Optical Bed Powder Inspection for Ceramic Substrate Flatness

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Solution Overview

Problem

The uneven adhesion of bed powder on ceramic compacts during the manufacturing process leads to surface waviness and decreased yield in ceramic substrates, particularly as production scales increase, making it difficult to detect and correct uneven adhesion visually.

Innovation Solution

A method involving an adhesion process followed by an inspection process using photoelectric or image sensors to detect the reflected or transmitted light of the bed powder on ceramic compacts, allowing for precise control of the adhesion amount through methods like spraying and edge detection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the sheet-like compact is made larger and processing volume is increased to improve productivity, then production efficiency is improved, but uneven adhesion of bed powder occurs more frequently leading to decreased yield

Engineering Contradiction:

Improveproduction efficiencyVSAvoidyield

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent implements an inspection process that detects the adhesion amount of bed powder on ceramic compacts and provides feedback to control the adhesion process. This closed-loop system monitors and adjusts bed powder application to maintain uniform adhesion even as production scale increases, preventing the yield decrease that would otherwise occur with larger processing volumes.

Inventive Principle:

Principle #23Feedback

2Productivity

If bed powder adhesion is performed while moving the sheet-like compact to improve productivity, then manufacturing efficiency is improved, but uneven adhesion of bed powder occurs making it difficult to discriminate with naked eye

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidadhesion uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent replaces visual inspection with an automated optical inspection system using sensors that detect reflected or transmitted light. This substitution of mechanical/visual detection with optical sensing enables precise measurement of bed powder adhesion uniformity during continuous movement, maintaining manufacturing precision while preserving the productivity benefits of continuous processing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces light as an intermediary to detect bed powder adhesion characteristics. By using reflected or transmitted light properties, the system can objectively measure adhesion uniformity without direct visual inspection, enabling precise detection of uneven adhesion that would otherwise be imperceptible during high-speed continuous processing.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If the adhesion amount of bed powder is not controlled precisely, then the inspection process is simplified, but surface waviness occurs and yield decreases

Engineering Contradiction:

Improveinspection process complexityVSAvoidsurface flatness

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The inspection process detects adhesion amount variations and provides feedback to control mechanisms that adjust bed powder application. This feedback loop enables precise control of adhesion amount to prevent surface waviness, while the automated nature of the inspection simplifies the overall process compared to manual visual inspection and adjustment.

Inventive Principle:

Principle #23Feedback

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 effectively inspects and adjusts the bed powder adhesion, improving yield and surface flatness of ceramic substrates by ensuring uniform adhesion, even in high-volume production scenarios.

Implementation Method 1

The inspection process includes inspecting an adhesion amount of the bed powder by using a photoelectric sensor or an image sensor and by detecting a reflected light or a transmitted light of the surface

Methodology Applied

Scientific EffectReflected light detection: Reflection

Implementation Method 2

Methodology Applied

Scientific EffectTransmitted light detection: Light

Data Source

PatentEP4640654A1Method for inspecting amount of floor powder adhered, and method for producing ceramic substrate using same

Publication Date: 2025.10.29 NITERRA MATERIALS CO LTD

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AI summary

An inspection method that inspects an adhesion amount of a bed powder on a ceramic compact is provided. Also, a method for manufacturing a ceramic substrate using the inspection method is provided. A method for inspecting an amount of adhered bed powder according to an embodiment includes an adhesion process and an inspection process. The adhesion process includes adhering a bed powder to a surface of a ceramic compact. The inspection process includes inspecting an adhesion amount of the bed powder by using a photoelectric sensor or an image sensor and by detecting a reflected light or a transmitted light of the surface.