Ceramic-Substrate Metamaterial Coextrusion for Higher Yield
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Solution Overview
Problem
Existing metamaterial manufacturing processes are complex, leading to low yield rates and high costs due to serial component manufacturing and multiple superimposed errors, with challenges in precision and high iteration costs.
Innovation Solution
A metamaterial manufacturing method involving coextrusion and sintering of insulating substrate powder, wave-absorbing agent powder, and metal electrode powder with thermoplastic resin, followed by cutting and sintering to form microstructure sheets, enabling multi-component one-off molding and sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multi-component microstructures are manufactured through microstructure overprinting process with serial component manufacturing, then each component can be manufactured with precision, but the procedure becomes complex and error ratios are multiplied and superimposed, resulting in low final microstructure yield rate
Solution Approach 1:
The patent merges multiple separate component manufacturing processes into a single parallel manufacturing process. All microstructure components are manufactured simultaneously on the same substrate using the same template, eliminating the need for multiple sequential overprinting operations. This combination approach maintains component precision while avoiding error accumulation and significantly improves the final yield rate.
Solution Approach 2:
The patent employs a universal template that can manufacture all microstructure components in one operation. Instead of requiring separate templates for each component, a single template design enables the simultaneous fabrication of multiple components, reducing procedural complexity and eliminating the need for multiple alignment operations.
2Adaptability or versatility
If counterpoint operation is performed for a plurality of times in overprinting technology, then multi-component microstructures can be formed, but it is difficult to ensure precision of the technology after counterpoint operation is performed for a plurality of times
Solution Approach 1:
The patent segments the manufacturing process into two distinct stages: template design (virtual segmentation) and single-step manufacturing (physical execution). By performing all counterpoint operations during the template design phase through computer-aided design software, the actual manufacturing requires only a single deposition operation, eliminating cumulative precision errors from multiple physical counterpoint operations.
Solution Approach 2:
The patent replaces repeated mechanical counterpoint operations with a computational design approach. The counterpoint operations are performed virtually during template design using software algorithms, and the final template is then manufactured in a single physical operation, substituting mechanical precision requirements with computational precision.
3Manufacturing precision
If a single template (for example, a silkscreen) needs to be manufactured for each component in overprinting technology, then each component can be optimized independently, but this causes relatively high metamaterial iteration costs and a long period
Solution Approach 1:
The patent combines multiple component templates into a single integrated template through computational design. Instead of manufacturing separate templates for each component, the design software merges all component requirements into one unified template that can be manufactured in a single operation, dramatically reducing iteration time and cost while maintaining component optimization capabilities.
Solution Approach 2:
The patent changes the design parameter from separate physical templates to a unified digital template model. This parameter change allows all component designs to be modified and optimized through software before final template manufacturing, enabling rapid iteration without the need to physically remake individual templates for each component change.
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 achieves high efficiency, low iteration costs, and improved yield rates, producing thinner and more efficient metamaterials with impedance matching and wave-absorbing capabilities.
Implementation Method 1
applying a coextrusion process to the raw material according to a metamaterial microstructure design, to form a microstructure unit rodlike material
Implementation Method 2
placing the impedance matching metamaterial biscuit in a sintering furnace for adhesive discharge and sintering
Data Source
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AI summary
The present disclosure provides a metamaterial manufacturing method. The manufacturing method includes the following steps: (a) separately adding insulating substrate powder and at least one of wave-absorbing agent powder and metal electrode powder to thermoplastic resin, and mixing them evenly to obtain a raw material; (b) applying a coextrusion process to the raw material according to a metamaterial microstructure design, to form a microstructure unit rodlike material; and (c) configuring the microstructure unit rodlike material in a cyclic microstructure configuration manner, placing the material in an extruder, and obtaining a cyclically configured metamaterial microstructure through coextrusion by using the extruder. The present disclosure further provides a metamaterial manufactured by using the foregoing method. The present disclosure provides a method for manufacturing a ceramic-substrate metamaterial that features high efficiency, low iteration costs, and a relatively high yield rate. A thinner and more efficient wave-absorbing metamaterial is obtained.