No.1 Application Background
Electronic components such as varistors, thermistors, and ceramic dielectric capacitors are widely used in consumer electronics, automotive electronics, industrial control systems, and new energy applications. These fields place increasingly stringent requirements on electrode conductivity, uniformity, and long-term reliability.
At present, terminal electrodes for many of these components are still manufactured using silver paste screen printing. With rising material costs and higher performance standards, traditional thick-film silver electrode processes are gradually revealing their limitations. The industry is seeking a more stable, controllable, and cost-effective metallization technology.
No.2 Challenges of Traditional Processes
1. High precious metal consumption and increasing cost pressure
In silver paste printing, electrode thickness typically reaches around 20 μm, resulting in significant precious metal usage. Material cost is highly sensitive to fluctuations in silver prices.
2. Electrode consistency affected by process variation
The screen-printing process strongly depends on printing parameters, paste condition, and operator experience. Maintaining long-term stability in electrode thickness and morphology is difficult, which impacts product yield and batch-to-batch consistency.
3. Potential long-term reliability risks
Conventional thick silver electrodes are prone to silver ion migration and sulfidation under high temperature, high humidity, or sulfur-containing environments. These effects can lead to electrical degradation or even failure, posing risks for high-reliability applications.
4. Limited process automation
Silver paste printing relies heavily on manual expertise, with limited compatibility for high-level automation and continuous production. This constrains the transition toward large-scale, continuous manufacturing of electronic components.
No.3 Zhuhua Vacuum Electrode Process for Electronic Components Solution
To address the upgrade requirements of terminal electrode manufacturing, Zhuhua Vacuum has developed a dedicated continuous vacuum coating production line for ceramic capacitors and resistors. This system utilizes vacuum magnetron sputtering metallization to replace conventional silver paste printing, transforming electrode fabrication from thick-film printing to high-performance functional thin films.
With a continuous in-line vacuum coating architecture, the production line enables precise control of film thickness and microstructure. It ensures excellent electrical conductivity while significantly reducing metal consumption and greatly improving electrode uniformity and long-term reliability.
Continuous Thin-Film Coating Line for Ceramic Capacitors and Resistors
Equipment Advantages
1. Advanced Process Technology
The system adopts magnetron sputtering technology supported by proprietary patented designs. Within a single vacuum cycle, it can realize double-sided deposition of two or more metal layers, ensuring high-precision and highly uniform electrode formation.
2. Performance and Cost Benefits
Compared with traditional printed silver electrodes, sputtered copper metallization offers superior electrical performance and reliability. It effectively eliminates silver ion migration risks and provides strong resistance to sulfidation, while significantly reducing material costs.
The horizontal continuous coating line can be integrated with automated loading and unloading systems, supports multiple ceramic component sizes, and delivers high throughput and large production capacity.
3. Proven Process Expertise
With more than 30 years of experience in vacuum coating technology, Zhuhua Vacuum has established comprehensive process laboratories and an experienced engineering team. Our capabilities cover PVD, PECVD, ALD, and other advanced thin-film technologies, enabling full support from R&D validation and pilot production to mass manufacturing.
4. Customization and Confidentiality
Equipment configurations and coating processes can be flexibly customized according to customer requirements, with the ability to integrate multiple coating technologies. Strict measures are implemented to ensure protection of customer intellectual property and process confidentiality.
Application Scope
1.Ceramic dielectric capacitors
2. Varistors (MOV)
3. Thermistors (NTC/PTC)
4.Thin-film resistors
5. Other ceramic-based electronic components
Zhuhua Vacuum continuous thin-film metallization technology provides a high-uniformity, high-reliability, and cost-efficient electrode manufacturing solution for next-generation electronic components.
-This article was published by vacuum coating equipment manufacturer Zhenhua Vacuum
Post time: Jan-29-2026