Ceramic Edge Strength via Polymer Coating
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Solution Overview
Problem
Ceramic articles are prone to damage, such as cracking, during processing due to their susceptibility to handling, polishing, and shipping, especially when they are thin, making conventional processing methods costly and cumbersome, and it is challenging to remove surface defects induced by setter boards or cutting.
Innovation Solution
A ceramic assembly is formed by depositing a polymer coating over the outer peripheral portion of a ceramic article, which increases the edge strength by reinforcing the ceramic article, stabilizing the outer peripheral portion, and filling defects, thereby reducing the risk of damage during processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If ceramic articles are made thin to reduce weight and improve flexibility, then weight and handling ease are improved, but susceptibility to damage and cracking increases
Solution Approach 1:
A polymer coating layer is applied to the ceramic article to provide flexibility and damage resistance. The polymer coating acts as a protective shell that can absorb stress and prevent cracking while allowing the ceramic to remain thin and lightweight.
Solution Approach 2:
The invention creates a composite structure combining ceramic and polymer materials. The ceramic provides hardness and chemical stability, while the polymer coating provides flexibility and impact resistance, resulting in a composite material that overcomes the limitations of pure ceramic.
2Ease of operation
If conventional processing methods are used for thin ceramic articles, then processing simplicity is maintained, but damage and cracking occur frequently
Solution Approach 1:
The polymer coating is applied to the ceramic article before final processing steps such as polishing and shipping. This preliminary protective action ensures that the ceramic is already protected against damage during subsequent handling and processing operations.
Solution Approach 2:
The polymer coating serves as a flexible protective shell that allows conventional processing methods to be used without causing damage. The coating absorbs handling stresses and prevents cracking during polishing, shipping, and other processing operations.
3Manufacturing precision
If surface defects are removed from thin ceramic articles using conventional methods, then surface quality is improved, but the risk of cracking and damage increases
Solution Approach 1:
The polymer coating is applied to the ceramic surface before defect removal processes. This allows surface defects to be addressed while the coating provides a buffer that prevents cracking during the defect removal process.
Solution Approach 2:
The polymer coating acts as a flexible protective layer during surface defect removal. It allows for polishing and surface treatment to improve manufacturing precision while the coating's flexibility prevents stress-induced cracking.
4Reliability
If polymer coating is applied to increase edge strength, then damage resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The polymer coating thickness and composition are optimized to achieve the required edge strength enhancement. By carefully controlling coating parameters such as thickness (can be several micrometers to millimeters) and material properties, sufficient protection is achieved without excessive complexity in the manufacturing process.
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 polymer coating enhances the edge strength of the ceramic assembly by 50 MPa or more, reducing the incidence of damage and simplifying handling, polishing, and shipping processes, while also potentially functioning in applications like waveguides or display components.
Implementation Method 1
a polymer coating deposited over at least an outer peripheral portion of the first major surface of the ceramic article
Data Source
AI summary
Ceramic assembly can comprise a ceramic article comprising a thickness defined between a first major surface and a second major surface. The thickness can be about 100 micrometers or less. The ceramic assembly can comprise a polymer coating deposited over at least an outer peripheral portion of the first major surface of the ceramic article. The polymer coating can comprise a thickness of about 30 micrometers or less. An edge strength of the ceramic assembly can be greater than an edge strength of the ceramic article by about 50 MegaPascals or more. Methods of forming a ceramic assembly can comprise depositing a polymer coating on an outer peripheral portion of a first major surface of a ceramic article. Methods can further comprise curing the polymer coating.