Hydraulic Cement Casing Crack Prevention via Fibrous Segmentation

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Solution Overview

Problem

Encasing electronic objects with hydraulically hardened inorganic cement compositions often results in uneven, deep cracks on the external visible surface due to thermomechanical warping and shrinkage during curing, which can lead to moisture ingress and damage.

Innovation Solution

Incorporating a division on the essential external visible surface or within the immediate substrate of the casing, using a hydraulically hardened inorganic cement composition, to mitigate crack formation, potentially with a sheet structure having openings or a dividing element that penetrates or is embedded within the cement layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electronic objects are encased with hydraulically hardened inorganic cement composition, then electrical insulation and protection from external influences is improved, but uneven deep cracks form on the external visible surface due to thermomechanical warping and shrinkage

Engineering Contradiction:

Improveprotection from moisture ingressVSAvoidsurface crack uniformity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The cement composition is segmented by incorporating a fibrous reinforcement phase that distributes and localizes shrinkage stresses throughout the matrix, preventing the formation of continuous crack paths. The fibers create a discontinuous structure that interrupts crack propagation while maintaining overall structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A composite material system is employed combining the hydraulically hardened inorganic cement matrix with a fibrous reinforcement phase. This composite structure leverages the complementary properties of both materials: the cement provides hydraulic hardening and chemical resistance, while the fibers provide tensile strength and crack bridging capability.

Inventive Principle:

Principle #40Composite materials

2Reliability

If additional potting materials are used to seal cracks, then moisture protection is improved, but device complexity and manufacturing steps increase

Engineering Contradiction:

Improvemoisture protectionVSAvoidnumber of coating layers

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The protective function previously requiring separate potting materials is merged into the primary cement coating itself. The fibrous reinforcement phase is incorporated directly into the cement composition during manufacturing, creating a single integrated coating that provides both structural integrity and moisture protection without requiring additional sealing layers.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cement-fiber composite coating is self-sufficient and does not require additional potting materials or secondary sealing operations. The fibrous reinforcement enables the coating to self-heal microcracks through fiber bridging and maintains its protective function inherently, eliminating the need for separate moisture-sealing steps.

Inventive Principle:

Principle #25Self-service

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 approach prevents undesirable crack formation, enhancing the structural integrity and water resistance of the casing, thereby protecting the internal electronic components without the need for additional potting materials.

Implementation Method 1

The term 'hydraulic hardening' used herein means setting in the presence of water or after the addition of water. An aqueous hydraulically curable inorganic cement preparation can harden hydraulically to form a hydraulically cured inorganic cement composition in the form of a hard solid

Methodology Applied

Scientific EffectHydraulic hardening: Mineral Hydration

Implementation Method 2

the casing made of the hydraulically hardened inorganic cement composition can dissipate heat from an electronic object encased in it, for example from an electronic assembly comprising active electronic components encased in it, during its operation

Methodology Applied

Scientific EffectHeat dissipation: Conduction (thermal)

Data Source

PatentEP4095894A1Electronic object with a coating of a hydraulically hardened inorganic material

Publication Date: 2022.11.30 HERAEUS ELECTRONICS GMBH & CO KG

AI summary

Electronic object with a casing having at least one substantial external visible surface made of a hydraulically hardened inorganic cement composition, wherein the respective substantial external visible surface of the casing is subdivided on its surface and/or within its immediate substrate.