Low-Temperature Ceramic-Metal Composite via Lithium Molybdate Precipitation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing ceramic composite materials often require high temperatures and complex processes, which can lead to diffusion between metal and ceramic phases, resulting in compromised electrical and magnetic properties and increased energy consumption.
Innovation Solution
A low-temperature process using lithium molybdate (Li2MoO4) powder, mixed with metal or ceramic particles, is employed to create ceramic-metal or ceramic-ceramic composites through pressure molding or 3D printing, where Li2MoO4 is precipitated onto the surface of particles, allowing for the formation of composite discs with controlled water content and subsequent drying at 120°C to maintain optimal dielectric and ferroelectric properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high temperature processing is used to manufacture ceramic composite materials, then the material achieves sufficient densification and structural integrity, but diffusion between metal and ceramic phases occurs resulting in compromised electrical and magnetic properties
Solution Approach 1:
The patent changes the temperature parameter from conventional high temperature (typically >1000°C) to low temperature (120°C) processing. This parameter change allows the ceramic composite to achieve sufficient densification and structural integrity without causing diffusion between metal and ceramic phases, thereby preserving electrical and magnetic properties.
Solution Approach 2:
The patent uses a composite material system consisting of ceramic particles (such as barium ferrite) combined with metal particles, where the ceramic phase provides structural integrity while the metal phase contributes electrical and magnetic properties. The low-temperature processing preserves the distinct phases without diffusion.
2Strength
If high temperature processing is used to manufacture ceramic composite materials, then the material achieves sufficient densification and structural integrity, but energy consumption increases
Solution Approach 1:
The patent changes the temperature parameter from conventional high temperature to low temperature (120°C) processing. This dramatically reduces energy consumption while still achieving sufficient densification and structural integrity through the unique low-temperature sintering mechanism that promotes particle bonding without requiring high thermal energy input.
3Reliability
If complex manufacturing processes are used to manufacture ceramic composite materials, then the material achieves desired properties, but phase diffusion occurs compromising electrical and magnetic properties
Solution Approach 1:
The patent applies preliminary action by pre-coating ceramic particles with metal particles before the sintering process. This preliminary coating ensures uniform distribution and prevents phase diffusion during processing, simplifying the overall manufacturing process while preserving electrical and magnetic properties.
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 method enables the production of ceramic composite materials with improved electrical and magnetic properties, reduced energy consumption, and minimal phase formation, suitable for electronic components and other applications, while maintaining the original properties of both ceramic and metal components.
Implementation Method 1
mixing metal powder or ceramic powder with an aqueous solution of lithium molybdate to obtain a powder containing lithium molybdate precipitated on the surface of the particles
Implementation Method 2
drying the disc to remove water from the ceramic-metal or ceramic-ceramic composite
Data Source
AI summary
A process for manufacturing ceramic-metal composite material, comprises dissolving ceramic powder into water to obtain an aqueous solution of ceramic; mixing metal powder having a multimodal particle size where largest particle size is one fourth of the minimum dimension of a device, with the aqueous solution of ceramic to obtain a powder containing ceramic precipitated on the surface of metal particles; mixing the powder containing ceramic precipitated on the surface of the metal particles, with ceramic powder having a particle size below 50 μιτι, to obtain a powder mixture; adding saturated aqueous solution of ceramic to the powder mixture to obtain an aqueous composition containing ceramic and metal; compressing the aqueous composition to form a disc of ceramic-metal composite material containing ceramic and metal; and removing water from the ceramic-metal composite material; wherein ceramic content of the disc is 10 vol-% to 35 vol-%. Alternatively, ceramic-ceramic composite material may be manufactured.