Core-Shell Polymer-Ceramic Composites for High-Dk Low-Df Parts
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Solution Overview
Problem
Existing ceramic-polymer composites struggle to achieve high ceramic content (greater than 50% by volume) with low dissipation factor (Df) and high dielectric constant (Dk) suitable for 5G network components due to limitations in manufacturing processes, such as long curing times, material incompatibilities, and structural differences.
Innovation Solution
Development of polymer-ceramic core-shell particles with a ceramic core and polymer shell, allowing for high ceramic content (50-90% by volume) and low Df (less than 0.005) and high Dk (greater than 4.5) through methods like solvent-based coating and cold sintering, enabling uniform distribution and agglomeration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ceramic filler content is increased to achieve high dielectric constant, then dielectric performance is improved, but manufacturing complexity and processing difficulty increase
Solution Approach 1:
The patent applies preliminary action by pre-coating ceramic particles with polymer material before compounding. This creates polymer-ceramic core-shell particles where the polymer shell is already formed on the ceramic core, enabling easier subsequent processing and reducing manufacturing complexity while maintaining high ceramic content for dielectric performance
Solution Approach 2:
The patent uses polymer coating as an intermediary substance between ceramic particles and the polymer matrix. This intermediary layer improves dispersion, prevents agglomeration, and facilitates processing of high ceramic content composites, thereby reducing manufacturing complexity while preserving dielectric properties
2Reliability
If ceramic filler content is increased to achieve high dielectric constant, then dielectric performance is improved, but dispersion uniformity deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-coating ceramic particles with polymer material before compounding. This creates polymer-ceramic core-shell particles where the polymer shell is already formed on the ceramic core, enabling easier subsequent processing and reducing manufacturing complexity while maintaining high ceramic content for dielectric performance
Solution Approach 2:
The patent uses polymer coating to create homogeneous core-shell structures where the polymer shell uniformly covers the ceramic core. This homogeneous structure ensures uniform dispersion in the polymer matrix, preventing agglomeration and maintaining composition stability even at high ceramic content levels
3Reliability
If thermoset approach is used to achieve high ceramic content, then dielectric properties are improved, but processing time increases
Solution Approach 1:
The patent applies parameter changes by switching from thermoset polymerization (which requires long curing times) to thermoplastic melting and solidification (which requires only heating and cooling). This parameter change in the polymer type enables high ceramic content composites to be processed much faster while maintaining acceptable dielectric properties
Solution Approach 2:
The patent utilizes phase transitions of thermoplastic polymers (melting and solidification) instead of chemical curing. The thermoplastic polymer melts during processing to allow compounding of high ceramic content, then solidifies upon cooling to form the final composite, eliminating long curing times while preserving dielectric properties
4Productivity
If conventional compounding is used to process high ceramic content, then processing speed is maintained, but material degradation occurs
Solution Approach 1:
The patent applies preliminary action by pre-coating ceramic particles with polymer material before compounding. This creates polymer-ceramic core-shell particles where the polymer shell is already formed on the ceramic core, enabling easier subsequent processing and reducing manufacturing complexity while maintaining high ceramic content for dielectric performance
Solution Approach 2:
The patent uses polymer coating as an intermediary substance between ceramic particles and the polymer matrix. This intermediary layer improves dispersion, prevents agglomeration, and facilitates processing of high ceramic content composites, thereby reducing manufacturing complexity while preserving dielectric properties
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 core-shell particles facilitate the production of composite parts with uniform ceramic distribution, reducing agglomeration and manufacturing costs, suitable for 5G components like antennas and RF filters.
Implementation Method 1
Development of polymer-ceramic core-shell particles with a ceramic core and polymer shell, allowing for high ceramic content (50-90% by volume) and low Df (less than 0.005) and high Dk (greater than 4.5) through methods like solvent-based coating and cold sintering
Implementation Method 2
Development of polymer-ceramic core-shell particles with a ceramic core and polymer shell, allowing for high ceramic content (50-90% by volume) and low Df (less than 0.005) and high Dk (greater than 4.5) through methods like solvent-based coating and cold sintering
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).