Precious Metal Coating Boundary Control on Composite Ceramics

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Solution Overview

Problem

Existing methods for depositing a metal layer on a surface for light shielding purposes lack precision in forming the metal layer only in the required location.

Innovation Solution

A method involving a composite ceramic member with a ceramic part and a connection part, where the connection part has stronger adhesion to a precious metal than the ceramic part, is used to dispose a precious metal layer on the surface. The precious metal layer is then selectively removed from the ceramic part while maintaining it on the connection part.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a metal layer is deposited on a surface for light shielding purposes, then light shielding function is achieved, but the precision of metal layer location is insufficient

Engineering Contradiction:

Improvemetal layer location precisionVSAvoidmetal layer deposition process complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The ceramic member is divided into two distinct parts: a ceramic part and a connection part. The connection part is specifically designed with enhanced adhesion properties to precious metals, allowing selective metal layer formation. This segmentation enables precise control of where the metal layer is deposited and retained, solving the location precision problem while maintaining manufacturing feasibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection part is given a special local quality - stronger adhesion to precious metals compared to the ceramic part. This localized property difference allows the metal layer to be selectively disposed on the connection part boundary, achieving high precision metal layer placement without requiring complex deposition processes.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If a metal layer is formed on the entire surface, then complete coverage is achieved, but selective location control is lost

Engineering Contradiction:

Improvemetal layer position controlVSAvoidprecious metal material usage

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The metal layer is selectively removed from the ceramic part while being retained on the connection part. This extraction approach allows the metal layer to be initially formed on the entire surface for simplicity, then precisely positioned by removing it from areas where it is not needed, achieving both complete coverage and selective location control.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The differential adhesion property between the ceramic part and connection part enables selective retention of the metal layer. The connection part's stronger adhesion causes the metal layer to remain there after removal from the ceramic part, achieving precise position control and optimized material usage.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If the connection part has stronger adhesion to precious metal, then selective metal layer retention is achieved, but material selection complexity increases

Engineering Contradiction:

Improvemetal layer boundary definitionVSAvoidcomposite ceramic member structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The ceramic member is segmented into a ceramic part and a connection part with different adhesion properties. This segmentation creates a natural boundary for metal layer disposition, achieving precise boundary definition through the inherent property difference between the two parts while maintaining a relatively simple composite structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection part is designed with a specific local quality - enhanced adhesion to precious metals. This localized property difference provides a clear, well-defined boundary for where the metal layer should be retained, achieving precise boundary definition without requiring complex multi-layer or multi-component structures.

Inventive Principle:

Principle #3Local quality

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 method allows for the precise formation of a metal layer on a surface, enhancing the precision of metal layer disposition and utilization in applications such as light emitting devices.

Implementation Method 1

the connection part has stronger adhesion to a precious metal than the ceramic part

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS12347998B2Method of manufacturing metal-coated member, metal-coated member, wavelength conversion member, and light emitting device

Publication Date: 2025.07.01 NICHIA CORP

AI summary

A method of manufacturing a metal-coated member includes: providing a composite ceramic member including a ceramic part, and a connection part connected to the ceramic part; disposing a precious metal layer on a surface region that includes at least a portion of a surface of the ceramic part and a portion of a surface of the connection part, the precious metal layer including a precious metal; and removing at least a portion of the precious metal layer that is on the surface of the ceramic part and delineated by the boundary between the ceramic part and the connection part. The connection part has stronger adhesion to the precious metal than the ceramic part.