Embedded Metal Traces in Ceramic Structures Without Interdiffusion
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Solution Overview
Problem
Existing methods for fabricating ceramic articles with metallic elements, such as chip carriers, face challenges with interdiffusion between ceramic and metallic components during high-temperature firing, which degrades the properties of small-dimensional metallic elements, limiting the shapes and dimensions of accommodated metallic features.
Innovation Solution
A 3D printing method involving the formation of a ceramic body with conductive traces entirely within the ceramic material, using a preceramic polymer resin and metallic particles, where the ceramic matrix includes Si, C, and N, and the metallic traces are composed of high-conductivity metals like gold, silver, and copper, with pyrolysis and heat treatments in inert, oxidizing, or reducing atmospheres to prevent interdiffusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-temperature firing is used to fabricate ceramic articles with metallic elements, then the ceramic structure is formed, but interdiffusion occurs between ceramic and metallic elements which degrades the properties of small-dimensional metallic elements
Solution Approach 1:
A diffusion barrier layer is introduced between the ceramic material and metallic elements to prevent interdiffusion during high-temperature firing. The barrier layer acts as an intermediary that blocks the harmful diffusion process while allowing the ceramic and metal to maintain their desired properties and functionality.
Solution Approach 2:
The firing process is conducted in an inert or controlled atmosphere to prevent unwanted chemical reactions and interdiffusion between ceramic and metallic elements. The inert environment protects the metallic elements from degrading through interdiffusion while still allowing the ceramic structure to form properly.
2Adaptability or versatility
If conventional fabrication methods are used, then ceramic articles can be manufactured, but the shapes and dimensions of metallic elements are constrained due to interdiffusion issues
Solution Approach 1:
The diffusion barrier layer enables greater design freedom for metallic elements by protecting them from interdiffusion. This allows metallic elements to be fabricated in diverse shapes and dimensions (including small features less than 500 microns) without degrading their properties, thus improving adaptability while maintaining reliability.
Solution Approach 2:
The invention changes the firing temperature parameters and atmosphere conditions to enable the use of diffusion barrier layers. By conducting firing at controlled temperatures in inert or reducing atmospheres, the patent achieves both protection of metallic element properties and freedom in designing their shapes and dimensions.
3Productivity
If metallic elements with small dimensions are used, then the ceramic article can achieve higher functionality, but interdiffusion degrades their properties during firing
Solution Approach 1:
The diffusion barrier layer is particularly critical for protecting small-dimensional metallic elements (less than 500 microns) during firing. The barrier prevents interdiffusion that would otherwise rapidly degrade these small features, enabling them to maintain their high functionality and desired properties throughout the ceramic fabrication process.
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 creation of ceramic articles with embedded metallic features that maintain their properties, enabling the fabrication of complex shapes and dimensions without interdiffusion, enhancing the reliability and functionality of ceramic chip carriers and other electronic components.
Implementation Method 1
pyrolysis and heat treatments in inert, oxidizing, or reducing atmospheres
Implementation Method 2
formation of a ceramic body with conductive traces entirely within the ceramic material, using a preceramic polymer resin and metallic particles
Implementation Method 3
pyrolysis and heat treatments in inert, oxidizing, or reducing atmospheres to prevent interdiffusion
Data Source
AI summary
A ceramic article. In some embodiments, the ceramic article includes a ceramic body composed of a ceramic material; and a first conductive trace, the first conductive trace having a first portion entirely within the ceramic material, the first portion having a length of 0.5 mm and transverse dimensions less than 500 microns, the ceramic material including a plurality of ceramic particles in a ceramic matrix.