Ceramic Green Sheet Lamination Aid for Peeling and Misalignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The miniaturization and increased capacity of electronic components like multilayer ceramic capacitors lead to issues such as peeling and lamination misalignment of ceramic green sheets during the lamination and thermal pressing steps, which compromise product quality and precision.
Innovation Solution
A ceramic green sheet lamination aid comprising a polyether compound with a specific structure, combined with polyvinyl butyral and ceramic powder, effectively suppresses peeling and lamination misalignment while maintaining sheet strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the ceramic green sheets are thinned to achieve miniaturization, then the capacity and miniaturization of electronic components are improved, but the sheet strength is reduced leading to fracture during lamination
Solution Approach 1:
The invention changes the chemical composition parameters of the binder resin by specifying a polyether compound with particular molecular weight (5,000-50,000) and structural characteristics (formula (1) with specific x, n, and AO values). This parameter optimization allows thin green sheets to maintain sufficient strength while achieving miniaturization goals.
Solution Approach 2:
The invention creates a composite binder system combining polyether compounds with specific structural features (Z—[O-(AO)n-H]x where Z is residual group of alcohol with 1-22 carbons and 1-6 hydroxyl groups, AO is oxyalkylene with 2-4 carbons, n=5-500, x×n=5-500). This composite approach provides both the strength needed for thin sheets and the adhesiveness for lamination.
2Strength
If binders of high strength are selected to prevent fracture, then the sheet strength is improved, but the adhesiveness between sheets is lowered causing peeling during lamination
Solution Approach 1:
The invention optimizes the molecular weight parameter of the polyether binder to 5,000-50,000, which is lower than conventional high-strength binders. This parameter change provides a balance between strength and adhesiveness, preventing both fracture and peeling during lamination and thermal pressing.
Solution Approach 2:
The invention introduces specific structural characteristics at different parts of the binder molecule: the Z group (residual group of alcohol with 1-22 carbons and 1-6 hydroxyl groups) provides one set of properties, while the polyether chain structure (with oxyalkylene groups having 2-4 carbons) provides another. This local differentiation of molecular properties enables simultaneous achievement of strength and adhesiveness.
3Reliability
If a large amount of plasticizer is added to improve adhesiveness, then the adhesiveness is improved, but the resin strength is lowered causing deformation during thermal pressing
Solution Approach 1:
The invention changes the fundamental approach by optimizing the binder resin's inherent properties through molecular structure design rather than adding large amounts of plasticizer. The specified polyether structure with controlled molecular weight (5,000-50,000) and composition ratios provides both adhesiveness and strength, eliminating the need for excessive plasticization that would compromise strength.
Solution Approach 2:
The invention uses a specific molecular structure model (formula (1) with defined parameters) as a template for the binder resin. By copying this optimized structure with precise control over x, n, and AO values, the invention achieves the desired balance of properties without relying on additive-based solutions like excessive plasticizer addition.
4Productivity
If the number of layers is increased to achieve multi-layered structure, then the capacity is improved, but the green sheets become more susceptible to peeling and lamination misalignment
Solution Approach 1:
The invention optimizes the binder resin parameters (molecular weight 5,000-50,000, polyether structure with specific x and n values) to provide consistent adhesiveness across multiple layers. This parameter optimization ensures that even with increased layer numbers, the green sheets maintain stable lamination without peeling or misalignment, enabling high-capacity multi-layered structures.
Data Source
AI summary
A ceramic green sheet lamination aid including a compound represented by formula (1).Z—[O-(AO)n-H]x (1)wherein Z represents a residual group of a compound having a number of carbons group of 1 to 22 and having hydroxyl groups of 1 to 6 in which all of the hydroxyl groups are removed; x represents a number of 1 to 6; AO represents an oxyalkylene group having a number of carbons of 2 to 4; n represents a number of 5 to 500; x×n is in a range of 5 to 500; and a weight ratio of oxyethylene group EO contained in the oxyalkylene group AO having the number of carbons of 2 to 4 is 0 to 80 weight %.