Metal-Ceramic Timepiece Component via Composite Electroforming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current manufacturing processes for high-precision metal-ceramic timepiece components using LIGA techniques face challenges with materials like copper, gold, nickel, and nickel phosphorus, which have unsatisfactory mechanical properties, poor tribological properties, and are difficult to depilate.
Innovation Solution
A method involving a substrate with a structurable resin layer, structured to form a mold with openings, followed by a chemical metallization process depositing a metal or metal alloy with ceramic particles, such as nickel phosphorus with hexagonal boron nitride, to enhance mechanical and tribological properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional materials like copper, gold, nickel, or nickel phosphorus are used in LIGA processes, then the manufacturing process is established and reliable, but the mechanical properties and tribological properties are unsatisfactory
Solution Approach 1:
The patent applies composite materials by co-depositing metal particles (nickel, copper, or their alloys) with ceramic particles (such as Al2O3, SiC, or BN) during the electroforming process. This creates a metal-ceramic composite material that combines the mechanical strength and ductility of metals with the hardness, wear resistance, and lubrication properties of ceramics, thereby simultaneously improving both mechanical properties and tribological properties
Solution Approach 2:
The patent changes the material composition parameters by controlling the concentration ratios of metal salts and ceramic particles in the electrolyte, as well as the deposition conditions. This allows optimization of the composite material properties to achieve the desired balance between mechanical strength and tribological performance
2Ease of manufacture
If nickel or nickel phosphorus is deposited by galvanic growth, then the manufacturing process is established, but the tribological properties are poor and depilation is difficult
Solution Approach 1:
The patent transforms pure metal deposits into metal-ceramic composites by adding ceramic particles to the electrolyte. The ceramic particles (such as Al2O3, SiC, or BN) provide excellent tribological properties including wear resistance and self-lubrication, while the metal matrix maintains good mechanical properties and processability
Solution Approach 2:
The patent uses aluminum as a sacrificial anode that can be easily removed after deposition. The aluminum anode serves to activate the substrate surface and can be completely eliminated, simplifying the manufacturing process and improving ease of manufacture
3Manufacturing precision
If complex high-precision components are manufactured, then the precision and mechanical properties are improved, but the manufacturing cost increases
Solution Approach 1:
The patent merges multiple functions into a single electroforming process: it simultaneously deposits metal, incorporates ceramic particles, achieves high precision through the LIGA technique's inherent accuracy, and creates complex three-dimensional structures. This integration eliminates the need for separate post-processing steps to add ceramic coatings, thereby reducing manufacturing cost while maintaining high precision
Solution Approach 2:
The patent optimizes process parameters including electrolyte composition, current density, temperature, and deposition time to achieve high manufacturing efficiency. By controlling these parameters, the process can produce high-precision components with complex geometries in a single step, reducing the number of manufacturing operations and associated costs
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 economical production of complex, high-precision components with improved mechanical and tribological properties, facilitating easier component release and reducing manufacturing costs.
Implementation Method 1
forming a metallic deposit in the openings of the resin mold; the metallic deposit comprising a metal or a metallic alloy and ceramic particles co-deposited with the metal or the metal alloy by a chemical metallization process
Implementation Method 2
structuring the resin so as to form a mold comprising openings revealing an active surface
Data Source
Figure 1~2a
Figure 2b
Figure 3~4
AI summary
The present invention relates to a process for manufacturing a timepiece component, comprising the steps of: providing a substrate (10), at least one of the faces (11) of which is intended to receive a structurable resin (20); applying a layer of the structurable resin (20) on said at least one face (11); structuring the resin (20) so as to form a mold comprising openings (21) that reveal an active surface (14) comprising at least one first level (14'); forming a metal deposit (40) in the openings (21) of the resin mold (20); releasing the metal deposit (40) from the mold (20) and from the substrate (10) so as to obtain the component. A first primer layer (12) is formed on, or produced by, at least one portion of the first level (14') of said active surface (14) before forming the metal deposit (40). The metal deposit (40) comprises a metal or metal alloy codeposited with ceramic particles, by a chemical or electrochemical metallization process.