Green Body Machining for Ceramic Electronic Components

Solution Overview

Problem

Ceramic materials used in portable electronic devices are difficult to machine with fine or precise features due to their hard and durable properties, leading to excessive tool wear and increased manufacturing costs and time.

Innovation Solution

Machining ceramic components before they are fully sintered, using a green body or partially sintered state, which allows for improved tool life and reduced machining time, enabling the formation of features such as small holes and complex shapes with enhanced precision and tolerance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional machining techniques are used on fully sintered ceramic parts, then the ceramic durability and hardness are maintained, but tool life is reduced and machining time increases

Engineering Contradiction:

Improveceramic durabilityVSAvoidmachining speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent applies preliminary action by machining the ceramic component while it is in the green body state (before full sintering). At this stage, the ceramic material is softer and more ductile, allowing for easier machining with standard tools. The component is then completed by sintering after machining, which restores the full hardness and durability. This sequence resolves the contradiction by performing the difficult machining operation when the material is most machinable, then restoring the desired material properties through sintering.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If traditional machining techniques are used on fully sintered ceramic parts, then the ceramic durability is maintained, but tool wear increases and manufacturing cost increases

Engineering Contradiction:

Improveceramic durabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by machining the ceramic component while it is in the green body state (before full sintering). At this stage, the ceramic material is softer and more ductile, allowing for easier machining with standard tools. The component is then completed by sintering after machining, which restores the full hardness and durability. This sequence resolves the contradiction by performing the difficult machining operation when the material is most machinable, then restoring the desired material properties through sintering.

Inventive Principle:

Principle #10Preliminary action

3Strength

If traditional machining techniques are used on fully sintered ceramic parts, then the ceramic hardness is maintained, but the ability to form fine features is reduced

Engineering Contradiction:

Improveceramic hardnessVSAvoidfeature precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by machining the ceramic component while it is in the green body state (before full sintering). At this stage, the ceramic material is softer and more ductile, allowing for easier machining with standard tools. The component is then completed by sintering after machining, which restores the full hardness and durability. This sequence resolves the contradiction by performing the difficult machining operation when the material is most machinable, then restoring the desired material properties through sintering.

Inventive Principle:

Principle #10Preliminary action

4Reliability

If traditional machining techniques are used on fully sintered ceramic parts, then the ceramic durability is maintained, but the amount of time required to drill holes increases

Engineering Contradiction:

Improveceramic durabilityVSAvoiddrilling time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent applies preliminary action by machining the ceramic component while it is in the green body state (before full sintering). At this stage, the ceramic material is softer and more ductile, allowing for easier machining with standard tools. The component is then completed by sintering after machining, which restores the full hardness and durability. This sequence resolves the contradiction by performing the difficult machining operation when the material is most machinable, then restoring the desired material properties through sintering.

Inventive Principle:

Principle #10Preliminary action

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 approach reduces manufacturing costs and time by improving tool life and enabling the creation of finer features with tighter tolerances, resulting in more durable and cost-effective ceramic components for portable electronic devices.

Implementation Method 1

heating the slurry includes heating it at a temperature sufficient to burn off or evaporate the water and solvent of the slurry

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

The partial sintering may be performed at a temperature ranging between 700 degrees Celsius and 1500 degrees Celsius

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS10335979B2Machining features in a ceramic component for use in an electronic device

Publication Date: 2019.07.02 APPLE INC

AI summary

A ceramic part and methods for making the ceramic part are disclosed. A green body or non-sintered part may be formed using a casting or molding process. The green body may not be sintered or may be partially sintered before machining one or more features into a surface of the green body. After machining, the component may be fully sintered to create a hardened ceramic component.