Inkjet Printed Ceramic Package Shrinkage Control
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Solution Overview
Problem
Conventional multilayer ceramic processes face limitations in accuracy due to material shrinkage during co-firing, and the inherent layered nature restricts the formation of layers with multiple materials and island structures, while inkjet printing offers improved accuracy but is slow and not conducive for mass production.
Innovation Solution
A two-step firing process is employed, where a multilayer ceramic base is initially fired, followed by inkjet printing and a second firing process, allowing for accurate placement of inkjet printed layers with multiple materials and island structures, overcoming shrinkage issues and enabling precise dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional co-firing processes are used for multilayer ceramic packages, then high productivity is achieved, but manufacturing precision deteriorates due to material shrinkage and limited accuracy of green side processes
Solution Approach 1:
The manufacturing process is segmented into two distinct stages: (1) conventional co-firing for the multilayer ceramic base to maintain high productivity, and (2) subsequent inkjet printing for adding precise features. This segmentation allows each process to optimize for its strength - mass production efficiency and precision respectively - without compromising the other.
Solution Approach 2:
The multilayer ceramic base is prepared and fired in advance using conventional high-productivity processes before the precision-critical features are added via inkjet printing. This preliminary action separates the bulk manufacturing step from the precision feature creation step, allowing the base structure to be established efficiently before detailed features require high precision.
2Productivity
If conventional green side processes are used, then high productivity is maintained, but manufacturing precision deteriorates due to inherent layer structure limitations and limited accuracy
Solution Approach 1:
The fired ceramic base serves as an intermediary substrate that bridges the conventional manufacturing process and the precision inkjet printing process. By providing a stable, pre-formed base with established layers, it enables the subsequent inkjet printing to achieve high precision without being constrained by the limitations of green side processes.
3Manufacturing precision
If inkjet printing is used for all layers, then manufacturing precision is improved, but productivity deteriorates due to slow printing speed not conducive for mass production
Solution Approach 1:
Inkjet printing is applied locally only to specific features and layers that require high precision, rather than to the entire multilayer structure. This localized application of precision technology minimizes the impact on overall production speed while maximizing dimensional accuracy where it is most needed.
Solution Approach 2:
The manufacturing process is segmented such that conventional printing methods handle the bulk of layer formation for productivity, while inkjet printing is selectively applied to specific features requiring high precision. This segmentation optimizes the overall process by applying each method where it provides the most value.
4Productivity
If conventional multilayer ceramic processes are used, then high productivity is achieved, but adaptability deteriorates due to inability to form layers with multiple materials and island structures
Solution Approach 1:
The package structure becomes composite, combining a multilayer ceramic base (produced by conventional processes) with inkjet-printed layers (enabling material variety). This composite structure allows the base to provide structural integrity through conventional manufacturing while the printed layers introduce diverse materials and complex geometries like island structures that would be difficult to achieve otherwise.
Solution Approach 2:
The device is segmented into a base structure (conventional multilayer ceramic) and feature layers (inkjet printed). This segmentation allows the base to be manufactured efficiently using proven conventional processes while the feature layers can incorporate multiple materials and complex structures through the flexibility of inkjet printing technology.
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 enhances process efficiency and accuracy, particularly in RF-related packages, by minimizing shrinkage variations and allowing for the combination of different materials and structures, such as island structures, in a single package.
Implementation Method 1
the multilayer ceramic base is fired in a first firing process before one or more inkjet printed layers are printed on the multilayer ceramic base
Implementation Method 2
the combination package is fired in a second firing process
Data Source
AI summary
The examples set forth herein involve inkjet printing one or more layers on a multilayer ceramic base. In some examples, the multilayer ceramic base is fired in a first firing process before one or more inkjet printed layers are printed on the multilayer ceramic base to form a combination package comprising the multilayer ceramic base and the one or more inkjet printed layers. In further examples, the combination package is fired in a second firing process.