Ceramic Multi-Layer Component Production via Late-Stage Singulation
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Solution Overview
Problem
The existing methods for producing ceramic multi-layer components are inefficient, leading to warping during thermal treatment, mechanical damage, and excessive material loss, as well as requiring additional processing steps for shaping and insulation zone formation.
Innovation Solution
A method involving the production of green layers, stacking, pressing, and thermal treatment of partial blocks with recesses, followed by precise singulation and selective etching, which reduces warping, mechanical damage, and material loss, while allowing for efficient adaptation to installation spaces and formation of insulation zones without additional processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multi-layer components are singulated early in the production process, then individual component handling is easier, but production effort increases and mechanical damage risk increases
Solution Approach 1:
The patent applies preliminary action by performing singulation at a late stage in the production process, after thermal treatment and machining, rather than early. This allows bulk processing of entire blocks during intermediate steps, reducing overall production effort while minimizing mechanical damage risk to individual components during handling
2Ease of manufacture
If multi-layer components are singulated early, then individual processing is simpler, but warping during thermal treatment increases
Solution Approach 1:
The patent merges multiple multi-layer components into a single block during thermal treatment and machining operations. This combined processing reduces warping because the thermal and mechanical loads are distributed across the entire block rather than concentrating stress on individual small components, thereby improving manufacturing precision
3Adaptability or versatility
If corners are cropped after singulation to adapt to installation space, then individual component adaptation is precise, but production steps increase and material loss increases
Solution Approach 1:
The patent performs corner cropping and shaping operations as preliminary actions on the entire block before singulation, rather than as individual post-processing steps. This approach reduces the total number of production steps and minimizes material loss because the shaping is done once on the bulk material rather than repeatedly on each individual component
4Manufacturing precision
If cutting precision is increased to meet surface quality requirements, then tolerance limits are met, but process complexity increases
Solution Approach 1:
The patent combines multiple cutting and surface finishing operations into integrated machining processes performed on the block before singulation. This merging of operations achieves the required cutting precision and surface quality while reducing process complexity, as the operations are performed on larger, more stable workpieces rather than on small individual components
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 significantly reduces production effort, minimizes warping and mechanical damage, and eliminates the need for further processing, enabling precise dimension control and effective adaptation of multi-layer components to specific installation spaces with improved surface quality and reduced material loss.
Implementation Method 1
thermal treatment by means of sintering
Data Source
AI summary
Methods for producing ceramic multi-layer components and multi-layer components made by such methods. A method includes the following steps: providing green layers for the ceramic multi-layer components, stacking the green layers into a stack and subsequently pressing the stack into a block, singulating the block into partial blocks each having a longitudinal direction, thermally treating the partial blocks and subsequently machining surfaces of the partial blocks. Recesses are produced on the surfaces of the partial blocks during the machining, and the partial blocks are singulated.