Barium Titanate Precursor Printing to Prevent Nozzle Clogging
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Solution Overview
Problem
Existing methods for manufacturing passive electrical components, such as multi-layer ceramic capacitors, face challenges in integrating them with integrated circuits due to high temperatures and material incompatibilities, leading to nozzle clogging in additive printing processes.
Innovation Solution
The use of barium titanate precursors, prepared through electrical-assisted breakdown processes like milling and grinding, combined with a solvent, plasticizer, and dispersant, prevents nozzle clogging by forming a non-ferroelectric material that allows for precise and dense integration of components like capacitors, inductors, and resistors into ceramic chip packages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If barium titanate precursor materials are used in additive printing, then manufacturing precision and component density are improved, but nozzle clogging occurs due to material buildup
Solution Approach 1:
The patent changes the chemical composition parameters of the printing material from finished barium titanate to precursor materials (barium carbonate and titanium dioxide). This parameter change fundamentally alters the material properties during printing, preventing clogging while maintaining the ability to form dense components after sintering.
Solution Approach 2:
The precursor materials act as intermediaries in the manufacturing process. Instead of printing the final barium titanate material directly, the patent uses precursor compounds that are chemically transformed during sintering. These intermediaries enable the printing process to proceed without clogging while still producing the desired final material.
2Ease of manufacture
If traditional photolithography methods are used, then manufacturing process is simpler, but integration with ceramic chip packages at high temperatures is not achievable
Solution Approach 1:
The patent makes the ceramic block serve multiple functions: it acts as both the structural package housing and the substrate for integrating passive components. This multi-functionality allows the same ceramic material to provide mechanical protection while also serving as the foundation for high-temperature component integration, eliminating the need for separate substrates.
3Temperature
If ceramic slurry is used for printing passive components, then high temperature sintering is achievable, but material waste increases compared to photolithography
Solution Approach 1:
The patent applies material deposition only where passive components are needed on the ceramic block, rather than applying ceramic slurry uniformly across the entire surface. This localized deposition approach minimizes material waste by placing material precisely at the required locations for capacitors, inductors, and resistors.
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
This method enables precise, dense, and efficient integration of passive components without nozzle clogging, enhancing dielectric strength and mechanical properties of the final products.
Implementation Method 1
A solid-state reaction between barium carbonate and titanium dioxide to form barium titanate is activated by the application of heat
Implementation Method 2
Solids of barium carbonate and titanium dioxide are prepared by an electrical-assisted breakdown process, such as, e.g., milling, blending, and/or grinding
Implementation Method 3
A solid-state reaction between barium carbonate and titanium dioxide to form barium titanate is activated by the application of heat, such as, e.g., through a sintering process
Data Source
AI summary
Systems and methods for additive printing of barium titanate (BaTiO3) components using precursors of barium titanate, i.e., barium carbonate (BaCO3) and titanium dioxide (TiO2), to prevent clogging of nozzles. Solid of barium carbonate and titanium dioxide are prepared by an electrical-assisted breakdown process, such as, e.g., milling, blending, and/or grinding. The assisted breakdown process allows for the reduction of particle size, thorough mixing, and consistent particle distribution of the precursors. In addition, the finer particles possess a much higher sinterability of the precursors while giving rise to denser final products. A planetary ball milling system with zirconia vial and balls at a fixed rotation speed may be used. The precursors are then printed into a green part. A solid-state reaction between barium carbonate and titanium dioxide to form barium titanate is activated by the application of heat, such as, e.g., through a sintering process, which forms the final product.