Layered Ceramic Substrate with Dual Pore Sizes for Waterproof Breathability
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Solution Overview
Problem
Existing mobile devices with gas sensors face challenges in achieving a waterproof structure while maintaining breathability, as conventional waterproof sheets are expensive and difficult to attach, especially in small devices.
Innovation Solution
A substrate with a layered ceramic insulation structure, featuring a first layer with fine through holes (10 μm to 50 μm in diameter) and a second layer with larger through holes (100 μm to 200 μm in diameter), providing a waterproof and breathable solution by allowing gas passage while preventing water entry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a waterproof sheet is attached to the housing to improve waterproof property, then waterproof performance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The substrate is divided into two distinct ceramic layers: a first layer with fine through holes (10-50 μm diameter) for waterproofing, and a second layer with larger through holes (100-200 μm diameter) for breathability. This segmentation allows each layer to perform its specific function independently, achieving both waterproof performance and gas permeability without requiring separate waterproof sheets or complex assembly steps.
Solution Approach 2:
The invention uses a composite structure of two ceramic layers with different pore characteristics. The first ceramic layer provides waterproof protection through its fine pore structure, while the second ceramic layer enables breathability through larger pores. This composite material approach integrates multiple functions (waterproofing and breathability) into a single substrate component, eliminating the need for separate waterproof sheets and reducing manufacturing complexity.
2Reliability
If a waterproof sheet is attached to the housing, then waterproof performance is improved, but manufacturing cost increases
Solution Approach 1:
The invention merges the waterproofing function and breathability function into a single integrated substrate structure. The first ceramic layer with fine through holes provides waterproof protection, while the second ceramic layer with larger through holes provides breathability. By combining these functions in one component, the invention eliminates the need for separate waterproof sheets and their associated attachment steps, thereby reducing manufacturing cost.
Solution Approach 2:
The substrate structure itself provides both waterproofing and breathability functions through its inherent layered design. The fine through holes in the first layer naturally prevent water ingress, while the larger through holes in the second layer naturally allow gas passage. This self-service approach eliminates the need for additional waterproofing components and their attachment processes, reducing both cost and manufacturing complexity.
3Reliability
If fine through holes are created in the substrate, then waterproof performance is improved, but breathability deteriorates
Solution Approach 1:
The invention resolves the contradiction between waterproofing and breathability by adding a dimensional aspect - creating a two-layer structure where the first layer (with fine through holes) handles waterproofing and the second layer (with larger through holes) handles breathability. This vertical dimensionality allows both functions to coexist without compromising either, as each layer operates at a different structural level.
Solution Approach 2:
The substrate is segmented into two functional layers: the first ceramic layer with fine through holes (10-50 μm) that prevents water ingress, and the second ceramic layer with larger through holes (100-200 μm) that facilitates gas passage. This segmentation allows the waterproofing function and breathability function to be performed by different parts of the same substrate, resolving the contradiction between these two requirements.
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 substrate achieves IPX7 or higher waterproofing with excellent breathability, reducing the risk of water ingress and corrosion, and is more cost-effective and easier to manufacture than traditional methods.
Implementation Method 1
a first layer that is a ceramic insulation layer including a plurality of first through holes; The plurality of first through holes each have a diameter of from 10 μm to 50 μm
Implementation Method 2
a second layer layered on the first layer, the second layer being a ceramic insulation layer including at least one second through hole. The at least one second through hole has a diameter larger than the diameter of each of the plurality of first through holes
Data Source
AI summary
A substrate includes: a first layer that is a ceramic insulation layer including a plurality of first through holes; and a second layer layered on the first layer, the second layer being a ceramic insulation layer including at least one second through hole. The plurality of first through holes each have a diameter of from 10 μm to 50 μm, and the diameter of the at least one second through hole is larger than the diameter of each of the plurality of first through holes. At least some of the plurality of first through holes overlap the at least one second through hole.