Continuous Ceramic Tape via Molten Spray Deposition
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Solution Overview
Problem
Conventional methods face challenges in efficiently producing thin sheets or tapes of materials like ceramics, which often require cumbersome processes such as slicing or tape casting, and struggle with achieving coatings that can be easily delaminated without fracturing.
Innovation Solution
A manufacturing process involving heating a feedstock material to a molten state and spraying it onto a deposition surface, where the coating forms with voids and lamellae structures, allowing for the coating to be peeled off as a continuous tape without fracture, utilizing a non-stick deposition surface like a thermoplastic polymer or fluoropolymer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods (slicing or tape casting) are used to produce thin ceramic sheets or tapes, then the manufacturing process becomes complex and cumbersome, but the production efficiency is low and the process is difficult to control
Solution Approach 1:
The patent replaces conventional mechanical methods (slicing, tape casting) with a thermal spray deposition process. Molten ceramic particles are sprayed onto a substrate and rapidly solidify to form a coating, eliminating the need for complex mechanical slicing or casting operations while enabling continuous production
Solution Approach 2:
The patent utilizes rapid cooling rates during the thermal spray process to control the microstructure and properties of the ceramic coating. By adjusting spray parameters (temperature, velocity, particle size) and substrate temperature, the coating can be formed with desired characteristics without requiring post-processing
2Ease of operation
If the coating is formed with voids and lamellae structures during deposition, then the coating can be easily delaminated as a continuous tape without fracture, but the coating density and mechanical strength are reduced
Solution Approach 1:
The patent creates different microstructural characteristics in different regions of the coating. The voids and lamellae are formed in specific patterns during deposition to enable easy delamination, while the overall coating structure maintains sufficient density and strength through controlled particle bonding and stacking
Solution Approach 2:
The coating is formed as a series of overlapping lamellae (flake-like structures) rather than a continuous dense layer. This segmented microstructure allows the coating to be delaminated as a continuous tape while maintaining structural integrity through the stacked arrangement of lamellae
3Ease of operation
If the deposition surface is made non-stick to enable easy peeling of the coating, then the coating can be removed as a continuous tape, but the bonding between the coating and substrate is reduced
Solution Approach 1:
The non-stick surface is prepared on the substrate before coating deposition. This preliminary surface treatment (using fluoropolymers or other non-stick materials) ensures that the coating can be easily peeled off as a continuous tape after formation, while the coating maintains adequate bonding during the deposition and service phases
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 process enables the production of elongate tapes with lower thermal and electrical conductivity, increased dielectric strength, and flexibility, while avoiding the need for high-temperature deposition surface melting, thus simplifying the manufacturing of thin ceramic tapes and sheets.
Implementation Method 1
heating a feedstock material to a molten state
Implementation Method 2
spraying molten particles or droplets of the feedstock material onto a deposition surface. The method further includes forming a coating on the deposition surface by accumulating the particles or droplets
Implementation Method 3
the deposition surface is non-stick with respect to the coating such that the coating may be peeled off the deposition surface (i.e. layer removed) as a continuous tape
Data Source
AI summary
A process for manufacturing continuous ceramic tape includes steps of heating a ceramic feedstock to a molten state and spraying molten droplets of the feedstock onto a deposition surface. The method further includes forming a ceramic coating on the deposition surface by accumulating the droplets, which solidify and are directly bonded to one another. The deposition surface is non-stick with respect to the ceramic coating such that the coating may be peeled off of the deposition surface as a continuous ceramic tape, without fracture. Additionally, in embodiments, the deposition surface is removed by running the deposition over a bending edge, chemically stripping or dissolving the deposition surface, or burning the deposition surface.