3D-Printable Piezoceramic Paste With High Ceramic Loading
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Solution Overview
Problem
Existing piezoelectric ceramics are brittle, fragile, and require costly, complex manufacturing processes, limiting their broader application and integration into devices.
Innovation Solution
A formulation comprising ceramic particles, a sol-gel, and a polymer binder, which can be printed using 3D printing techniques, allowing for high ceramic content and improved piezoelectric performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional sputtering processes are used to manufacture piezoelectric ceramics, then manufacturing precision and material quality are improved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent replaces complex mechanical sputtering processes with a chemical sol-gel formulation approach. The sol-gel chemistry enables precise control of piezoelectric material properties through chemical composition rather than complex physical deposition processes, thereby maintaining manufacturing precision while reducing process complexity
Solution Approach 2:
The patent changes the fundamental processing parameters from high-temperature sputtering (>250°C) to lower-temperature sol-gel processing. By modifying the chemical composition and processing temperature parameters, the patent achieves comparable material quality through a simpler chemical pathway rather than complex physical vapor deposition
2Manufacturing precision
If high-temperature sintering is applied to ceramic piezoelectric materials, then material density and piezoelectric properties are improved, but energy consumption and manufacturing cost increase
Solution Approach 1:
The patent fundamentally changes the temperature parameter from high-temperature sintering (>250°C) to lower-temperature sol-gel processing. The sol-gel chemistry enables material densification and piezoelectric property development at reduced temperatures, thereby maintaining material quality while significantly reducing energy consumption
Solution Approach 2:
The patent replaces thermal sintering with chemical sol-gel transformation. Instead of relying on high thermal energy for densification, the patent uses chemical reactions and controlled drying processes to achieve material consolidation, substituting a high-energy thermal process with a lower-energy chemical pathway
3Manufacturing precision
If ceramic piezoelectric materials are used, then piezoelectric performance is improved, but brittleness and processability worsen
Solution Approach 1:
The patent creates a composite sol-gel formulation containing ceramic particles suspended in a polymer matrix. This composite structure combines the piezoelectric performance of ceramic materials with the flexibility and processability of polymers, enabling both high performance and ease of manufacturing through additive processes
Solution Approach 2:
The patent changes the physical state parameter from brittle solid ceramic to processable sol-gel slurry. By transforming the material into a fluid or semi-fluid sol-gel state, the patent enables additive manufacturing and complex shaping operations that are impossible with traditional brittle ceramics, while maintaining piezoelectric functionality
4Adaptability or versatility
If additive manufacturing is used for piezoelectric components, then design freedom and integration are improved, but manufacturing precision and material quality worsen
Solution Approach 1:
The patent uses a composite sol-gel formulation that maintains piezoelectric ceramic performance while enabling additive manufacturing. The sol-gel matrix allows the material to be extruded and deposited in complex 3D geometries, and subsequent controlled drying and sintering preserve material quality, thereby achieving both design freedom and manufacturing precision
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The formulation enables the production of self-supporting piezoelectric structures with high ceramic loading, minimizing cracking and enhancing piezoelectric response through annealing, thus facilitating easier integration and cost-effective manufacturing.
Implementation Method 1
A formulation comprising ceramic particles, a sol-gel, and a polymer binder, with a high boiling point solvent, is developed for 3D printing
Implementation Method 2
the ceramic particles are suspended in a sol-gel matrix that transforms into piezoelectric material upon sintering
Implementation Method 3
Piezoelectric materials are able to convert mechanical pressure into electric potential (e.g., pressure sensor)
Implementation Method 4
by the inverse piezoelectric effect, electric potential to a mechanical distortion
Data Source
AI summary
The present disclosure is directed towards a formulation for piezoelectric materials. The formulation may be printed including 2D or 3D printing. The formulation contains ceramic particles, a sol-gel, a high boiling point solvent and a binder.