Ceramic Sheet Orientation via Angular Slicing
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Solution Overview
Problem
There is a need for ceramic sheets with improved attributes, specifically a novel orientation structure that enhances thermal conductivity and anisotropy, which existing methods have not adequately addressed.
Innovation Solution
A method involving shaping a composition of resin and ceramic material into a sheet, stacking, slicing at an angle of 45° or less, and firing, with debinding at 300° C+ and firing at 1000° C+ to achieve a ceramic sheet with a positive a-axis orientation, resulting in enhanced thermal conductivity and anisotropy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional ceramic sheet production methods are used, then manufacturing simplicity is maintained, but the orientation structure and thermal conductivity are insufficient
Solution Approach 1:
The production process is divided into distinct stages: forming primary sheets, stacking them in a specific orientation, slicing at precise angles, and firing. This segmentation allows each step to contribute to the final orientation structure, achieving high thermal conductivity through systematic breakdown of the manufacturing process rather than a single conventional step
Solution Approach 2:
The invention introduces angular orientation (slicing at 45° or less relative to stacking direction) as a new dimensional parameter beyond simple stacking. This angular dimension creates the novel orientation structure where ceramic grains align in specific crystallographic directions (a-axis or c-axis perpendicular to sheet surface), thereby enhancing thermal conductivity without requiring excessively complex manufacturing equipment
2Quantity of substance
If the primary sheet thickness is increased, then material utilization is improved, but the orientation structure quality deteriorates
Solution Approach 1:
The invention optimizes the primary sheet thickness parameter to 2.5 mm or less, which is a specific parameter change from conventional thicker sheets. This thickness control ensures that during stacking and slicing, the ceramic grains maintain proper orientation alignment. The parameter optimization balances material utilization (using sufficient thickness) with orientation quality (maintaining thin enough sheets for proper grain alignment during processing)
3Temperature
If the ceramic material volume fraction is decreased, then processing ease is improved, but the thermal conductivity and anisotropy are reduced
Solution Approach 1:
The invention specifies an optimal range for ceramic material volume fraction (50-75 vol%), which is a parameter optimization balancing thermal conductivity and processing ease. Within this range, there is sufficient ceramic material to achieve high thermal conductivity and anisotropy through orientation, while maintaining enough resin matrix to ensure proper forming, stacking, and slicing processing. This parameter range resolves the contradiction between high performance and ease of manufacture
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 efficiently produces a ceramic sheet with a novel orientation structure, exhibiting higher thermal conductivity in the thickness direction and anisotropy, as confirmed by Lotgering analysis and thermal conductivity measurements.
Implementation Method 1
shaping a composition containing a resin and a ceramic material into a sheet-like form through pressure application
Implementation Method 2
debinding of the secondary sheet is performed through heating in an atmosphere of 300° C. or higher
Implementation Method 3
debinding of the secondary sheet is performed through heating
Implementation Method 4
firing the secondary sheet, and in this manner, the inventor completed the present disclosure
Implementation Method 5
the firing is performed in an atmosphere of 1000° C. or higher
Implementation Method 6
an a-axis among crystallographic axes of constituent ceramic of the ceramic sheet is oriented in a thickness direction of the ceramic sheet
Data Source
AI summary
A method of producing a ceramic sheet includes: shaping a composition containing a resin and a ceramic material into a sheet-like form through pressure application to perform primary sheet shaping; stacking a plurality of the primary sheet in a thickness direction or performing folding or winding of the primary sheet to obtain a laminate; slicing the laminate at an angle of 45° or less relative to a stacking direction to obtain a secondary sheet; and firing the secondary sheet.