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The magical transformation of ceramics: Do you know how to make high-efficiency capacitors using thin film technology?
Capacitors play a vital role in electronic products. As technology continues to advance and demand grows, methods for manufacturing high-efficiency capacitors are also evolving. Among them, thin-film technology is valued for its ability to produce ceramic capacitors with excellent performance. The process involves a series of steps, including preparation of ceramic slurry, casting and sintering.
The rise of thin film technology has opened new doors for the application of ceramic materials.
Historical Background of Thin Film Technology
The use of thin film technology dates back to the early 20th century, but it was first used in mass production of capacitors in 1947. At that time, a machine capable of extruding ceramic slurry on a moving belt and forming thin sheets laid the foundation for further research and product development. By 1960, the first patent for multilayer film casting was filed, and in 1996, the first films below 5 microns were produced.
Detailed explanation of the production process
The process of film casting can be simply summarized as converting ceramic powder into film. The main steps include:
- Make a slurry from the powder.
- Pour the slurry onto a flat surface to form a thin film.
- Dry to remove solvent.
- Cut and punch to create desired shapes.
- Multiple layers of green film are laminated together under specific conditions.
- Sintered to obtain final properties.
This process is undoubtedly part of powder metallurgy and plays an important role in the demand for high-performance capacitors.
Preparation of slurry and its composition
The key to thin film casting lies in the preparation of ceramic slurry. The ingredients of these slurries include ceramic powder, solvents, plasticizers and other additives. The particle size of the powder is usually small, not exceeding 5 microns at most, to ensure the quality of casting. In the preparation process of slurry, in addition to powder, the selection of binding materials and surfactants is also crucial, as these materials will affect the structure and properties of the final product.
Process from slurry to film
During the pouring process, the slurry is transported from the storage tank to the pouring machine through a pipe. To ensure the quality of the film, the slurry is filtered before casting to remove imperfect particles. The slurry that has been poured is called green layer, which requires further processing such as drying and cutting. To achieve a flat surface, different pouring mechanisms are used, using blades called “doctor’s knives” whose shape and the angle at which they are placed affect the quality of the final product.
Challenges in the drying process
The drying process of the green layer is usually carried out from only one side, which leads to the problem of uneven drying. Drying relies on evaporation and diffusion of the solvent and must be performed in a controlled environment to avoid cracking or warping of the film. A well-controlled drying process is key to producing a consistent and high-quality product.
Application Areas
Thin film casting technology is currently widely used in ceramic capacitors, polymer batteries, photovoltaic technology, and electrodes for molten carbonate fuel cells. Thin films with a thickness of up to 5 micrometers show great potential in electronic devices.
SummaryWith the advancement of science and technology, ceramic thin film technology not only improves the performance of capacitors, but also lays the foundation for the development of other high-tech products. Through continued research, more innovative and effective ceramic application methods may emerge in the future, which makes us wonder: in the near future, how can these technologies break through existing boundaries and change our lives?
