Foamable Composition Using Recovered Silicon Sludge Filler

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Solution Overview

Problem

The disposal of waste silicon sludge generated during silicon wafer cutting in semiconductor manufacturing poses environmental and economic challenges due to air pollution from incineration and high costs and land scarcity for burial, necessitating an effective reuse method to enhance its economic value.

Innovation Solution

A foamable composition incorporating a polymer component, foaming agent, crosslinking agent, filler, and recovered silicon sludge containing silicon carbide and silicon, which is processed into a foamed material and further integrated into a composite product with functional layers to enhance mechanical properties and reduce the need for natural resource exploitation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If waste silicon sludge is disposed by incineration, then the volume of waste is reduced, but air pollution is caused

Engineering Contradiction:

Improvewaste volumeVSAvoidair pollution

Core Design Contradiction:

Loss of substanceVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful waste silicon sludge into a beneficial filler material for foam compositions. The silicon sludge containing silicon carbide and silicon is processed and incorporated into the polymer matrix as a filler, transforming the waste disposal problem into a value-added material application that reduces both waste volume and environmental pollution.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Object-affected harmful factors

If waste silicon sludge is disposed by burial, then the waste is isolated from environment, but high cost and land scarcity problems occur

Engineering Contradiction:

Improveenvironmental isolationVSAvoiddisposal cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

Instead of permanently burying the waste silicon sludge, the patent recovers and reuses it as a filler material in foam compositions. The silicon sludge is processed and incorporated into the polymer matrix, converting a disposal cost center into a potential value-added product that reduces both environmental impact and disposal expenses.

Inventive Principle:

Principle #34Discarding and recovering

3Quantity of substance

If recovered silicon sludge is used as filler in foamable composition, then economic value is increased and waste is reused, but the mechanical properties of the foam may be affected

Engineering Contradiction:

Improveeconomic valueVSAvoidfoam mechanical strength

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The patent optimizes the composition and concentration of silicon sludge filler within the foamable composition to balance mechanical strength and economic value. By controlling the amount and distribution of silicon sludge particles, the formulation maintains adequate structural integrity while maximizing waste reuse and cost benefits.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite material system combining polymer matrix with silicon sludge filler particles. This composite approach leverages the complementary properties of the polymer (providing structural framework) and silicon sludge (providing reinforcement and value), achieving both mechanical performance and economic advantages.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS12152123B2Foamable composition containing recovered silicon sludge, foamed material prepared therefrom and composite product including the same

Publication Date: 2024.11.26 NAM LIONG GLOBAL CORP

AI summary

Disclosed herein is a foamable composition including a polymer component, a foaming agent, a crosslinking agent, a filler, and a recovered silicon sludge containing silicon carbide and silicon. The polymer component is present in an amount ranging from 15 wt % to 60 wt % based on a total weight of the foamable composition. A foamed material prepared from the foamable composition and a composite product including the same are also disclosed.