MLCC Lamination Upper Mold Anti-Deflection Design
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Solution Overview
Problem
Conventional upper molds for MLCC lamination cause distortion and damage to ultra-thin film sheets due to the cushion effect of porous mesh plates, leading to lamination array defects and frequent mesh plate replacement, which is economically disadvantageous and results in short-circuits and circuit defects.
Innovation Solution
An upper mold design featuring a vacuum head with anti-deflection parts and a contact plate with fine holes to prevent mesh plate deformation and ensure precise lamination, using a mesh plate with a porous structure for homogeneous suction and exhaust, and a contact plate made of stainless steel or titanium to support the mesh plate and prevent pressing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a porous mesh plate is used for vacuum suction of ultra-thin film sheets, then homogeneous suction is achieved, but the mesh plate deforms under pressing force causing lamination distortion
Solution Approach 1:
The mold is divided into three distinct sections: a first section with through-holes for vacuum suction, a second section with air-suction holes for holding the contact plate, and a third section providing pressing force. This segmentation allows each section to perform its specific function independently, preventing the mesh plate from bearing the full pressing load while maintaining suction effectiveness.
Solution Approach 2:
A contact plate is introduced as an intermediary component between the mesh plate and the pressing force. The contact plate is attracted to the second section by air suction, creating a stable interface that transmits pressing force without deforming the mesh plate. This intermediary protects the mesh plate from direct mechanical stress.
2Reliability
If a mesh plate is used for vacuum suction, then ultra-thin film sheets can be sucked without damage, but the mesh plate requires frequent replacement due to deformation
Solution Approach 1:
The contact plate serves as a protective intermediary that absorbs the mechanical pressing force, preventing direct stress on the mesh plate. This extends the mesh plate's service life by eliminating the primary cause of deformation and damage during the lamination process.
Solution Approach 2:
The mold design applies different local qualities to different sections: the first section provides vacuum suction through through-holes, the second section uses air suction to hold the contact plate, and the third section applies pressing force. This localized functional differentiation ensures the mesh plate operates only in the suction zone without exposure to pressing forces.
3Productivity
If pressing force is applied during lamination, then film sheets are laminated, but the mesh plate deforms causing lamination array distortion
Solution Approach 1:
The pressing function is separated from the suction function by dividing the mold into distinct sections. The third section is dedicated to applying pressing force, while the first section handles vacuum suction. This segmentation prevents the mesh plate from experiencing both forces simultaneously, maintaining lamination precision without sacrificing efficiency.
Solution Approach 2:
The contact plate acts as a mediator that transmits pressing force from the third section to the film sheet, bypassing the mesh plate entirely. This allows pressing force to be applied effectively for lamination while the mesh plate remains undeformed and maintains its suction function.
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
The solution prevents mesh plate deformation, extends its replacement cycle, ensures precise lamination of ultra-thin film sheets, and prevents surface damage, facilitating stable and defect-free lamination of MLCCs.
Implementation Method 1
a thin-film wound around a supply roll is moved to a predetermined position along a conveyor, and then is cut into a predetermine size. An upper mold is installed above the conveyor such that the upper mold is movable along a rail. The upper mold is moved down to contact and vacuum-suck the surface of the cut thin-film sheet
Implementation Method 2
a porous mesh plate in a type of nonwoven fabric (mesh) is applied onto the surface of the upper mold, so that the thin-film sheet can be sucked through pores of the mesh plate
Implementation Method 3
a contact plate made of stainless steel or titanium to support the mesh plate and prevent pressing
Data Source
AI summary
An upper mold for MLCC lamination comprising: a vacuum head comprising a first area formed by a plurality of base holes, which communicate with an air channel formed on the upper surface, and by through-holes that connect the lower surface and respective base holes so as to communicate with each other such that air flows between the base holes and the lower surface, the first area having a predetermined area, and the vacuum head comprising a second area configured, thereby suctioning air; a mesh plate fixed to the lower surface of the vacuum head to have a size corresponding to that of the first area, the mesh plate having a porous structure such that, when air flows through the through-holes of the first area, suction and discharge can occur evenly; and a contact plate fixed to the lower surface of the vacuum head by adhesion of the second area.