High Silicate Glass Substrate Sintering Moisture Control
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Solution Overview
Problem
Producing high-frequency substrate materials with large area porous glass is challenging due to cracking issues during the sintering process, often caused by residual moisture.
Innovation Solution
A method involving the preparation of a glass precursor with specific composition, phase separation, acid treatment, controlled drying to achieve a moisture change within a specific range, and subsequent sintering to produce a high silicate glass substrate with a large area without cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If large area porous glass is produced for high-frequency substrate applications, then the area increases, but cracking occurs during sintering due to residual moisture
Solution Approach 1:
The patent applies preliminary drying treatment to the porous glass before sintering to remove residual moisture. This preliminary action prevents the harmful effect of moisture expansion during sintering, thereby preventing cracking while maintaining large area. The drying step is performed at controlled temperature and humidity conditions prior to the sintering process.
Solution Approach 2:
The patent controls the drying conditions (temperature, humidity, time) to achieve optimal moisture removal without causing thermal stress or deformation. By adjusting these parameters, the glass can be dried sufficiently to prevent cracking during sintering while maintaining the large area required for high-frequency substrate applications.
2Loss of energy
If silica glass is used for high-frequency substrate materials, then dielectric loss is reduced, but production and processing cost increases
Solution Approach 1:
The patent creates porous glass with localized high silicate content by phase separation, where silica-rich regions provide low dielectric loss properties while the overall composition includes cost-reducing components. This local quality approach maintains the essential performance characteristic (low dielectric loss) while reducing overall material cost.
Solution Approach 2:
The patent produces composite porous glass materials that combine silica-rich phases (for low dielectric loss) with other glass components (for cost reduction and processability). The phase-separated structure creates a composite material that achieves both performance and cost objectives.
3Manufacturing precision
If porous glass is sintered at high temperature to densify, then dielectric properties improve, but cracking risk increases due to residual moisture
Solution Approach 1:
The patent performs preliminary drying treatment before sintering to remove moisture that would cause cracking at high temperatures. This preliminary action ensures that when high-temperature sintering is applied to achieve good dielectric properties, the glass structure is already stable and resistant to moisture-induced cracking.
Solution Approach 2:
The patent uses rapid or controlled drying processes to quickly remove moisture before it can cause harmful effects during sintering. By rushing through the moisture removal step efficiently, the glass is prepared for high-temperature sintering without the time for moisture to cause structural damage.
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 method enables the production of high silicate glass substrates with large areas suitable for high-frequency applications, reducing the risk of cracking and achieving desired dielectric properties.
Implementation Method 1
an alkali borosilicate-based glass is phase-separated into an insoluble phase rich in SiO2 and a soluble phase rich in B2O3 by heat treatment
Implementation Method 2
the soluble phase is leached by acid to thereby produce a porous glass having SiO2 as its main component
Implementation Method 3
when a porous glass having a specific composition is dried to have an amount of moisture within a specific range before the porous glass is sintered
Implementation Method 4
the porous glass is sintered to be densified
Data Source
AI summary
A method for producing a high silicate glass substrate, includes: (1) obtaining a glass precursor containing, as represented by mol % based on oxides, 60% to 75% of SiO2, 0% to 15% of Al2O3, 15% to 30% of B2O3, 0% to 3% of P2O5, and 1% to 10% in total of at least one selected from R2O and R′O; (2) applying first heat treatment to the glass precursor to cause phase separation so as to obtain a phase-separated glass; (3) applying acid treatment to the phase-separated glass to make the phase-separated glass porous so as to obtain a porous glass; (4) drying the porous glass so that a rate of change in mass reaches 10% to 50%; and (5) applying second heat treatment to the porous glass to sinter the porous glass so as to obtain a high silicate glass substrate.