Dielectric Ceramic Composition Manufacturing via Reactive Surface Groups

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Solution Overview

Problem

The existing methods for manufacturing dielectric ceramic compositions, particularly those with a perovskite structure, face challenges such as agglomeration, uneven dispersion, and imbalance in grain growth, leading to issues with additive uniformity and electrical properties like dielectric constant and high-temperature withstand voltage.

Innovation Solution

A manufacturing method involving the attachment of a reactive functional group to the surface of base material powder particles, followed by the controlled diffusion of additives, ensures uniform dispersion and solid solubility, thereby improving dispersion stability and electrical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a solid-phase reaction method is used to manufacture dielectric ceramic composition, then the method is useful for manufacturing relatively thick sheets, but a large amount of agglomeration occurs in the dispersion process and grain growth becomes unbalanced

Engineering Contradiction:

Improvemanufacturing capability for thick sheetsVSAvoiddispersion uniformity and grain growth balance

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-coating the ceramic powder particles with a surfactant before the dispersion process. This pre-treatment modifies the particle surface properties, preventing agglomeration during subsequent mixing and ensuring uniform grain growth. The surfactant forms a protective layer on particle surfaces, enabling better dispersion control while maintaining the ability to manufacture thick sheets.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes physical-chemical parameters by introducing surfactants that alter surface tension and interfacial properties between ceramic particles and the liquid medium. This parameter modification enables controlled wetting and dispersion, resolving the contradiction between manufacturing thick sheets and achieving uniform grain growth without agglomeration.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If liquid precipitation method or spray drying method is used to disperse ceramic powder, then dispersion is improved, but additive component does not precipitate uniformly or anion component remains as impurity

Engineering Contradiction:

Improvedispersion uniformityVSAvoidadditive uniformity and purity

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent uses surfactants as intermediary substances that mediate between the ceramic powder particles and the liquid medium. These surfactants facilitate uniform dispersion while controlling the precipitation behavior of additive components. The surfactant molecules act as intermediaries that ensure uniform distribution of additives and prevent impurity formation, resolving the contradiction between dispersion quality and additive uniformity.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If conventional dispersion methods are used, then processing is simple, but additive component is easily separated from dielectric powder

Engineering Contradiction:

Improveprocess simplicityVSAvoidadditive-powder binding stability

Core Design Contradiction:

Device complexityVSStability of the object's composition

Solution Approach 1:

The surfactant serves as a binding intermediary that creates stable associations between additive components and dielectric powder particles. This intermediary layer prevents separation during processing while maintaining relative process simplicity. The surfactant molecules anchor to both the powder surface and additive components, creating a stable composite structure without requiring complex equipment or procedures.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 method achieves uniform dispersion and enhanced electrical properties, including a high dielectric constant and improved high-temperature withstand voltage, by ensuring uniform solid solubility of subcomponents within the dielectric ceramic composition.

Implementation Method 1

a manufacturing method involving the attachment of a reactive functional group to the surface of base material powder particles, followed by the controlled diffusion of additives

Methodology Applied

Scientific EffectSurface diffusion: Diffusion

Implementation Method 2

a step of attaching a reactive functional group to a surface of a base material powder particle of a perovskite structure

Methodology Applied

Scientific EffectSurface modification: Adsorption

Data Source

PatentUS11618716B2Manufacturing method of dielectric ceramic composition and dielectric ceramic composition manufactured by the same

Publication Date: 2023.04.04 SAMSUNG ELECTRO MECHANICS CO LTD

AI summary

A manufacturing method of a dielectric ceramic composition includes attaching a reactive functional group to a surface of a base material powder particle of a perovskite structure.