Ceramic Green Sheet Lamination for Complex 3D Structures
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Solution Overview
Problem
Existing methods for producing ceramic green sheets and laminates struggle to efficiently form complex three-dimensional shapes and spaces, such as conductors or cavities, with precise control and uniformity, especially when dealing with multiple layers.
Innovation Solution
A ceramic green sheet production method involving the molding and solidification of a ceramic slurry with a gelling agent, where a distinct body is exposed on both surfaces, allowing for the formation of conductors or cavities that connect or remain separate, enabling the creation of complex three-dimensional structures upon firing. This method includes the use of molding dies with adjustable mold release forces and peeling forces to facilitate layering and handling of the sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional gelcasting process is used to form ceramic green sheets, then ceramic components can be produced, but complex three-dimensional shapes and spaces cannot be efficiently formed with precise control
Solution Approach 1:
The ceramic green sheet is segmented into multiple layers, with conductive paste layers and ceramic paste layers alternately stacked. This segmentation allows complex three-dimensional shapes to be constructed layer by layer, enabling precise control of the final geometry while maintaining production efficiency through standardized layering procedures
Solution Approach 2:
Conductive paste patterns and space-forming structures are prepared in advance as separate layers before stacking. The conductive paste is applied and dried to form predetermined patterns, and space-forming structures are created by selective omission of ceramic paste in specific regions. These preliminary actions enable precise three-dimensional shaping without requiring complex in-situ forming processes
2Shape
If multiple ceramic green sheets are laminated to form complex structures, then three-dimensional shapes can be created, but deformation occurs during handling and stacking
Solution Approach 1:
A release paper is introduced as an intermediary layer between the ceramic green sheet and the molding die. This release paper prevents direct adhesion between the green sheet and die surface, allowing the sheet to be easily removed and handled without deformation. The release paper acts as a temporary carrier that maintains sheet integrity during the lamination process
Solution Approach 2:
The adhesion characteristics of the molding die surface are modified by controlling the gelation process and using release papers, changing the interaction parameters between the green sheet and die. This allows the sheet to be firmly held during molding but easily released afterward, preventing deformation during handling while maintaining structural integrity
3Device complexity
If ceramic slurry is molded and solidified to form green sheets, then flat-plate structures are obtained, but complex internal structures like conductors and cavities cannot be formed
Solution Approach 1:
The ceramic component is divided into multiple functional layers: conductive paste layers for electrical pathways, ceramic paste layers for structural support, and space-forming layers for cavities. Each layer is manufactured separately with simple processes, then stacked to create the final complex internal structure. This segmentation maintains manufacturing simplicity while achieving device complexity
Solution Approach 2:
Complex three-dimensional structures are achieved by adding the stacking dimension to simple two-dimensional layers. Conductive patterns, cavities, and other complex features are created by varying the arrangement and composition of layers in the stacking direction, transforming simple planar manufacturing into complex volumetric structures
4Reliability
If molding dies with high adhesion are used to ensure sheet integrity, then green sheets maintain structural stability, but sheet release and handling become difficult
Solution Approach 1:
Release paper serves as an intermediary layer between the green sheet and molding die, providing controlled adhesion. The release paper maintains sheet integrity during molding through sufficient adhesion, then allows easy release through its low-friction surface. This intermediary resolves the contradiction between needing strong adhesion for stability and weak adhesion for easy release
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
Enables the formation of ceramic components with continuous complex three-dimensional shapes or cavities, improving the precision and efficiency in producing electronic components like coils, inductors, and antennas, while preventing deformation and ensuring easy handling and release from the molding dies.
Implementation Method 1
a ceramic slurry containing a ceramic powder, a dispersion medium, and a gelling agent is subject to molding in a mold, and the resulted molded ceramic slurry is solidified (gelated) to form a ceramic green body
Implementation Method 2
the ceramic paste contains ceramic powder, an organic solvent, and an organic binder
Data Source
Figure 1
Figure 2
Figure 3(a)~3(d)
AI summary
The present invention provides a ceramic green sheet with a thin flat plate shape obtained by molding and solidifying a ceramic slurry, which contains a ceramic powder, dispersion medium, and gelling agent, into a thin flat plate. The ceramic green sheet partially includes a body that is obtained by molding and solidifying a conductor paste, which becomes a conductor later, and the body is exposed on a part of each of the both surfaces of the sheet. Plural ceramic green sheets described above are produced. The plural ceramic green sheets are successively stacked and press-bonded in the thickness direction in such a manner that the bodies included in the respective sheets are connected to each other for all combinations of the adjacent two sheets. As a result, a ceramic green sheet laminate is formed, which includes one body that is obtained by connecting the bodies included in the respective sheets.