Gravure Printing Position Correction for Ceramic Components
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Solution Overview
Problem
In the manufacturing of ceramic electronic components, such as multilayer capacitors, existing gravure-printing methods face issues with displacement along the width of the ceramic green sheet, leading to inaccurate positioning and thickness variations of step-reducing dielectric patterns, which can result in structural defects like delamination and hinder high-definition multicolor printing.
Innovation Solution
A method that involves preparing a composite sheet with a supporting film and ceramic green sheet, using first and second gravure-printing steps to apply conductive and step-reducing pastes, with precise positioning correction by comparing the position of print marks formed in the first gravure-printing step to their desired positions, and adjusting the ceramic green sheet's movement accordingly to ensure high accuracy in the second printing step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If gravure printing is used to apply paste on ceramic green sheet, then productivity is improved, but manufacturing precision deteriorates due to displacement along width direction
Solution Approach 1:
The patent implements feedback control by detecting the actual position of the ceramic green sheet during conveyance and using this information to correct the positioning of the gravure roll. A position detection device monitors the sheet location, and the system adjusts the gravure roll position based on detected deviations, ensuring accurate paste application despite sheet displacement during high-speed production.
Solution Approach 2:
The patent introduces dynamic adjustment capabilities to the gravure printing system. The gravure roll position is made adjustable in real-time along the width direction based on detected sheet position variations. This dynamic adaptation allows the system to maintain manufacturing precision while operating at high productivity levels.
2Manufacturing precision
If the second gravure roll is moved along its axis to correct displacement, then positioning accuracy is improved, but distortion of the step-reducing dielectric pattern occurs
Solution Approach 1:
The patent applies preliminary action by detecting and compensating for sheet position displacement before the paste application occurs. The system measures the sheet position in advance and pre-adjusts the gravure roll position accordingly, preventing pattern distortion before it happens rather than attempting to correct it after displacement occurs.
Solution Approach 2:
The patent replaces manual or simple mechanical adjustment of the gravure roll with an automated control system that uses position detection and computational algorithms to determine optimal roll positioning. This substitution of mechanical adjustment with automated control enables more precise positioning without causing pattern distortion.
3Productivity
If gravure printing is used for multicolor printing, then productivity is improved, but manufacturing precision deteriorates due to displacement causing high-definition printing difficulty
Solution Approach 1:
The patent implements feedback control for multicolor gravure printing by detecting the actual position of the ceramic green sheet and using this information to correct positioning for each color layer. The system continuously monitors sheet location and adjusts gravure roll positions accordingly, maintaining high-definition printing quality across multiple colors while preserving production efficiency.
Data Source
AI summary
A method for manufacturing a ceramic electronic component includes first and second gravure-printing steps in which conductive paste and step-reducing ceramic paste are printed on a composite sheet including a ceramic green sheet. A first print mark is printed before the second gravure-printing step is performed, and the position of the first print mark is determined and compared with a desired position of the first print mark before the second gravure-printing step. Then, the second gravure-printing step is performed such that a second print mark is printed at a suitable position with respect to the position of the first print mark.