Aqueous Green Sheet Slurry for Flexible, Strong Ceramic Lamination
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Solution Overview
Problem
Conventional aqueous ceramic green sheet compositions face challenges in achieving increased flexibility while maintaining strength and adhesiveness, particularly when stacking multiple sheets, due to limitations in solvent choice and binder properties.
Innovation Solution
A baking slurry composition comprising inorganic powder, polyvinyl alcohol resin, and an acrylic polymer with specific glass transition temperature and acid value ranges, which enhances the flexibility, strength, and adhesiveness of the green sheet, allowing for efficient stacking and sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an aqueous solvent is used instead of organic solvent in baking slurry composition, then environmental safety and health concerns are reduced, but the flexibility and strength of the resulting green sheet deteriorate
Solution Approach 1:
The patent uses a composite binder system combining polyvinyl alcohol resin and acrylic polymer in specific ratios. The polyvinyl alcohol provides base binding strength while the acrylic polymer (with Tg of -50°C to 30°C and acid value of 50-200 mg KOH/g) enhances flexibility and interlaminar adhesion. This composite approach allows aqueous solvent usage while maintaining sheet strength through synergistic binder interactions.
Solution Approach 2:
The patent optimizes specific parameters of the acrylic polymer including glass transition temperature (-50°C to 30°C), acid value (50-200 mg KOH/g), and weight percentage (0.1-5.0% relative to total solid content). These parameter adjustments tailor the binder properties to achieve both flexibility and strength in aqueous-based green sheets, resolving the contradiction between environmental safety and mechanical performance.
2Ease of operation
If the green sheet is made more flexible, then processability and stacking ease are improved, but the strength and structural integrity of the sheet deteriorate
Solution Approach 1:
The dual-binder system with polyvinyl alcohol and acrylic polymer creates a composite material that balances flexibility and strength. The polyvinyl alcohol resin provides structural strength while the acrylic polymer component (with specific Tg and acid value ranges) imparts flexibility, allowing the sheet to be both easy to handle and maintain structural integrity.
Solution Approach 2:
The patent applies different binder functions to different aspects of sheet performance: polyvinyl alcohol primarily contributes to strength and cohesion, while acrylic polymer specifically enhances flexibility and interlaminar bonding. This functional differentiation within the binder system allows simultaneous optimization of both flexibility and strength without compromise.
3Ease of manufacture
If conventional binders are used in aqueous baking slurry, then manufacturing simplicity is maintained, but the adhesiveness of stacked sheets deteriorates
Solution Approach 1:
The patent specifies precise parameter ranges for the acrylic polymer including acid value (50-200 mg KOH/g) and glass transition temperature (-50°C to 30°C). These parameter optimizations enhance the chemical and physical properties of the binder, improving adhesion between stacked sheets while maintaining manufacturing simplicity through straightforward slurry preparation and processing.
Solution Approach 2:
The combination of polyvinyl alcohol resin and acrylic polymer creates a composite binder system where the acrylic component specifically enhances interlaminar adhesion. This composite approach improves stacking adhesiveness without complicating the manufacturing process, as the binders can be mixed and applied using conventional ceramic green sheet fabrication methods.
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 composition achieves improved flexibility, strength, and adhesiveness in the green sheet, enabling effective stacking and sintering, thereby facilitating the production of high-quality monolithic ceramic capacitors with reduced thickness.
Implementation Method 1
The acrylic polymer (D) has a glass transition temperature higher than or equal to −50° C. and lower than or equal to 30° C.
Implementation Method 2
The acrylic polymer (D) has an acid value greater than or equal to 50 mg KOH/g and less than or equal to 200 mg KOH/g
Data Source
AI summary
A baking slurry composition for producing a green sheet of the present invention contains inorganic powder, a polyvinyl alcohol resin, acrylic polymer, and water. The acrylic polymer has a glass transition temperature higher than or equal to −50° C. and lower than or equal to 30° C. and an acid value greater than or equal to 50 mg KOH/g and less than or equal to 200 mg KOH/g. The acrylic polymer has a weight percentage of more than or equal to 0.1 and less than or equal to 5.0 relative to a total solid content of the baking slurry composition.