. In the method, when an external layer ceramic green sheet is pressure-bonded, for example, to a sheet made of a good quality paper having a rough surface, which is placed on a supporting member, followed by peeling off its carrier film, a first-layer ceramic green sheet is formed. The first-layer external layer ceramic green sheet uses a sterically hindered dispersing agent, such as an aryl ether polymer, as a dispersing agent. Since it is light in weight, the binder segregates at the upper side, and hence a C concentration changes in the thickness direction. More particularly, compared to a C concentration at a surface at a carrier film side supported by the carrier film, a C concentration at an open surface opposite to the surface at the carrier film side is about 1.5 to about 4.0 times.