MLCC的制造工艺流程与相关设备
这是一套多层陶瓷电容器(MLCC)的制造工艺流程。MLCC是广泛应用于电子设备中的一种电容器,以其小型化、高可靠性和高电容密度而闻名。制造MLCC的过程包括多个步骤,从原料的混合和研磨开始,经过流延、印刷、叠层、切割、排胶、烧结、倒角、封端、电镀,到最终的电性能检测和包装。每个步骤都需要特定的设备来确保产品质量和性能符合要求。
*MLCC主要设备及其功能 (Main Equipment and Their Functions):
- (1) 混料及研磨设备 (Mixing and Grinding Equipment)
- *功能 (Function)*: 将陶瓷粉进行分散混合,研磨均匀,达到所需要求的粒径。
- *Function*: To disperse and mix ceramic powder to achieve a uniform particle size as required.
- (2) 砂磨机 (Sand Mill)
- *功能 (Function)*: 利用泵将预先在浆料桶内经高速搅拌混合的瓷浆输入密闭的研磨腔体内,与高速转动研磨介质接触,加快磨细微粒和分散团聚体。
- *Function*: Utilizes a pump to transfer the previously mixed slurry in the tank to a sealed grinding chamber, where it contacts high-speed grinding media to accelerate the grinding of fine particles and dispersion of agglomerates.
- (3) 真空脱泡机 (Vacuum Deairing Machine)
- *功能 (Function)*: 利用真空环境进行浆料的消泡处理,不需要添加除泡剂化学品,属于物理消泡方法。
- *Function*: Performs defoaming of the slurry in a vacuum environment without the need for chemical defoamers, a physical defoaming method.
- (4) 三辊机 (Three-Roll Mill)
- *功能 (Function)*: 三辊机利用水平的三根辊筒的不同转向和不同转速形成的剪切力,对粘稠性材料进行研磨、分散、均质;可进行在陶瓷浆料和电子浆料小尺寸粒径制备。
- *Function*: Uses the shearing force created by the different directions and speeds of the three horizontally mounted rollers to grind, disperse, and homogenize viscous materials, suitable for fine ceramic and electronic paste preparation.
- (5) 流延机 (Tape Casting Machine)
- *功能 (Function)*: 将浆体均匀涂在薄膜上流延形成生瓷带;对精度及稳定性要求极高;属于国产化“卡脖子”设备,日本高端产品可以做到1µm。
- *Function*: Evenly applies the slurry onto a film to form a green ceramic tape; requires high precision and stability. High-end Japanese products can achieve 1µm precision.
- (6) 印刷机 (Printing Machine)
- *功能 (Function)*: 通过丝网设备将内电极浆料印刷到陶瓷膜片上,烘干后得到清晰、完整的介质膜片。需要配合精密网版一起使用。
- *Function*: Uses a screen printing device to print the internal electrode paste onto the ceramic film, resulting in a clear and complete dielectric film after drying. Requires precise mesh screens for use.
- (7) 叠层机 (Lamination Machine)
- *功能 (Function)*: 将印刷好电极的流延浆体块依照容值的不同叠加起来,形成电容坯体版。
- *Function*: Stacks the printed and tape-cast slurry blocks according to different capacitance values to form a capacitor green body plate.
- (8) 层压机 (Press Machine)
- *功能 (Function)*: 一般采用水等静压机,使多层的坯体版能够结合紧密。
- *Function*: Typically uses a hydrostatic press to bond multi-layer green body plates tightly.
- (9) 切割机 (Cutting Machine)
- *功能 (Function)*: 将坯体版切割成单体的坯体;目前有主流微刀片切割方式。
- *Function*: Cuts the green body plate into individual green bodies using the mainstream micro-blade cutting method.
- (10) 排胶、烧结设备 (Debinder and Sintering Equipment)
- *功能 (Function)*: 通过控制炉子内部的气氛及温度,使化学试剂排出,陶瓷粉体致密化。
- *Function*: Controls the furnace atmosphere and temperature to expel chemical reagents and densify the ceramic powder.
- (11) 倒角机 (Chamfering Machine)
- *功能 (Function)*: 将方体的棱角磨掉,并且将电极露出来,形成倒角,方便外部连接。
- *Function*: Removes the edges of the rectangular body and exposes the electrodes to form chamfers for easy external connection.
- (12) 封端机 (Sealing Machine)
- *功能 (Function)*: 通过封端机,将端浆涂覆在经倒角处理后的芯片外露内部电极的两端上,将同侧内部电极连接起来形成外部电极。
- *Function*: Uses a sealing machine to apply end paste to the exposed internal electrodes at both ends of the chip after chamfering, connecting the same side internal electrodes to form an external electrode.
- (13) 电镀设备 (Electroplating Equipment)
- *功能 (Function)*: 将陶瓷电容初体电极端(铜端或银端)电镀上一层薄薄的镍层;一般有镀笼式和振盘式。
- *Function*: Electroplates a thin nickel layer onto the initial ceramic capacitor ends (copper or silver ends). Common methods include cage plating and vibratory plating.
- (14) 电性能检测设备 (Electrical Property Testing Equipment)
- *功能 (Function)*: 针对电容产品的容量、损耗、绝缘、耐压四个方面的性能,对产品进行100%测试和分选,将不良品剔除,同时按不同容量范围分选出来。
- *Function*: Tests and sorts 100% of the products for capacitance, loss, insulation, and withstand voltage, removing defective products and sorting them into different capacitance ranges.
- (15) 外观及内部检测设备 (Appearance and Internal Inspection Equipment)
- *功能 (Function)*: 六面体检测设备可检测MLCC产品的外观是否有开裂,沾污,破损等;超声扫描成像系统可检测内部结构缺陷。
- *Function*: The six-sided body inspection equipment can detect cracks, contamination, and damage on the appearance of MLCC products; the ultrasonic scanning imaging system can detect internal structural defects.
- (16) 编带包装机 (Taping and Packaging Machine)
- *功能 (Function)*: 编带工程是将测试后的MLCC编入载带,并按固定数量卷成一个胶盘。编带是为了方便SMT制程中大量高速的自动贴装生产。
- *Function*: Taping involves inserting tested MLCCs into a tape and rolling them into a plastic tray in fixed quantities for convenient high-speed automatic mounting in the SMT process.