Glass Ceramic Composition for Uniform Densification and Insulation
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Solution Overview
Problem
Glass ceramic materials with high SiO2 content require extended retention times at high temperatures, leading to pore generation and poor insulation due to gasification of carbon components, resulting in low density and poor insulation in sintered products.
Innovation Solution
A glass ceramic material containing SiO2, B2O3, and an alkali metal oxide (M2O) with specific metal oxides like MnO, NiO, CuO, or ZnO, which reduces glass viscosity and promotes uniform densification, even with extended firing times, ensuring a dense sintered product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the retention time at maximum temperature is extended to ensure sufficient densification of materials that reach maximum temperature later, then densification is improved, but pores are generated due to gasification of carbon components in quickly densified portions, resulting in poor insulation and low density
Solution Approach 1:
The patent changes the chemical composition parameters of the glass ceramic material by adding specific metal oxides (MnO, NiO, CuO, or ZnO) in controlled amounts (0.01-5 wt%). This compositional modification alters the densification behavior and gasification characteristics during firing, enabling uniform densification without pore formation even with extended retention times.
Solution Approach 2:
The metal oxide acts as an intermediary substance that mediates between the glass matrix and carbon components. It facilitates controlled reaction with carbon to prevent excessive gasification while maintaining densification progress, thereby preventing pore formation in quickly densified regions.
2Manufacturing precision
If the retention time at maximum temperature is extended for high SiO2 content glass ceramic materials, then densification is improved, but pore generation is accentuated, resulting in low density and poor insulation
Solution Approach 1:
The patent modifies the chemical composition by incorporating metal oxides (MnO, NiO, CuO, or ZnO) at specific concentrations. This parameter change alters the densification kinetics and carbon gasification behavior, enabling achievement of high density (≥95% relative density) even with extended retention times required for high SiO2 content materials.
3Manufacturing precision
If the retention time at maximum temperature is extended to accommodate variation in reaching maximum temperature, then uniform densification is improved, but manufacturing time is increased
Solution Approach 1:
The patent changes the compositional parameters by adding metal oxides that modify the densification rate and temperature-dependent behavior. This allows the material to achieve uniform densification across the entire firing cycle even with extended retention times, as the metal oxides facilitate controlled densification kinetics throughout the 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
The solution enables the production of dense sintered products with improved insulation and mechanical strength, maintaining high relative density and low dielectric loss, suitable for electronic components.
Implementation Method 1
densification proceeds due to viscous flow of the glass while the maximum temperature is retained
Implementation Method 2
pores will be generated due to gasification of a carbon component remaining in a trace amount
Data Source
AI summary
A glass ceramic material that contains: glass containing SiO2, B2O3, and M2O, where M is an alkali metal; filler containing quartz; and at least one metal oxide selected from MnO, NiO, CuO, and ZnO, wherein an amount of the metal oxide is 0.05 parts by weight to 2 parts by weight relative to a total 100 parts by weight of the glass and the filler.