3D Structures with Tunable Micro-porosity for High Temperature Stability
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Solution Overview
Problem
Current 3-D printed structures lack high temperature stability and low permittivities over a broad range of electromagnetic frequencies, making them unsuitable for high temperature communication applications.
Innovation Solution
The development of 3-D structures with tunable micro-porosity achieved through the judicious selection of 3-D printing ink and processing conditions, where the air in micro-pores acts as a dielectric modifier, maintaining low permittivities across a broader range of electromagnetic frequencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If 3-D structures are made from high temperature polymers, then high temperature stability is improved, but permittivity remains high and does not maintain low values over a broad range of electromagnetic frequencies
Solution Approach 1:
The patent applies porous materials by incorporating micro-pores into the 3-D printed structure made from high temperature polymers. The air-filled micro-pores act as dielectric modifiers that reduce and stabilize permittivity across a broad range of electromagnetic frequencies while preserving the high temperature stability of the polymer matrix.
Solution Approach 2:
The patent creates composite materials by combining high temperature polymers with air-filled micro-pores. This composite structure integrates the thermal stability of the polymer with the dielectric properties of air, achieving both high temperature stability and low, frequency-stable permittivity.
2Reliability
If micro-porosity is added to 3-D structures, then permittivity is reduced over a broader frequency range, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by incorporating porosity-generating agents into the printing ink formulation before the 3-D printing process. This allows micro-pores to form automatically during or after printing through phase separation or solvent evaporation, eliminating the need for subsequent complex post-processing steps to create pores.
Solution Approach 2:
The patent applies parameter changes by modifying the chemical composition of the printing ink to include porosity-generating components. By changing the ink's physical and chemical parameters, the printing process itself generates the desired micro-porous structure, simplifying manufacturing while achieving the target permittivity properties.
3Ease of manufacture
If conventional 3-D printing inks are used, then manufacturing is simple, but micro-porosity cannot be controlled or tuned
Solution Approach 1:
The patent applies parameter changes by formulating printing inks with adjustable compositional parameters, including porosity-generating agents, solvents, and polymer concentrations. These compositional parameters can be tuned to control the amount, size, and distribution of micro-pores, enabling versatile control over dielectric properties while maintaining the simplicity of the printing process.
Solution Approach 2:
The patent develops composite printing inks that combine polymers, solvents, and porosity-generating agents in adjustable ratios. By varying the composition parameters of this composite ink system, manufacturers can tune the resulting micro-porosity to achieve specific permittivity values and frequency responses without complicating the printing process.
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 resulting 3-D structures exhibit improved high temperature stability and low permittivities, enhancing communication performance in high temperature environments, particularly in communication devices like array antennas.
Implementation Method 1
the air in the 3-D structure's micro-pores acts as a dielectric modifier. Thus, low permittivities over a broader range of electromagnetic frequencies can be obtained from the 3-D structure
Data Source
AI summary
The present invention relates to 3-D structures having high temperature stability and improved micro-porosity as well as processes of making and using same. The disclosed 3-D are advantageous because they have low densities and low permittivities. When compared to previous 3-D structures, the present structures maintain their low permittivities over a broader range of electromagnetic frequencies. Thus, when used in communication devices such as array antennas, can provided higher communication performance in high temperature environments.