JPH07169638A - Manufacture of multilayer ceramic electronic component - Google Patents

Abstract

PURPOSE:To provide a method for manufacturing a stacked ceramic electronic component by which a flat green sheet with no projections of an internal electrode on its surface can be manufactured and the green sheet can easily be peeled off and which is suitable for high lamination. CONSTITUTION:On one surface of a base film 3, a separating layer of a two- layer structure which is constituted of melamine resin 4, a first layer, and butyral resin 5, a second layer, is formed. After directly printing a specified electrode pattern 10 on the separating layer and drying it, ceramic slurry is applied and dried to make a ceramic green sheet 14. This ceramic green sheet 14 is cut in a required size and then a plurality of the cut sheets are stacked and burned.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a monolithic ceramic electronic component used in the electronics industry,
In particular, the present invention provides an electrode pattern which can be printed directly on the base film without any trouble and which has a significantly improved and improved surface of the laminate.

[0002]

2. Description of the Related Art In recent years, examples of products represented by monolithic ceramic electronic parts include monolithic chip capacitors, LC chip parts and multi-layered multilayer substrates. These ceramic electronic components are formed by forming a conductive electrode pattern to be an internal electrode on a green sheet, and then laminating the required number of sheets. Then, this laminated body is pressed and cut into a predetermined size, and then heated and baked to apply the external electrodes to the end portions. Conventionally, the following method has been used to manufacture this ceramic sintered body.

First, a ceramic slurry is applied on a base film by a doctor blade method or a knife blade method to a predetermined thickness and dried to form a film,
After being sufficiently dried, it is peeled from the base film to obtain a ceramic green sheet. Next, the obtained ceramic green sheet is cut or punched to a required size, and a conductive paste is printed on one surface of the internal electrode by a screen printing method and dried. As shown in FIG. 5, the ceramic green sheet 2 on which the internal electrodes 1 are printed in this way
Are stacked on top of each other, and raw ceramic green sheets 2 on which the internal electrodes 1 are not printed are stacked on the upper and lower sides thereof, and the stacked body is put into a mold and compressed to be integrated. Here, when stacking the ceramic green sheets 2, the ceramic green sheets 2 are stacked while being aligned in a predetermined stacking direction so as not to shift. The integrated laminated body is cut into a predetermined size along a cutting line corresponding to the position where the internal electrode 1 is formed, heated and baked, and then external electrodes are provided to obtain a ceramic electronic component.

[0004]

However, in the above conventional manufacturing method, as shown in FIG. 5, when the ceramic green sheets are laminated, the formation positions of the internal electrodes 1 are directly changed to the steps on the ceramic green sheets 2. However, there is a problem that the flatness of the surface of the laminate is impaired. In such a state, a high pressure is applied only to the internal electrodes 1 at the time of stacking and pressing, and a very non-uniform pressure is applied to the ceramic green sheet 2 as a whole. As a result, sufficient lamination is not performed, and the phenomenon that the ceramic green sheet 2 is peeled off occurs. Further, too much pressure is applied to the protruding portion of the internal electrode 1 to break the internal electrode 1 or cause defects such as stacking misalignment.

In particular, recently, as the demand for higher density increases,
When unevenness occurs on the surface of the laminate as described above, it is an essential element for high density, and it is difficult to manufacture for high stacking, so it becomes impossible to meet the request Occurs. It is obvious that such a phenomenon becomes more prominent as the thickness of the ceramic green sheet 2 becomes thinner.

The present invention solves the above-mentioned problems of the prior art. It is possible to manufacture a flat ceramic green sheet without the protrusion of internal electrodes on the surface of the ceramic green sheet, and it is also excellent in the releasability of the ceramic green sheet for high lamination. An object of the present invention is to provide a method for manufacturing a suitable multilayer ceramic electronic component.

[0007]

To achieve this object, the present invention provides a release layer having a two-layer structure in which a first layer is a melamine resin layer and a second layer is a butyral resin layer on one side of a base film. , And print the predetermined internal electrodes directly on it.
After drying, a ceramic slurry is applied and dried to produce a ceramic green sheet, which is cut to a required size, and a plurality of layers are laminated and fired.

[0008]

As described above, since the internal electrodes are printed directly on the base film, the ceramic slurry is applied onto the internal films and dried to produce the ceramic green sheet, the internal electrodes are embedded and the surface of the ceramic green sheet is It becomes difficult for unevenness of the internal electrode to occur on the top. Therefore, high pressure is not applied only to the internal electrodes at the time of stacking and pressing, so that uniform pressure is applied to the entire ceramic green sheet, and stacking is performed with high accuracy. Moreover, since the pressure on the internal electrodes is also relieved, the destruction of the internal electrodes is eliminated and the stacking deviation is less likely to occur. As a result, not only is it possible to achieve a high level of stacking, but it is also possible to deal with a thinner ceramic green sheet,
Higher density can be achieved.

Regarding the releasability of the ceramic green sheet, a two-layer release layer provided on one surface of the base film, that is, an interface between the first melamine resin layer and the second butyral resin layer Since it is peeled off without any trouble, the laminating property of the ceramic green sheet is not impaired.

[0010]

Embodiments of the present invention will now be described with reference to the drawings, a method of manufacturing a laminated ceramic capacitor as a representative of laminated ceramic electronic components.

First, as shown in FIGS. 1 to 4, a melamine resin solution is applied on one surface of a long base film 3 made of synthetic resin such as polyester or polypropylene and having a thickness of 75 μm by a wire bar method. An extremely thin coating was applied by the coating head 6 and dried by the dryer 8, and then the butyral resin solution was applied by the same wire bar type coating head 7 on the continuously dried melamine resin layer and dried by the dryer 8. hand,
The first layer is the melan resin layer 4, and the second layer is the butyral resin layer 5.
To obtain a long raw fabric 9 made of.

Next, a commercially available thick film silver paste (product number H-4566, manufactured by Shoei Chemical Co., Ltd.) was used to form an electrode pattern 10 on the resin layer composed of these two layers by screen printing so as to have a thickness of 3 μm. Dried. This electrode pattern 1
Reference numeral 0 is a test pattern having an area of 2 × 3 mm as shown in FIG. Then, as shown in FIG. 4, the ceramic slurry 13 was applied from above onto the doctor blade 11 and the feed roller 12 and dried to prepare a long ceramic green sheet 14 having a thickness of 10 μm. The ceramic slurry 13 had a composition shown below, and a coating material prepared by ball mill dispersion was used.

Alumina + borosilicate glass powder 70 parts by weight Butyral resin + plasticizer 10 parts by weight Solvent (n-butyl acetate) 20 parts by weight Then, the ceramic green sheet 14 is cut to a predetermined size and peeled to form each electrode pattern 10. 50 to overlap
Layers were laminated and pressed under the conditions of a pressure of 100 kg / cm ² , a temperature of 100 ° C. and a pressing time of 5 seconds to produce a laminate. At the time of pressing, a stainless steel plate having a flat surface and a thickness of 0.5 mm was used, but no unevenness on the surface of the laminate or destruction of the electrode pattern 10 could be confirmed at all.

The problem here is the releasability of the ceramic green sheet 14, but before that, the point is whether the electrode pattern 10 is successfully formed on the surface of the resin layer. In this embodiment, not only the unevenness of the electrode pattern 10 generated on the surface of the laminated body matters, but the electrode pattern 10 printed on the base film 3 is not a problem.
It is considered that the first condition is that there is no bleeding or repelling, and at the same time, the releasability of the ceramic green sheet 14 is also paid attention to. As the second layer, a release layer having a two-layer structure provided with a butyral resin layer 5 was developed. The reason for the two-layer structure is
The melamine resin layer 4 alone has good releasability, but the electrode pattern 10 cannot be printed well due to the wettability. On the other hand, the butyral resin layer 5 alone adversely affects the electrode pattern 10.
However, it was found that the peelability was extremely poor. Therefore, in the sense of utilizing the merits of both resin liquids,
By providing the melamine resin layer 4 having good releasability on the lower layer side and the butyral resin layer 5 on which the electrode pattern 10 can be printed without trouble on the upper layer side, a ceramic green sheet 14 having no problem was produced.

Also in this embodiment, since the ceramic green sheets 14 can be stacked in a flat state without affecting the releasability of the ceramic green sheets 14, it is possible to obtain a laminate having no unevenness on the surface. Therefore, it goes without saying that high stacking has become possible.

The above-mentioned laminated body was cut along the cutting line so as to correspond to the position where the electrode pattern 10 was formed into a chip shape, which was fired at 900 ° C., but cracks and lamination defects should be confirmed at all. I couldn't.

Next, in order to further clarify the effect of the present embodiment, the electrode pattern 10 is formed on a normal PET film and on a PET film (trade name, manufactured by Toray Co., Ltd.) on which one surface of the film is release-treated. Is printed as a comparative example.

(Comparative Example-1) Long P having a thickness of 75 μm
Electrode pattern 1 directly on one surface using ET film
Formed 0 and dried. The electrode pattern 10 was formed by using the thick film silver paste (product number H-4566, manufactured by Shoei Kagaku Co., Ltd.) used in the examples and by a screen printing method to a thickness of 3 μm.
I adjusted it to be. The pattern is a test pattern having an area of 2 × 3 mm as shown in FIG.
Then, a ceramic slurry was applied onto the formed and dried electrode pattern 10 by a doctor blade 11 and dried to produce a long ceramic green sheet 14 having a thickness of 10 μm. As the ceramic slurry, a paint prepared in the same manner as in the example was used.

Next, a long ceramic green sheet 14
Is cut into a predetermined size and peeled off. At the time of peeling, the ceramic green sheet 14 is removed from the base film 3
A defect such as not peeling off occurred. After that, until the end of the long raw fabric, the distance property was confirmed although it was an arbitrary distance, but all peeling defects occurred and it was not possible to obtain a ceramic green sheet 14 having no defects.

(Comparative Example-2) The base film used in Comparative Example-1 was changed to a PET film (trade name: Serapile Toray Co., Ltd.) having one surface subjected to a release treatment, and the side subjected to the release treatment. An electrode pattern was formed on. The silver paste, forming method, and forming pattern are exactly the same as in Comparative Example-1.

Observation of the electrode pattern 10 after screen printing revealed that the spots were rounded into a grain shape and the pattern was disturbed. After that, about 20 samples were repeatedly formed with the electrode pattern 10 by the screen printing method, and the same defect was observed in each case. This is considered to be related to the wettability of the release-treated surface of the base film. That is, it is considered that the wettability of the release treated surface was large and the silver paste was repelled into a grain shape.
It is considered that since the repelling method was not uniform, the electrode pattern 10 could not maintain a regular shape and was disturbed.

[0022]

INDUSTRIAL APPLICABILITY As described above, according to the present invention, by providing a release layer having a two-layer structure such as a melamine resin layer on the lower side of one side of the base film and a butyral resin layer on the upper side, the release layer is directly formed on the release layer. The electrode pattern to be formed can be formed without any trouble, and the production of the ceramic green sheet with excellent releasability can be realized. In addition, since the electrode pattern is embedded with the ceramic slurry, uniform pressing can be performed even at the time of pressing after the ceramic green sheets are laminated, and the production without unevenness on the surface of the laminated body can be realized. Therefore, it is possible to provide a highly reliable manufacturing method for electronic components such as capacitors, laminated coils, and filters that require a laminated structure.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing the structure of a ceramic green sheet of a method for manufacturing a laminated ceramic electronic component according to an embodiment of the present invention.

FIG. 2 is a schematic view showing steps of the manufacturing method.

FIG. 3 is a plan view showing an electrode pattern in the same method.

FIG. 4 is an explanatory view when forming a ceramic green sheet in the same method.

FIG. 5 is a cross-sectional view of a laminated body of ceramic green sheets in a conventional method for manufacturing a laminated ceramic electronic component.

[Explanation of symbols]

 3 Base Film 4 Melamine Resin Layer 5 Butyral Resin Layer 6 Coating Head 7 Coating Head 8 Dryer 9 Raw Fabric 10 Electrode Pattern 11 Doctor Blade 12 Feed Roller 13 Ceramic Slurry

Front page continuation (72) Inventor Ryo Kimura 1006 Kadoma, Kadoma City, Osaka Prefecture Matsushita Electric Industrial Co., Ltd.

Claims (1)

[Claims] 1. A release layer having a two-layer structure of a melamine resin layer as a first layer and a butyral resin layer as a second layer is provided on one side of a base film, and a predetermined electrode pattern is directly printed and dried on the release layer. After that, a ceramic slurry is applied and dried to produce a ceramic green sheet, which is cut into a required size, and a plurality of layers are laminated and fired, which is a method for producing a laminated ceramic electronic component.