Dielectric Slurry Redispersion for Uniform Particle Size
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Solution Overview
Problem
Conventional methods using zirconium oxide beads for pulverizing dielectric particles in dielectric slurry lead to bead wear and contamination, affecting the purity and size uniformity of the particles, which in turn impacts the performance of multilayer ceramic capacitors.
Innovation Solution
A non-bead method involving a particle dispersing module for collision-induced dispersion, followed by a centrifugal separator for size classification and recovery, with redispersion of larger particles to reduce their size, forming a dielectric slurry without bead contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If zirconium oxide beads are used for pulverizing dielectric particles, then the particles can be dispersed, but the beads wear and contaminate the dielectric particles with Zr component
Solution Approach 1:
The invention removes the bead medium from the pulverization process entirely. Instead of using zirconium oxide beads that cause contamination, the patent employs a bead-free dispersion system where dielectric particles are dispersed through mechanical agitation and shear forces in a controlled environment, eliminating the source of Zr component contamination while maintaining dispersion effectiveness
Solution Approach 2:
The invention replaces the mechanical bead-pulverization system with an alternative dispersion mechanism. The patent uses a dispersion apparatus that generates controlled shear forces and turbulence to break down agglomerates and disperse particles without physical contact with beads, substituting the harmful mechanical interaction with a cleaner force field-based approach
2Productivity
If conventional bead pulverization is used, then dielectric particles can be processed, but particle size uniformity deteriorates due to bead wear
Solution Approach 1:
The invention implements a feedback control system that continuously monitors particle size distribution during the dispersion process. Sensors detect particle characteristics in real-time, and the system automatically adjusts dispersion parameters such as agitation speed, shear rate, and processing time to maintain optimal particle size uniformity, preventing the degradation that occurs with conventional bead methods
Solution Approach 2:
The invention employs dynamic adjustment of dispersion conditions throughout the processing cycle. The dispersion apparatus varies shear forces, flow rates, and mixing intensity based on real-time particle state, transitioning from high-intensity initial dispersion to gentler finishing stages, thereby achieving uniform particle size without the wear-related variability inherent in static bead pulverization systems
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 improved particle size uniformity and reduced dispersion time, enhancing the electrical characteristics and manufacturing efficiency of multilayer capacitors.
Implementation Method 1
spraying, by the particle dispersing module, the dielectric particles to collide with each other
Implementation Method 2
the classifying module may include a centrifugal separator
Data Source
AI summary
A method of manufacturing a dielectric slurry, includes supplying a dielectric slurry including dielectric particles and a solvent to a slurry supply module, dispersing the dielectric slurry by inserting the dielectric slurry into a particle dispersing module, classifying the dielectric particles according to particle size by inserting the dispersed dielectric slurry into a classifying module, recovering at least a portion of the dielectric particles to the slurry supply module, and redispersing the dielectric slurry including the dielectric particles recovered to the slurry supply module to the particle dispersing module.