Ceramic Porous-Frame Structure With Stress Relaxation Boundary
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Solution Overview
Problem
Existing methods for manufacturing ceramic articles with integrated porous and non-porous structures using additive manufacturing techniques face challenges such as weak adhesive layers and thermal stress-induced cracking, leading to reduced mechanical strength and reliability.
Innovation Solution
The integration of a stress relaxation part between the porous and non-porous structures within the ceramic article, formed using a direct manufacturing method with a powder bed fusion technique, where the porous and non-porous parts are bonded with a stress relaxation part to alleviate thermal stress and enhance mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a porous structure and a no-porous structure are integrated in a ceramic article manufactured by additive manufacturing, then the functional versatility is improved, but the mechanical strength deteriorates due to cracks at the boundary caused by thermal stress differences
Solution Approach 1:
The patent applies local quality by providing a stress relaxation part with specific structural characteristics (reduced thickness or porosity) only at the boundary region between porous and no-porous structures, while maintaining the original structures in their respective zones. This localized modification addresses the thermal stress concentration at the interface without compromising the functional properties of the porous and no-porous regions.
Solution Approach 2:
The patent segments the ceramic article into distinct functional zones: a porous structure region, a no-porous structure region, and an intermediate stress relaxation part. This segmentation allows each zone to be optimized for its specific function while the stress relaxation part acts as a buffer zone that mitigates the adverse thermal stress interactions between the contrasting structural regions.
2Productivity
If a direct manufacturing method is used to integrate porous and no-porous ceramic structures, then the manufacturing efficiency is improved, but the manufacturing precision deteriorates due to crack formation during heat treatment
Solution Approach 1:
The stress relaxation part is designed and incorporated into the additive manufacturing process before the final heat treatment step. This preliminary structural preparation ensures that when heat treatment is subsequently applied, the thermal stresses are already mitigated by the stress relaxation part, preventing crack formation and ensuring structural integrity throughout the manufacturing process.
3Strength
If heat treatment is performed to reduce cracks in the manufactured object, then the mechanical strength is improved, but the reliability deteriorates due to stress concentration at the boundary between porous and no-porous parts
Solution Approach 1:
The stress relaxation part serves as an intermediary element between the porous and no-porous structures. During heat treatment, this intermediate zone absorbs and redistributes thermal stresses, preventing stress concentration at the sharp boundary. This mediator structure allows the heat treatment to proceed effectively for crack reduction while maintaining boundary integrity and overall reliability.
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 results in a high-strength ceramic article with reduced cracking and improved mechanical properties, suitable for applications like chuck plates and semiconductor wafer fixation, where the stress relaxation part effectively mitigates thermal expansion differences between the porous and non-porous regions.
Implementation Method 1
irradiating the powder layer with an energy beam to melt and solidify or sinter the powder
Implementation Method 2
irradiating the powder layer with an energy beam to melt and solidify or sinter the powder
Implementation Method 3
there is a large difference in thermal behavior between the porous part and the no-porous part. Due to this difference in thermal behavior, a large stress occurs at the boundary between the porous structure part and the no-porous structure part during the heat treatment
Data Source
AI summary
An article including an inorganic compound according to the present invention includes a porous part and a no-porous frame body surrounding the porous part in a plane direction, and includes a stress relaxation part between the porous part and the frame body.