MLCC的制造工藝流程與相關設備
這是一套多層陶瓷電容器（MLCC）的制造工藝流程。MLCC是廣泛應用于電子設備中的一種電容器，以其小型化、高可靠性和高電容密度而聞名。制造MLCC的過程包括多個步驟，從原料的混合和研磨開始，經(jīng)過流延、印刷、疊層、切割、排膠、燒結、倒角、封端、電鍍，到最終的電性能檢測和包裝。每個步驟都需要特定的設備來確保產(chǎn)品質(zhì)量和性能符合要求。
*MLCC主要設備及其功能 (Main Equipment and Their Functions):
- (1) 混料及研磨設備 (Mixing and Grinding Equipment)
- *功能 (Function)*: 將陶瓷粉進行分散混合，研磨均勻，達到所需要求的粒徑。
- *Function*: To disperse and mix ceramic powder to achieve a uniform particle size as required.
- (2) 砂磨機 (Sand Mill)
- *功能 (Function)*: 利用泵將預先在漿料桶內(nèi)經(jīng)高速攪拌混合的瓷漿輸入密閉的研磨腔體內(nèi)，與高速轉(zhuǎn)動研磨介質(zhì)接觸，加快磨細微粒和分散團聚體。
- *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) 真空脫泡機 (Vacuum Deairing Machine)
- *功能 (Function)*: 利用真空環(huán)境進行漿料的消泡處理，不需要添加除泡劑化學品，屬于物理消泡方法。
- *Function*: Performs defoaming of the slurry in a vacuum environment without the need for chemical defoamers, a physical defoaming method.
- (4) 三輥機 (Three-Roll Mill)
- *功能 (Function)*: 三輥機利用水平的三根輥筒的不同轉(zhuǎn)向和不同轉(zhuǎn)速形成的剪切力，對粘稠性材料進行研磨、分散、均質(zhì)；可進行在陶瓷漿料和電子漿料小尺寸粒徑制備。
- *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) 流延機 (Tape Casting Machine)
- *功能 (Function)*: 將漿體均勻涂在薄膜上流延形成生瓷帶；對精度及穩(wěn)定性要求極高；屬于國產(chǎn)化“卡脖子”設備，日本高端產(chǎn)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) 印刷機 (Printing Machine)
- *功能 (Function)*: 通過絲網(wǎng)設備將內(nèi)電極漿料印刷到陶瓷膜片上，烘干后得到清晰、完整的介質(zhì)膜片。需要配合精密網(wǎng)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) 疊層機 (Lamination Machine)
- *功能 (Function)*: 將印刷好電極的流延漿體塊依照容值的不同疊加起來，形成電容坯體版。
- *Function*: Stacks the printed and tape-cast slurry blocks according to different capacitance values to form a capacitor green body plate.
- (8) 層壓機 (Press Machine)
- *功能 (Function)*: 一般采用水等靜壓機，使多層的坯體版能夠結合緊密。
- *Function*: Typically uses a hydrostatic press to bond multi-layer green body plates tightly.
- (9) 切割機 (Cutting Machine)
- *功能 (Function)*: 將坯體版切割成單體的坯體；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) 排膠、燒結設備 (Debinder and Sintering Equipment)
- *功能 (Function)*: 通過控制爐子內(nèi)部的氣氛及溫度，使化學試劑排出，陶瓷粉體致密化。
- *Function*: Controls the furnace atmosphere and temperature to expel chemical reagents and densify the ceramic powder.
- (11) 倒角機 (Chamfering Machine)
- *功能 (Function)*: 將方體的棱角磨掉，并且將電極露出來，形成倒角，方便外部連接。
- *Function*: Removes the edges of the rectangular body and exposes the electrodes to form chamfers for easy external connection.
- (12) 封端機 (Sealing Machine)
- *功能 (Function)*: 通過封端機，將端漿涂覆在經(jīng)倒角處理后的芯片外露內(nèi)部電極的兩端上，將同側(cè)內(nèi)部電極連接起來形成外部電極。
- *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) 電鍍設備 (Electroplating Equipment)
- *功能 (Function)*: 將陶瓷電容初體電極端（銅端或銀端）電鍍上一層薄薄的鎳層；一般有鍍籠式和振盤式。
- *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) 電性能檢測設備 (Electrical Property Testing Equipment)
- *功能 (Function)*: 針對電容產(chǎn)品的容量、損耗、絕緣、耐壓四個方面的性能，對產(chǎn)品進行100%測試和分選，將不良品剔除，同時按不同容量范圍分選出來。
- *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) 外觀及內(nèi)部檢測設備 (Appearance and Internal Inspection Equipment)
- *功能 (Function)*: 六面體檢測設備可檢測MLCC產(chǎn)品的外觀是否有開裂，沾污，破損等；超聲掃描成像系統(tǒng)可檢測內(nèi)部結構缺陷。
- *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) 編帶包裝機 (Taping and Packaging Machine)
- *功能 (Function)*: 編帶工程是將測試后的MLCC編入載帶，并按固定數(shù)量卷成一個膠盤。編帶是為了方便SMT制程中大量高速的自動貼裝生產(chǎn)。
- *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.
