Low-Density Glass Bubbles With Small Size and Crush Strength
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Solution Overview
Problem
Existing glass bubbles face a trade-off between size, density, and strength, with smaller sizes and lower densities being desired for applications like 5G communication and automotive surfaces, but current technologies struggle to achieve these properties simultaneously.
Innovation Solution
Control the particle feed size and size distribution, along with the blowing agent content, to produce glass bubbles with a D50 of no greater than 13 microns, an average true density of no greater than 0.42 grams per cubic centimeter, and a 90% crush strength of at least 55 megapascals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If glass bubbles are made smaller to meet HDI PCB requirements, then the dielectric loss factor is reduced, but the crush strength decreases
Solution Approach 1:
The patent applies parameter changes by precisely controlling the glass bubble size (D50 ≤ 13 micrometers) and density (≤ 0.42 g/cc) through modified blowing agent amounts and feed particle size distribution. This enables achieving both small size for low dielectric loss and sufficient strength (≥ 55 MPa) that was previously unattainable together
Solution Approach 2:
The patent uses composite materials by combining glass bubbles with specific polymer matrices in sheet molding compounds and copper clad laminates. The glass bubbles serve dual functions: providing low dielectric constant for signal transmission and maintaining structural integrity through controlled size and strength properties
2Weight of moving object
If glass bubbles are made with lower density to reduce weight, then the weight is reduced, but the strength decreases
Solution Approach 1:
The patent applies parameter changes by optimizing the blowing agent to feed ratio and controlling feed particle size distribution to achieve glass bubbles with density ≤ 0.42 g/cc while maintaining D50 ≤ 13 micrometers and crush strength ≥ 55 MPa, breaking the traditional trade-off between density and strength
3Loss of energy
If glass bubbles are made with smaller size for high-frequency applications, then the dielectric properties are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies preliminary action by pre-controlling the feed particle size distribution before the blowing process. By optimizing the feed preparation stage (milling and classification), the final glass bubble size distribution is predetermined, achieving D50 ≤ 13 micrometers with reduced manufacturing complexity
Data Source
AI summary
A plurality of glass bubbles having, in combination, a D50 size of no greater than 13 micrometers, an average true density of no greater than 0.42 grams per cubic centimeter, and a 90% crush strength of at least 55 megapascals are described. Methods of making such glass bubbles and compositions and articles such as sheet molding compounds and dielectric layers prepared from such glass bubbles are also described.