Multilayer Electronic Component Inkjet Printing Process
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Solution Overview
Problem
Conventional roll-to-roll processes for producing multilayer electronic components suffer from position misalignment issues during lamination and cutting, leading to decreased formation accuracy and yield, especially in miniaturized components, where the properties of multilayer ceramic capacitors and NTC thermistors often fail to meet predetermined standards.
Innovation Solution
A process utilizing an ejection device that electrically charges ink using an electrostatic attraction force to directly print green functional and conductor parts, allowing for high-accuracy lamination and omission of cutting steps, with specific ink formulations and viscosity settings to ensure uniformity and precision in forming multilayer bodies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional roll-to-roll process is used to produce multilayer electronic components, then production efficiency is maintained, but position misalignment occurs during lamination and cutting leading to decreased formation accuracy
Solution Approach 1:
The patent replaces the conventional mechanical roll-to-roll printing system with an ink jet method that uses electrostatic attraction force to eject ink droplets. This substitution eliminates the need for physical contact between printing heads and substrates, thereby preventing position misalignment during lamination and cutting operations while maintaining production efficiency.
Solution Approach 2:
The patent changes the ejection mechanism from mechanical pressure-based (roll-to-roll) to electrostatic force-based (ink jet). By controlling the electrostatic attraction force through voltage application, the system achieves precise droplet placement without mechanical contact, thereby improving formation accuracy without significantly increasing process complexity.
2Productivity
If miniaturization of electronic components is pursued, then higher performance is achieved, but formation accuracy of multilayer body deteriorates leading to decreased yield
Solution Approach 1:
The ink jet method using electrostatic attraction force enables precise deposition of functional and conductor materials even at miniaturized dimensions. The non-contact nature of the process allows for accurate positioning of tiny droplets, maintaining formation accuracy despite component miniaturization and thereby preserving high yield.
Solution Approach 2:
The patent applies different ink formulations (functional ink and conductor ink) with specific viscosity characteristics to different regions of the multilayer body. By optimizing the local properties of each material layer through precise ink selection and ejection control, the system maintains high formation accuracy in miniaturized components.
3Manufacturing precision
If normal ink jet method is used, then droplets can be ejected, but impact accuracy is limited to about 10 μm which is not enough for high precision requirements
Solution Approach 1:
The patent optimizes the electrostatic attraction force parameters by controlling the voltage applied to the ejection device. By adjusting the voltage magnitude and timing, the system achieves precise control over droplet ejection velocity and placement accuracy, surpassing the 10 μm limitation of normal ink jet methods while maintaining efficient energy usage.
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 significantly enhances the formation accuracy of multilayer electronic components, particularly for small-sized components, by stabilizing ink ejection and reducing variations in properties, thereby improving the yield and compliance with predetermined standards.
Implementation Method 1
ink is electrically charged at an ejection part by applying a voltage and the electrically charged ink is ejected from the ejection part by an electrostatic attraction force
Data Source
AI summary
A process for production of a multilayer electronic component having an element body wherein a functional part and a conductor part are laminated, using an ejection device wherein ink is electrically charged at an ejection part by applying a voltage and the electrically charged ink is ejected from the ejection part by an electrostatic attraction force, and including a first step of forming a green functional part by using a first ink including a functional particle as the ink, a second step of forming a green conductor part by using a second ink including a conductive particle as the ink, a step of forming a green multilayer body by repeating the first step and the second step, and a step of treating the green multilayer body to obtain the element body.