Ceramic Sheet Surface Marks for Easy Post-Firing Separation
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Solution Overview
Problem
The existing methods for manufacturing ceramic sheets, particularly those using a resin film substrate, face challenges in separating green sheets after firing due to adhesion and cracking, especially when inorganic releasing powders are used, leading to laborious washing processes and reduced yield, especially for thin film sheets.
Innovation Solution
A method involving attaching organic particles with an average size of 0.1 to 50 µm to the surface of green sheets, allowing them to be piled directly and fired in a stacked body, where the particles form particle marks that facilitate easy separation after firing, eliminating the need for post-firing powder removal and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inorganic powder is sprinkled and laid between green sheets as releasing powder, then green sheets can be prevented from direct contact and adhesion, but laborious washing processes are required and yield is reduced
Solution Approach 1:
The patent extracts the harmful inorganic releasing powder from the system and replaces it with organic particles that serve the same releasing function without requiring post-firing removal. The organic particles are attached to green sheets before stacking, and after firing they can be easily removed or decomposed, eliminating the washing step entirely.
Solution Approach 2:
The patent changes the material parameter from inorganic powder to organic particles, and changes the size parameter to 0.1-50 µm. This parameter change allows the particles to be effectively removed after firing through simple mechanical means or decomposition, rather than requiring laborious washing processes.
2Reliability
If inorganic powder is used as releasing powder, then sheet adhesion is prevented, but additional devices and washing steps are required
Solution Approach 1:
The patent removes the complex washing devices and ultrasonic treatment equipment from the manufacturing process by using organic particles that can be easily removed after firing. The process complexity is reduced to simple stacking and firing operations.
Solution Approach 2:
The organic particles serve as a temporary, disposable releasing agent that is attached to green sheets, performs its function during firing, and is then easily removed or decomposed. This eliminates the need for expensive and complex washing equipment.
3Ease of manufacture
If green sheets are piled through surfaces which were in contact with substrate films, then sheets can be stacked directly, but sheets adhere firmly after firing
Solution Approach 1:
The patent applies organic particles to the green sheet surfaces before stacking. This preliminary action creates a releasing layer that prevents adhesion during firing, while allowing the green sheets to be stacked directly without complex handling procedures.
Solution Approach 2:
The organic particles act as an intermediary substance between the green sheet surfaces. They prevent direct contact and adhesion of the sheets during firing, while allowing easy stacking before firing. The particles are removed after firing, leaving clean sheet surfaces.
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 approach simplifies the manufacturing process, reduces costs, and achieves ceramic sheets with sufficient flexural strength, allowing for easy separation of sheets without damaging them, while maintaining characteristics similar to those produced by conventional methods.
Implementation Method 1
attaching organic particles having an average particle size of 0.1 to 50 µm to at least one surface of a green sheet
Implementation Method 2
firing the green sheets in a state of the stacked body
Implementation Method 3
first firing the green sheets at 150 to 600°C to remove organic components included in the green sheets
Data Source
Figure 1
Figure 2A~2C
Figure 3
AI summary
A ceramic sheet including a principal surface having particle marks is disclosed. The average width of the particle marks is 0.2 to 50 µm, the average depth of the particle marks along the sheet thickness direction is 0.1 to 25 µm, and the coefficient of variation of the widths of the particle marks is 0.23 or more.