WO2004068516A1 - セラミックグリーンシートの製造方法および当該セラミックグリーンシートを用いた電子部品の製造方法 - Google Patents
セラミックグリーンシートの製造方法および当該セラミックグリーンシートを用いた電子部品の製造方法 Download PDFInfo
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- WO2004068516A1 WO2004068516A1 PCT/JP2004/000950 JP2004000950W WO2004068516A1 WO 2004068516 A1 WO2004068516 A1 WO 2004068516A1 JP 2004000950 W JP2004000950 W JP 2004000950W WO 2004068516 A1 WO2004068516 A1 WO 2004068516A1
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- photosensitive material
- light
- exposure
- ceramic green
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Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
- H01L21/48—Manufacture or treatment of parts, e.g. containers, prior to assembly of the devices, using processes not provided for in a single one of the subgroups H01L21/06 - H01L21/326
- H01L21/4803—Insulating or insulated parts, e.g. mountings, containers, diamond heatsinks
- H01L21/481—Insulating layers on insulating parts, with or without metallisation
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G4/00—Fixed capacitors; Processes of their manufacture
- H01G4/002—Details
- H01G4/018—Dielectrics
- H01G4/06—Solid dielectrics
- H01G4/08—Inorganic dielectrics
- H01G4/12—Ceramic dielectrics
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
- H01L21/48—Manufacture or treatment of parts, e.g. containers, prior to assembly of the devices, using processes not provided for in a single one of the subgroups H01L21/06 - H01L21/326
- H01L21/4814—Conductive parts
- H01L21/4846—Leads on or in insulating or insulated substrates, e.g. metallisation
- H01L21/4867—Applying pastes or inks, e.g. screen printing
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/0011—Working of insulating substrates or insulating layers
- H05K3/0017—Etching of the substrate by chemical or physical means
- H05K3/0023—Etching of the substrate by chemical or physical means by exposure and development of a photosensitive insulating layer
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/0006—Printed inductances
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/12—Insulating of windings
- H01F41/127—Encapsulating or impregnating
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/03—Use of materials for the substrate
- H05K1/0306—Inorganic insulating substrates, e.g. ceramic, glass
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/10—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
- H05K3/20—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern by affixing prefabricated conductor pattern
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/46—Manufacturing multilayer circuits
- H05K3/4611—Manufacturing multilayer circuits by laminating two or more circuit boards
- H05K3/4626—Manufacturing multilayer circuits by laminating two or more circuit boards characterised by the insulating layers or materials
- H05K3/4629—Manufacturing multilayer circuits by laminating two or more circuit boards characterised by the insulating layers or materials laminating inorganic sheets comprising printed circuits, e.g. green ceramic sheets
Definitions
- the present invention relates to a method for manufacturing an electronic component, particularly a so-called laminated ceramic formed by laminating ceramics, and a method for manufacturing a so-called ceramic green sheet used for the same.
- Specific examples of the multilayer ceramic electronic component described here include a multilayer ceramic capacitor, a multilayer ceramic inductor, an LC composite component incorporating these, or an EMC-related component.
- a conventional manufacturing method used for manufacturing the above-described ceramic multilayer electronic component for example, a multilayer ceramic capacitor having electrodes formed therein, is a so-called metal-ceramic integrated firing technology as a technology capable of meeting these requirements.
- the metal-ceramic integrated firing technique will be briefly described.
- a plurality of electrodes are simultaneously formed on the surface of a so-called ceramic green sheet using a conductive paste made of a metal powder and an organic binder.
- a single ceramic green sheet and a ceramic dary after electrode formation A plurality of sheets are laminated to obtain a ceramic laminate.
- These electrodes will be the internal electrodes of the finished ceramic multilayer electronic component.
- the ceramic laminate is pressed in the thickness direction to improve the adhesion between the green sheets.
- the adhered laminate is cut into a predetermined size, separated, and fired.
- the ceramic green sheet which is a material of the ceramic laminate, be made thinner and the above-described process be performed.
- the thickness of the thinnest ceramic green sheet currently used is about 2-3 m.
- the thickness of the electrodes printed on these ceramic Darling sheets is about 1.5-2.0 / xm. For this reason, the thickness of the part where the internal electrodes overlap when the ceramic laminate is obtained is extremely large compared to the part where the internal electrodes do not exist, and there is a tendency for partial steps to occur. . In addition, due to this step, there was a possibility that a lamination displacement might occur when laminating the green sheets.
- pressure is applied in the thickness direction after the formation of the laminate, and the pressure step preferably substantially eliminates the step.
- a press pressure of, for example, tonZcm 2 is required, and improvement in the process is required.
- these pressures are locally applied only to the portion where the internal electrodes overlap, there is a possibility that insufficient pressure contact or deformation after pressing may occur in other regions. It was also considered that such local application of pressure may cause a delamination phenomenon called so-called delamination in the laminated body after sintering.
- the technique disclosed in Japanese Patent Application Laid-Open No. Hei 9-1115766 is a method devised to suppress the occurrence of such a step. Specifically, when an electrode is formed on a green sheet by screen printing, the conductive paste used for this is formed from an organic binder having a water-repellent function and metal powder. In addition, after forming the electrode, a water-based ceramic slurry is applied thereon, and the slurry is repelled from the electrode by the above-described water-repellent function, thereby forming a ceramic sheet for filling a step around the electrode pattern. It is to be formed.
- the adhesive strength at the interface between the water-repellent electrode surface and the ceramic green sheet pressed against the surface may be inferior to the conventional adhesive strength between the electrode and the sheet.
- the water-based slurry is considered to have a high tendency to increase its thickness due to the surface tension thereof, which may cause a decrease in lamination accuracy.
- a recess is formed in advance in the electrode forming portion on the ceramic green sheet, and a conductive paste is buried in the recess by screen printing.
- a technique for reducing the occurrence of steps on a sheet is disclosed.
- the green sheet when the green sheet is thin, the green sheet follows the convex portion of the base that forms the green sheet, and the green sheet has a convex portion formed on the surface opposite to the concave portion forming surface which is equivalent to the concave portion forming position.
- the present invention has been made in view of the above problem and the above background, and has been made in consideration of the above circumstances, and provides a sheet for reducing steps in each layer including a ceramic green sheet and an internal electrode formed thereon (hereinafter, the description will be made briefly).
- the sheet is generally referred to as a ceramic green sheet.
- It is intended to provide a forming method. By providing the method, it is intended to reduce variations in electrical characteristics of the ceramic multilayer electronic component, and to reduce or avoid the frequency of occurrence of delamination and the like during firing of the multilayer body.
- a method for manufacturing a ceramic green sheet according to the present invention is a method for manufacturing a ceramic green sheet using exposure and development processing, wherein a base that can transmit light used for exposure processing is provided. Adhering a photosensitive material containing powder having predetermined electrical characteristics on the surface and exposing with light, and irradiating the photosensitive material with the light from the back surface of the base. And a step of performing an exposure process at an exposure amount at which the photosensitive material is exposed to a predetermined thickness from the base, and a process of performing a development process on the photosensitive material after the exposure process. .
- a method for manufacturing a ceramic green sheet according to the present invention is a method for manufacturing a ceramic green sheet using exposure and development processing, wherein a base capable of transmitting light used for exposure processing is provided.
- a first photosensitive material that contains a powder having predetermined electrical characteristics on its surface, and that can be exposed to light
- the first photosensitive material is irradiated with light from the back side of the base, and the first photosensitive material is exposed from the base at an exposure amount of the first predetermined thickness.
- first photosensitive material and a second photosensitive material that contains powder having predetermined electrical characteristics on the surface of the light-shielding portion after the development process and that can be exposed to light.
- the second photosensitive material is irradiated with light from the back surface of the base, and the second photosensitive material is exposed from the front surface of the first photosensitive material to a second predetermined thickness. And subjecting the second photosensitive material after the exposure process to a development process. It is set to.
- a step of forming a light-shielding portion made of a member that does not transmit light used for exposure processing on the surface of the base is performed before the step of attaching the photosensitive material to the base.
- the predetermined thickness at which the photosensitive material is exposed is substantially equal to the thickness of the light shielding portion.
- the first predetermined thickness at which the first photosensitive material is exposed is the thickness of the other light-shielding portion. Is preferably approximately equal to Alternatively, it is preferable that the second predetermined thickness at which the second photosensitive material is exposed is substantially equal to the thickness of the light shielding portion.
- a method for manufacturing a ceramic green sheet according to the present invention is a method for manufacturing a ceramic green sheet using exposure and development processing, wherein a portion capable of transmitting light used for exposure processing is formed.
- a photosensitive material containing powder having electrical characteristics and capable of being exposed to light is attached Irradiating the photosensitive material with light from the back surface of the member, and performing an exposure process at an exposure amount at which the photosensitive material is exposed to a predetermined thickness from the member; Performing a development process on the conductive material.
- a method for manufacturing a ceramic green sheet according to the present invention is a method for manufacturing a ceramic green sheet using exposure and development processing, wherein the method uses a material that does not transmit light used for the exposure processing.
- the photosensitive material is irradiated from the back side of the table with light, and the photosensitive material is exposed from the base at a predetermined exposure amount, and the exposed material is developed. It is characterized by including a step of performing processing.
- the thickness of the photosensitive material to be deposited is larger than the thickness of the material forming the pattern, and the predetermined thickness of the photosensitive material exposed by the exposure process is the thickness of the material forming the pattern. Is preferably approximately equal to Further, it is preferable that the thickness of the photosensitive material adhered is substantially equal to the thickness of the material forming the pattern, and the predetermined thickness of the photosensitive material exposed by the exposure process is substantially equal to the thickness of the material forming the pattern. .
- a method for manufacturing an electronic component according to the present invention is a method for manufacturing a laminated ceramic electronic component, comprising: It is characterized in that a plurality of ceramic green sheets including sheets are laminated, and the laminated ceramic green sheets are pressed in the thickness direction to form a laminate.
- a method for manufacturing a ceramic green sheet according to the present invention is a method for manufacturing a ceramic green sheet using exposure and development processing, wherein a portion capable of transmitting light used for exposure processing is formed.
- a powder having predetermined electrical characteristics on the surface of the member having the sheet-formed surface as a surface Including a powder having predetermined electrical characteristics on the surface of the member having the sheet-formed surface as a surface, And a step of attaching a photosensitive material that can be exposed by light, and irradiating the photosensitive material with light from the back surface of the member to expose the photosensitive material to a predetermined thickness from the surface of the member. And a step of subjecting the photosensitive material after the exposure processing to a development processing.
- the photosensitive material formed on the surface of the member is subjected to exposure processing from the back surface of the light-transmitting member, so that the exposed photosensitive material remaining on the member after the exposure and development processing (described later)
- the feature is that the thickness of the solidified slurry can be controlled accurately. Therefore, it can be said that the manufacturing method including the step of exposing the photosensitive material on the surface of the member from the back surface of the member having the light transmitting portion is the manufacturing method according to the present invention. That is, as described in detail in Examples, before performing the process, various layers on the base, specifically, a layer for obtaining a releasing action, a ceramic layer, a conductor pattern, and a ceramic portion are used.
- the present invention also includes a layer formed with a different layer or the like.
- the present invention also includes a case where a method of performing exposure and development from the back surface of the member to form a sheet in which a plurality of layers are stacked is formed.
- the step of forming a light-shielding portion made of a material that cannot transmit light to a predetermined region of the surface of the member May be performed before the step of attaching the photosensitive material to the surface of the member.
- the predetermined thickness is substantially equal to the thickness of the light shielding portion.
- the member may be subjected to a release treatment for facilitating the peeling of the ceramic green sheet from a surface thereof.
- the member may include a portion that is peeled off from the front ceramic green sheet and a portion that forms a part of the ceramic green sheet.
- a part of the ceramic green sheet may be a layer made of a material different from the photosensitive material.
- a part of the glass green sheet may be made of a material obtained by exposing a photosensitive material and a material that cannot transmit light.
- a step of attaching a photosensitive material, a step of exposing the photosensitive material, and a step of developing the photosensitive material Forming a further light-shielding portion on the outermost surface of the applied sheet, attaching a further photosensitive material, exposing the further photosensitive material from the back surface of the member, and developing the further photosensitive material A process may be performed.
- the material forming the light-shielding portion does not need to be the same as the material forming the further light-shielding portion, and the photosensitive material and the further photosensitive material need not be the same.
- a method of manufacturing an electronic component according to the present invention comprising the steps of: forming a ceramic green sheet formed by the above-described method of manufacturing a ceramic green sheet; And stacking a plurality of ceramic green sheets including the following, and pressing the stacked ceramic green sheets in a thickness direction thereof to form a laminate. Since the ceramic green sheet obtained by the manufacturing method according to the present invention is superior in terms of thickness accuracy and the like to the sheet obtained by the conventional manufacturing method, all sheets are required to obtain high-quality electronic components. It is desirable to form by the manufacturing method according to the invention. However, by manufacturing an electronic component including a sheet obtained by a conventional manufacturing method according to the characteristics required of the electronic component, it is possible to obtain effects such as a reduction in manufacturing cost.
- the present invention it is possible to form a ceramic green sheet having a smaller step in each layer, including the ceramic green sheet and the internal electrodes formed thereon.
- the method it is possible to reduce the variation in the electrical characteristics of the ceramic multilayer electronic component and to reduce or avoid the frequency of occurrence of the delamination phenomenon during firing of the multilayer body.
- the thickness of the layer is precisely controlled by the amount of light exposure as a distance from the surface of the substrate on which the layer is formed. Therefore, a ceramic green sheet made of a material having desired electric characteristics is formed by using a slurry containing a powder having predetermined electric characteristics by screen printing or coating. Compared with the conventional method, the controllability of the sheet thickness is greatly improved, and it is possible to provide a sheet having a thin thickness which has been considered impossible so far and having excellent thickness uniformity. Become. Therefore, it is possible to obtain an electronic component having a smaller size and excellent electrical characteristics while suppressing manufacturing variations.
- FIG. 1 is a flowchart showing a method for forming a ceramic green sheet according to an embodiment of the present invention.
- FIG. 2 is a diagram showing the relationship between the exposure amount and the remaining thickness of the photosensitive slurry after development.
- FIG. 3A is a flowchart showing a method for forming a ceramic green sheet as a first application example of the embodiment of the present invention.
- FIG. 3B is a flowchart showing a method of forming a ceramic green sheet as a first application example of the embodiment of the present invention.
- FIG. 3C is a flowchart showing a method of forming a ceramic green sheet as a first application example of the embodiment of the present invention.
- FIG. 4 shows a second embodiment of a ceramic dary according to the embodiment of the present invention.
- FIG. 4 is a flowchart showing a method for forming a sheet.
- FIG. 5 is a flowchart showing a third application example of a method for forming a ceramic Darline sheet according to the embodiment of the present invention.
- FIG. 6 is a flowchart showing a method of forming a ceramic dust sheet as a fourth application example of the embodiment of the present invention.
- FIG. 7 is a flowchart showing a main part of a method for forming a multilayer ceramic capacitor using the present invention.
- FIG. 8 is a flowchart showing a main part of a method for forming a multilayer ceramic capacitor using the present invention.
- FIG. 9 is a flowchart showing a main part of a method for forming a multilayer ceramic condenser using the present invention.
- FIG. 10 is a flowchart showing a main part of a method for forming a multilayer ceramic inductor using the present invention.
- FIG. 11A is a flowchart showing a main part of a method for forming a multilayer ceramic inductor using the present invention.
- FIG. 11B is a flowchart showing a main part of a method for forming a multilayer ceramic inductor using the present invention.
- FIG. 12 is a diagram illustrating an example of a method of forming an electrode portion on a base.
- FIG. 13 is a diagram illustrating an example of a method of forming an electrode portion on a base.
- FIG. 1 shows a method for forming a single layer of a ceramic green sheet including an electrode portion in a method of manufacturing an electronic component according to an embodiment of the present invention.
- substrate 1 For example, a PET film whose surface has been subjected to an appropriate release treatment using a transparent silicon resin or the like is used.
- the electrode portion 3 is formed on the surface of the substrate 1 subjected to the release treatment in Step 1 by a method of screen-printing a conductive paste conventionally used for forming an electrode.
- the electrode portion is formed as a predetermined pattern having a predetermined thickness by a light shielding portion made of a material that does not transmit ultraviolet light used in an exposure process described later.
- step 2 the sheet in this state is pressed from the electrode upper surface 3a to flatten the upper surface 3a and to make the thickness of the electrode portion 3 uniform. This step may be omitted if the flatness of the upper surface 3a and the thickness of each of the electrode portions 3 satisfy desired conditions.
- a photosensitive slurry 4 for forming a ceramic layer is applied to the upper surfaces of the base 1 and the electrode section 3.
- the photosensitive slurry 4 is mainly composed of a mixture of a negative type organic binder which becomes insoluble in a developing solution by irradiation with ultraviolet rays and a ceramic powder having electric characteristics such as a predetermined dielectric constant. Is formed from That is, the photosensitive slurry contains a powder having predetermined electrical characteristics, and is used as a photosensitive material that can be exposed to ultraviolet light.
- the light-sensitive slurry 4 is applied and formed not only on the upper surface of the substrate 1 on which the electrode portions 3 are not formed but also on the upper surfaces of the individual electrode portions 3.
- the photosensitive slurry 4 is exposed to ultraviolet light from the surface (back surface) of the substrate 1 opposite to the surface on which the electrode portions 3 are formed, and the photosensitive slurry 4 is exposed.
- the photosensitive slurry 4 becomes a slurry solidified portion 5 through the exposure processing and a developing step described later.
- the electrode section 3 acts as a mask for exposing the photosensitive slurry 4 to shield ultraviolet rays, and prevents exposure of the photosensitive slurry 4 existing on the upper surface of the electrode section 3. That is, in the next development step, the photosensitive slurry existing on the upper surface of the electrode unit 3 is melted and removed. Also, when exposing The thickness of the photosensitive slurry 4 (slurry solidified part 5) that remains insoluble during development by optimizing the amount of ultraviolet light, that is, light intensity and exposure time, and developing conditions It becomes possible.
- the thickness of the slurry solidified portion 5 can be accurately controlled, and if necessary, the thickness can be made to exactly match the thickness of the electrode portion 3. It is possible. Thereafter, a layer including the slurry solidified portion 5 and the electrode portion 3 is separated from the base 1, and this is used as a ceramic green sheet for manufacturing electronic components.
- the electrode portion 3 serving as an internal electrode is formed on the surface of the substrate 1, the photosensitive slurry 4 is applied thereon, and then the substrate 1 is exposed from the back.
- the thickness of the solidified slurry portion 5 can be controlled with high accuracy by appropriately controlling the irradiation conditions of the ultraviolet light used for exposure and optimizing the development conditions. Therefore, it is possible to form a ceramic green sheet in which a ceramic dielectric portion and an internal electrode which have substantially the same thickness as the internal electrode portion 3 and hardly have an interface gap in the thickness direction are mixed.
- the variation in the film thickness of the slurry solidified portion 5 after the exposure and development processes in the above steps is affected by the properties of the ceramic powder and the like contained therein. However, by optimizing the conditions of each step, values of about ⁇ 2 to 3% have been obtained. Normally, ceramic green sheets are formed using a doctor blade, but the thickness variation at that time is about 3 to 5% of soil. That is, by using the present invention, a ceramic green sheet having a more uniform film thickness can be formed.
- FIG. 1 An example of the relationship between the amount of ultraviolet irradiation and the thickness of the ceramic green sheet obtained after exposure and development is shown in FIG.
- the horizontal axis indicates the exposure amount per unit area of ultraviolet light having a wavelength of 405 nm
- the vertical axis indicates the sheet thickness after development.
- the photosensitive slurry used is a mixture of barium titanate powder having a diameter of about 0.2 m and a negative binder at a volume ratio of 1/1. After forming this about 8 m thick on the surface of the substrate (not shown), exposure processing etc. is performed from the back surface of the substrate.
- the illuminance of ultraviolet light during exposure is 5 Omw per unit area, and the amount of exposure varies depending on the irradiation time.
- the sample was immersed in a developer consisting of a 1% by weight aqueous solution of sodium carbonate maintained at 30 ° C for 30 seconds, and then immersed in pure water maintained at 30 ° C for 90 seconds. are doing. As shown in the figure, a clear correlation is obtained between the exposure amount and the obtained sheet thickness. Further, as shown by the error bars in the figure, the value of ⁇ 0.5 to 2.0% is almost constant as the variation of the film thickness. As described above, it is possible to control the exposure thickness, that is, the sheet thickness, of the photosensitive slurry containing the powder having the predetermined electrical characteristics by changing the exposure amount. confirmed. The present invention has been made based on these confirmed matters.
- FIGS. 3A and 3B show a cross section of the substrate 1 and the like and the slurry solidification portion 5 and the like with respect to the step of forming the slurry solidified portion 5 having a predetermined thickness on the surface of the substrate 1.
- the photosensitive slurry 4 is applied on the surface of the substrate 1 on which the release treatment has been performed, in a thickness not less than a predetermined thickness.
- the coating method is not particularly limited.
- ultraviolet light is irradiated from the back surface of the substrate 1 to perform an exposure process up to a predetermined thickness of the photosensitive slurry 4. Further, by optimizing the developing process, the photosensitive slurry 4 which becomes a portion having a predetermined thickness or more is melted and removed. After the above steps, the base 1 is removed, so that the thickness variation is small. It becomes possible to obtain a lamic green sheet (step 3).
- the thickness at which the slurry can be applied substantially uniformly on the substrate is limited by various conditions such as the viscosity of the slurry. For this reason, it has been difficult to obtain a ceramic green sheet having a thickness less than a certain value.
- the slurry is applied with a thickness that allows easy application, and the thickness of the sheet is controlled in the subsequent exposure processing. As described above, in this exposure process, the exposure thickness (thickness of the ceramic green sheet remaining after the development process) can be controlled independently of the coating thickness, and the sheet in the conventional forming method can be controlled. It is possible to control the thickness at a value below the lower limit of the thickness.
- the surface of the substrate 1 has been subjected to a mold release treatment in advance.
- a material that is difficult to perform a so-called release treatment is used as the base 1.
- a light-transmitting release layer (layer indicated by reference numeral 2 in the figure) is applied to the surface of the substrate 1 that has not been subjected to any surface treatment in Step 10. May be formed in advance, and a layer made of the photosensitive slurry 4 may be formed thereon.
- a layer having a so-called bleeding preventing action which prevents bleeding of an edge (end) of the formation part at the time of forming the light shielding part or the like, may be formed.
- this layer 2 is ultimately peeled off and removed from the slurry solidified portion 5 together with the substrate 1. That is, the base 1 and the layer 2 integrally function as a member having a portion that transmits light.
- a sheet corresponding to the lowermost layer of the electronic component may require characteristics different from predetermined electrical characteristics.
- the method shown in Figure 3C addresses such cases.
- the release layer 2 is formed on the base 1 (step 10), and a light-transmitting ceramic layer 6 is formed thereon (step 10 ').
- the ceramic layer 6 is formed for a purpose different from that of the slurry solidification unit 5 formed in a later step. In this case, it is conceivable that the ceramic layer 6 may not require the level of film thickness uniformity required when the slurry solidified portion 5 is formed.
- the ceramic layer 6 may be formed from the steps in steps 10 to 12 of FIG. 3A, or may be formed by a conventional coating method.
- the substrate 1 and the layer 2 are separated from the ceramic green sheet by a peeling operation, and the ceramic layer 6 forms a part of the ceramic green sheet.
- the exposure of the photosensitive slurry adhering to the upper surface of the electrode is reliably prevented, and the slurry on the electrode surface can be reliably removed through the development process.
- the second application example of the present invention described below focuses on the effect. Specifically, it is conceivable that the electrode portion and the ceramic green sheet in which the electrode portion is located are relatively thick, and for example, the allowable range of the electrical characteristics can be sufficiently satisfied by the conventional light-sensitive slurry coating technology.
- a second application example of the present invention will be described with reference to FIG.
- step 2 the electrode portion 3 is formed on the surface of the base 1 on which the release processing has been performed.
- step 1 described in the above-described embodiment of the present invention may be performed.
- a photosensitive slurry 4 for forming a ceramic layer is applied to the upper surfaces of the base 1 and the electrode section 3.
- the photosensitive slurry 4 is applied on the base 1 by a conventional application method in a thickness substantially equal to the thickness of the electrode portion 3.
- the slurry 4 is applied and formed not only on the upper surface of the substrate 1 where the electrode portions 3 are not formed but also on the upper surfaces of the individual electrode portions 3 (Step 3 ′).
- the photosensitive slurry 4 is irradiated with ultraviolet rays from the surface (back surface) of the substrate 1 opposite to the surface on which the electrode portion 3 is formed, and the photosensitive slurry 4 is exposed over the entire thickness thereof.
- the photosensitive slurry 4 becomes a slurry-solidified portion 5 through the exposure processing and a developing step described later.
- the electrode section 3 acts as a mask for exposing the photosensitive slurry 4 to shield ultraviolet rays, and reliably prevents the photosensitive slurry 4 present on the upper surface of the electrode section 3 from being exposed. Therefore, the upper surface 3a of the electrode portion 3 is exposed by the developing process, and, for example, a good connection is easily obtained when connecting another electrode to this.
- a method for forming an electrode pattern in a ceramic green sheet and a so-called post for coupling the electrode pattern to a further electrode or the like in another ceramic green sheet Is shown in FIG.
- an electrode portion 3 serving as a post is formed on the surface of the base 1 subjected to the release treatment.
- the electrode portion 3 functions as a light shielding member in the exposure processing.
- applying a photosensitive slurry 4 as a first photosensitive material exposing the photosensitive slurry 4 from the back surface of the base 1 to a first predetermined thickness, and melting and removing excess photosensitive slurry by a developing process.
- the boost electrode 3 and the solidified slurry 5 shown in Step 22.
- step 23 pattern electrodes 7 serving as internal electrodes are formed on the upper surface of the sheet shown in step 2.
- the pattern electrode 7 functions as a light shielding member in the exposure processing.
- a photosensitive slurry 14 as a second photosensitive material is applied again on the upper surface of the pattern 7 electrode and the like.
- the first photosensitive material and the second photosensitive material are the same, but they may be different materials depending on desired electrical characteristics and the like.
- a second predetermined thickness exposure process is performed on the re-applied photosensitive slurry 4 from the back of the base 1 and a developing process for melting and removing the excess portion of the re-applied photosensitive slurry 4 Then, a sheet composed of the base 1, the post electrode 3, the pattern electrode 7, and the slurry solidified portion 5 shown in Step 24 is formed.
- the base 1 is removed from the sheet, so that the internal pattern electrodes and It becomes possible to obtain a ceramic green sheet having a post and a post (step 25).
- this embodiment is a modified example including the step of forming two layers.
- the present modification can be described as a case where the embodiment of the present invention itself is simply repeated a plurality of times.
- an electrode portion 3 to be a post is formed on the surface of the base 1 subjected to the release treatment.
- photosensitive slurry 14 is applied, and exposure processing is performed from the back side of base 1. At this time, the exposure amount is adjusted so that the photosensitive slurry 4 is exposed to a predetermined thickness regardless of the thickness of the electrode portion 3.
- excess photosensitive slurry 4 is melted and removed by a developing process to form a sheet comprising a base 1, a post electrode 3, and a slurry solidifying section 5 shown in step 33. Since the electrode portion 3 functions as a mask, the photosensitive slurry 4 on the upper surface 3a is not exposed, and the photosensitive slurry 4 is removed by a developing process. That is, the penetrating patterns 9 corresponding to the internal electrode portions 3 are formed on the slurry solidified portion 5 having a predetermined thickness in a self-aligned manner.
- step 34 the upper surface of the electrode portion 3, that is, the through pattern 9 is filled with, for example, a conductive paste to form an additional electrode portion 11.
- an internal electrode having the same upper surface as the upper surface of the slurry solidification unit 5 is formed.
- these ceramic green sheets are used as materials for forming electronic components such as multilayer ceramic capacitors and multilayer ceramic inductors.
- the following is an example of a method of forming a multilayer ceramic capacitor and a multilayer ceramic inductor.
- Figure 7 shows the main parts of the method for forming a multilayer ceramic capacitor.
- the electrode portion 3 having a predetermined thickness is formed on the base 1.
- the product in this method is a capacitor, and the electrode part 3 is used as an electrode in the capacitor. Therefore, although not explicitly shown in the drawing showing the cross section, the electrode portion 3 is formed in a flat plate shape. Subsequently, through the processes shown in steps 3 and 4, the electrode portion 3 and the dielectric portion (solidified slurry portion 5) having a predetermined thickness are formed on the base 1. In this method, in step 4 ′, a dielectric portion 6 having a predetermined thickness is further formed on the upper surfaces of the electrode portions 3 and the like. Then, in step 5 ', the substrate 1 is removed from the electrode portions 3 and the like to obtain a ceramic green sheet for a capacitor.
- the multilayer ceramic green sheet is obtained by firing the pressurized multilayer ceramic green sheet and forming terminal electrodes and the like outside the multilayer ceramic green sheet.
- the dielectric portion 6 is directly formed on the electrode portion 3 and the like in Step 4 ′ from the viewpoint of reducing the number of steps.
- the forming method is printing Method, doctor blade method, etc. can be applied.
- the slurry solidification part 5 according to the first application example described above is formed in advance, and the ceramic green comprising the sheet 5, the electrode part 3, and the dielectric part (5) is formed. It is preferable to use a sheet. By laminating these sheets and going through the steps of pressing and firing (steps 6 to 8), it is possible to obtain a multilayer ceramic capacitor with less variation in electrical characteristics compared to the above-mentioned method. .
- a slurry solidification part 5 according to the first application example of the present invention is previously formed on the base 1 (steps 11 ′ and 12 ′), and the base 1 and the slurry solidification are formed.
- the part 5 may be used as a new base on which a part composed of the electrode part 3 and the dielectric part (5) is formed (steps 2 'to 4').
- the slurry solidification unit 5 needs to sufficiently transmit ultraviolet light and the like used in the exposure processing, there is a possibility that a material limitation with respect to the photosensitive slurry may occur.
- the thickness of the slurry solidified portion 5 formed on the substrate 1 is controlled by performing an exposure process from the back of the substrate 1.
- the case where the sheet obtained by the method is used for the outermost layer of the multilayer capacitor, or the case where the sheet is used only for the wiring portion instead of forming the capacitor is also considered.
- the thickness accuracy of the slurry solidification part 5 is not so required. Therefore, from the viewpoint of simplification of the process, strict thickness control is performed by, for example, subjecting the layer to an exposure treatment from a conventionally used surface. May not be performed.
- FIG. 10 shows a main part of a method for forming a multilayer ceramic inductor.
- an electrode portion 3A or 3B having a predetermined thickness is formed on the substrate 1.
- the product in this method is an inductor, and the electrodes 3A and 3B are used as the inductor body. Therefore, although not shown in the figure showing the cross section, the electrode portion 3A is formed in a frame shape with a part cut away when viewed from the upper surface.
- the electrode portion 3B is used as a post electrode for connecting the electrode portion 3A formed in a ceramic green sheet laminated above and below the ceramic green sheet including the electrode portion 3B and formed in a columnar shape. Is done.
- an inductor body is formed.
- the photosensitive slurry 4 is applied onto the substrate 1 and the electrode portions 3A or 3B through the processes shown in steps 3A and 3B, respectively.
- Each of these sheets is exposed to light from the back surface of the substrate 1 and further subjected to a development process to form an electrode portion 3 and an insulator portion or a magnetic portion (5) having a predetermined thickness on the substrate 1.
- the ceramic green sheets obtained by removing the substrate 1 from these sheets are sequentially laminated (Step 6).
- the laminated ceramic inductor is obtained by pressing the laminated ceramic green sheets from the thickness direction (Step 7), firing them (Step 8), and forming terminal electrodes and the like outside the laminated ceramic green sheets.
- the number of layers may increase in order to obtain an inductor having desired characteristics.
- the number of connection points of the electrode portion between the layers may increase, and the connection reliability and the like may be reduced.
- the width (thickness in the direction of the paper shown in the drawing) of the electrode portion 3A serving as the main body of the inductor becomes narrower, it becomes difficult to align the electrode portion 3A and the electrode portion 3B during lamination. It is possible.
- Figures 11A and 11B show an inductive manufacturing method to deal with such a case. Specifically, the third application example shown in Fig. 5 is applied. In the method shown in FIG.
- the boost electrode portion 3 in FIG. 5 becomes the boost electrode portion 3B and the pattern electrode portion 7 becomes the frame-shaped pattern electrode portion 3A.
- a ceramic green sheet including the post electrode portion 3B and the pattern electrode portion 3A joined to the post electrode portion 3B shown in Step 25 is obtained according to the steps shown in the second application example. As shown in Steps 6 to 8, the sheets are alternately laminated, pressurized, fired, and then the terminal electrodes and the like are formed outside the laminated sheet, whereby a laminated ceramic inductor having higher lamination accuracy can be obtained.
- the inductor by this method, the number of stacked layers is reduced, and the number of connection points of the electrode portions between the layers is also reduced. As a result, the lamination accuracy can be easily improved, and the connection reliability can be improved.
- a layer including the post electrode 3A may be formed by a conventional technique as shown in FIG. 11B. Specifically, a slurry solidified portion 5 is formed on the base 1 by a conventional method (Step 20 ′), and a through hole 3B ′ is formed thereon by mechanical punching, laser processing, or the like (Step 20). Step 21 ′), the layer is formed by filling the through hole 3B ′ with an electrode material.
- the through holes 3B may be formed by ordinary exposure, patterning, or the like.
- the ceramic green sheet according to the present invention it is possible to form a ceramic green sheet including internal electrodes and having excellent thickness uniformity. Since the ceramic green sheet according to the present invention is excellent in flatness, it is possible to reduce the press pressure in the step of pressing after lamination to 10 O kg / cm 2 or less. The value varies depending on the arrangement of the electrodes in the sheet, the material or viscosity of the photosensitive slurry, etc. In some cases, it can be reduced to 5 O kgZcm 2 or less. Therefore, the deformation at the time of pressurization is suppressed to a small value, and desired electrical characteristics can be obtained with high accuracy. In addition, the frequency of deformation such as delamination during firing caused by the pressure treatment can be significantly reduced. Also, since the press pressure is greatly reduced, the production equipment can be simplified, and the production cost can be greatly reduced.
- the metal material used for forming the internal electrode include powders of Ag, Ni, AgPd, Pd, Cu, and the like, and ethyl cellulose and the like as the organic binder, but the present invention is not limited thereto. It is desirable that the material be appropriately selected from various materials according to the electrical characteristics or the method of forming the electrode portion.
- the screen printing method has been described as an example of the method for forming the electrode portion, the electrode portion may be formed by so-called photo processing for performing exposure and development processes. According to this method, it is possible to control the shape, the formation position, and the like of the electrode portion with higher accuracy.
- FIGS. 12 and 13 show the base 1 and the electrode section 3 as viewed from the cross section, and the process proceeds according to the arrows in the figures.
- step 1 for example, an ultraviolet-sensitive electrode portion 13 made of a conductive metal powder and an organic binder is formed on the base 1 to form an electrode portion.
- step 2 the pattern of the electrode unit 3 is exposed by irradiating ultraviolet rays through the photomask 15. By developing this, the electrode portion 3 can be formed with high accuracy. By performing the above steps, it is possible to control the shape, the formation position, and the like of the electrode portion with higher accuracy.
- the cross-sectional shape of the electrode not only forming a vertical side surface, but also tapering, etc. can be easily performed, so that by adjusting these, the integration between the electrode and the slurry-solidified portion can be improved. Expected.
- the formation portion of the photosensitive electrode portion 13 is limited to some extent by using screen printing or the like in advance.
- the photosensitive electrode portion 13 By forming the photosensitive electrode portion 13 only in the vicinity of the position, it is possible to reduce the amount of photosensitive electrode material, developer used, and the like, and to reduce the cost as a process.
- the amount of photosensitive electrode material to be removed by development is reduced, the effect of shortening the time required for development can be obtained.
- an organic binder having negative-type characteristics and a dielectric material, particularly barium titanate have been described herein, but the present invention is not limited to these materials. It is desirable that the organic binder is appropriately determined in consideration of various characteristics such as exposure characteristics, viscosity, and releasability. Furthermore, the present invention is applicable not only to capacitors and inductors, but also to various laminated ceramic electronic components such as resistors, Paris, thermistors, and piezoelectric elements. Therefore, the powder material applied to the present invention also has various electrical properties, such as dielectric materials, glass materials, ferrite materials, and other ceramic materials including metal oxides, having desired electrical characteristics, depending on the application. Materials can be used.
- the electrode portion is used as a mask at the time of the exposure processing.
- the present invention is not limited to this, and not only the electrode material but also a material that does not transmit light used for the exposure processing is used. It is preferable to use various materials such as a ferrite material according to desired electric characteristics and the like.
- a photosensitive slurry is used to form a layer made of a dielectric material, but various methods can be used as long as the photosensitive material is attached to and formed on the base, such as by attaching a photosensitive sheet to the base. Is applicable.
- a layer obtained by implementing the present invention may be used for a part of the plurality of layers.
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- Microelectronics & Electronic Packaging (AREA)
- Power Engineering (AREA)
- Condensed Matter Physics & Semiconductors (AREA)
- Ceramic Engineering (AREA)
- Physics & Mathematics (AREA)
- Chemical & Material Sciences (AREA)
- General Physics & Mathematics (AREA)
- Computer Hardware Design (AREA)
- Inorganic Chemistry (AREA)
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Abstract
Description
Claims
Priority Applications (1)
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US10/543,710 US7540931B2 (en) | 2003-01-31 | 2004-01-30 | Method of producing ceramic green sheet and method of producing electronic component using this ceramic green sheet |
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JP2003023245 | 2003-01-31 | ||
JP2003-023245 | 2003-01-31 | ||
JP2003282557A JP3683891B2 (ja) | 2003-01-31 | 2003-07-30 | セラミックグリーンシートの製造方法および当該セラミックグリーンシートを用いた電子部品の製造方法 |
JP2003-282557 | 2003-07-30 |
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PCT/JP2004/000950 WO2004068516A1 (ja) | 2003-01-31 | 2004-01-30 | セラミックグリーンシートの製造方法および当該セラミックグリーンシートを用いた電子部品の製造方法 |
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US (1) | US7540931B2 (ja) |
JP (1) | JP3683891B2 (ja) |
TW (1) | TWI286330B (ja) |
WO (1) | WO2004068516A1 (ja) |
Cited By (1)
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US8426249B2 (en) | 2004-12-13 | 2013-04-23 | Panasonic Corporation | Chip part manufacturing method and chip parts |
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US7467928B2 (en) * | 2002-12-12 | 2008-12-23 | Board Of Trustees Of The University Of Arkansas | Microfluidic device utilizing magnetohydrodynamics and method for fabrication thereof |
US20050079450A1 (en) * | 2003-08-28 | 2005-04-14 | Tdk Corporation | Method for manufacturing ceramic green sheet and method for manufacturing electronic part using that ceramic green sheet |
JP2006173163A (ja) * | 2004-12-13 | 2006-06-29 | Matsushita Electric Ind Co Ltd | チップコイル |
US20060163774A1 (en) * | 2005-01-25 | 2006-07-27 | Norbert Abels | Methods for shaping green bodies and articles made by such methods |
DE102010035488B4 (de) * | 2010-08-26 | 2018-11-15 | Snaptrack, Inc. | Herstellung von keramischen Grünfolien sowie deren Verwendung zur Herstellung von Keramiken |
WO2012161058A1 (ja) * | 2011-05-20 | 2012-11-29 | パナソニック株式会社 | 有機エレクトロルミネッセンス素子 |
CN103891421B (zh) * | 2011-11-03 | 2018-06-22 | 陶瓷技术有限责任公司 | 具有铜结构的AlN印制电路板及其制备方法 |
KR20150005292A (ko) * | 2013-07-05 | 2015-01-14 | 삼성전기주식회사 | 코일 부품 |
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US7540931B2 (en) | 2009-06-02 |
JP2004253771A (ja) | 2004-09-09 |
JP3683891B2 (ja) | 2005-08-17 |
US20060213602A1 (en) | 2006-09-28 |
TW200423163A (en) | 2004-11-01 |
TWI286330B (en) | 2007-09-01 |
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