Ceramic Exterior Part Lamination for Portable Devices
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional tape casting methods are limited in forming ceramic exterior parts for portable devices due to viscosity constraints, resulting in maximum thicknesses less than 0.8 mm and potential deformations or cracks, making it unsuitable for thicker, stronger ceramic components.
Innovation Solution
A method involving the preparation of a casting slurry with specific compositions and processing steps, including high-speed rotation for defoaming, tape casting, lamination, dry pressing, and firing, to achieve a thicker, uniform ceramic green tape lamination that can be shaped and fired to produce a strong, thin ceramic exterior part with a thickness greater than 0.8 mm without deformations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If conventional tape casting method is used, then thin ceramic films can be produced, but the thickness is limited to less than 0.8 mm and deformations or cracks occur
Solution Approach 1:
The patent divides the ceramic exterior part into multiple green tape laminations (first green tape lamination, second green tape lamination, etc.) that are stacked and bonded together. Each lamination can be produced within the reliable thickness range of tape casting (<0.8mm), while the composite structure achieves the desired total thickness (≥0.8mm) without deformations or cracks
Solution Approach 2:
Multiple green tape laminations are nested together in a stacked configuration, with each lamination containing ceramic particles and organic binder. The laminations are bonded through organic-organic bonding to form a integrated multi-layer structure that maintains structural integrity while achieving greater thickness
2Length of stationary object
If tape casting is used to increase thickness, then more material can be deposited, but viscosity constraints prevent forming thicker uniform structures
Solution Approach 1:
Instead of attempting to cast a single thick layer that would suffer from viscosity constraints and non-uniformity, the patent segments the thick structure into multiple thin uniform laminations. Each lamination is cast with controlled thickness using tape casting, ensuring uniformity within each layer, and the stack as a whole achieves the target thickness
Solution Approach 2:
The patent performs preliminary actions by preparing multiple green tape laminations with uniform thickness before final assembly. Each lamination is pre-formed with consistent ceramic particle distribution and organic binder content, ensuring uniformity is established before the lamination and bonding processes
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 method enables the production of thin but strong ceramic exterior parts for portable devices with thicknesses up to 1.5 mm, overcoming viscosity limitations and ensuring structural integrity and stability.
Implementation Method 1
The casting slurry is subjected to high-speed rotation to remove air bubbles therefrom
Implementation Method 2
The green tape lamination is heated at an elevated temperature to remove the organic binder and the organic plasticizer therefrom
Implementation Method 3
The shaped green tape lamination is fired to achieve the thin ceramic exterior part
Data Source
AI summary
A method for making a thin ceramic part involves making a casting slurry including a ceramic powder, a solvent, a binder, a plasticizer, and a dispersant. The casting slurry is tape casted to achieve a single layer green tape. At least two single layer green tapes are laminated to form a green tape lamination. The green tape lamination is dry pressed, dried, shaped, degreased, and fired to achieve the exterior component required.