Core-Shell Polymer-Ceramic Composites for High Dk and Low Df
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Solution Overview
Problem
Existing ceramic-polymer composites face challenges in achieving high ceramic content (greater than 50% by volume) due to limitations in compounding technology, which can damage equipment and degrade polymers, and not all ceramics can be effectively cold sintered, resulting in unsuitable structural properties for 5G applications.
Innovation Solution
The development of polymer-ceramic core-shell particles with a ceramic core and polymer shell, allowing for higher ceramic content (50-90% by volume) and uniform distribution, formed through methods that include mixing ceramic particles with a polymer in a solvent, superheating, and precipitating the polymer on the ceramic to create a shell, enabling molding without agglomeration and using conventional processes like compression molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional compounding technology is used to mix ceramic filler with polymer, then processing is simplified, but ceramic filler content is limited to significantly less than 50% by volume due to equipment damage and polymer degradation
Solution Approach 1:
The patent applies preliminary action by pre-coating ceramic particles with polymer material before compounding. This pre-coating protects both the ceramic particles and the polymer matrix during the compounding process, enabling higher ceramic filler content (greater than 50% by volume) without damaging extruder screws or degrading the polymer. The pre-coated particles are then compounded with additional polymer to form the final composite pellets.
2Quantity of substance
If ceramic filler content is increased to achieve high dielectric constant, then dielectric performance improves, but dispersion and distribution become highly dependent on mixing parameters and agglomeration occurs
Solution Approach 1:
The patent applies preliminary action by pre-coating ceramic particles with polymer material before compounding. This pre-coating creates a protective layer that prevents agglomeration and ensures uniform dispersion of ceramic particles in the polymer matrix, even at high filler contents greater than 50% by volume. The pre-coated particles maintain consistent distribution throughout the composite material.
3Reliability
If thermoset approach is used with monomer and porous ceramic, then composite formation is achieved, but curing time becomes unacceptably long and density depends on pore size and resin viscosity
Solution Approach 1:
The patent applies parameter changes by transitioning from a thermoset system requiring chemical curing to a thermoplastic system using physical melting and solidification. This parameter change eliminates the need for lengthy curing processes while maintaining reliable composite formation. The thermoplastic polymer melts at elevated temperatures to impregnate the ceramic structure, then solidifies upon cooling to form the final composite part.
4Temperature
If cold sintering is used to process ceramic-polymer composites, then processing temperature is reduced, but not all ceramics can be effectively cold sintered and structural properties become unsuitable for 5G applications
Solution Approach 1:
The patent applies parameter changes by using a thermoplastic processing approach that operates at elevated temperatures to melt the polymer and impregnate the ceramic structure, then solidifies upon cooling. This parameter change enables effective processing of all ceramic types including those that cannot be cold sintered, while producing composite parts with structural properties suitable for 5G applications.
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 composite parts with low dissipation factor (Df) and high dielectric constant (Dk), suitable for 5G components, and allows for uniform distribution and reduced agglomeration, facilitating the production of high-performance materials at lower manufacturing costs.
Implementation Method 1
cooling the mixture to or below a second temperature below the boiling point of the solvent to cause the polymer to precipitate on the particles of the ceramic and thereby form a plurality of core-shell particles
Implementation Method 2
cooling the mixture to or below a second temperature below the boiling point of the solvent
Data Source
AI summary
Polymer-ceramic composite articles with relatively low dissipation factor (Df) and relatively high dielectric constant (Dk), as well as polymer-ceramic core-shell powders and pellets adapted for making such composite articles. The ceramic-polymer composites, in powder and/or pellet forms, comprise a plurality of core-shell particles, where: each of the core-shell particles comprises a core and a shell around the core; the core comprises a ceramic that is selected from the group of ceramics consisting of: BaTiO3, SrTiO3, TiO2, CaTiO3, MgTiO3, and combinations of any two or more thereof; and the shell comprises a polymer selected from the group of polymers consisting of: polyetherimide (PEI), polyetherimide (PEI) copolymers, polyphenylene ether (PPE), polyphenylene sulfide (PPS), polyaryl ether ketone (PAEK), polypropylene (PP), polytetrafluoroethylene (PTFE), perfluoroalkoxy alkane (PFA), fluorinated ethylene propylene (FEP), ethylene tetrafluoroethylene (ETFE), polyvinylidene fluoride (PVDF), and ethylene chlorotrifluoroethylene (ECTFE). The core-shell particles can be in a powder form (e.g., a dry powder). In pellet form, shells of adjacent core-shell particles are joined to resist separation of the adjacent core-shell particles and deformation of a respective pellet. Methods of forming a ceramic- polymer composite comprise: superheating a mixture of the polymer (PEI, PEI copolymers, PPE, PPS, PAEK, PP, PTFE, PFA, FEP, ETFE, PVDF, and/or ECTFE), solvent, and the ceramic (BaTiO3, SrTiO3, TiO2, CaTiO3, and/or MgTiO3), to dissolve the polymer in the solvent; agitating the superheated mixture while substantially maintaining the mixture at an elevated temperature and pressure; and cooling the mixture to cause the polymer to precipitate on the particles of the ceramic and thereby form a plurality of the present polymer-ceramic core-shell particles. Methods of molding a part comprise subjecting a powder or pellets of the present polymer-ceramic core-shell particles that substantially fills a mold to a first pressure while the powder is at or above a first temperature above a glass transition temperature (Tg) or if no Tg then above a melting temperature (Tm) of the polymers.