Orientational Ceramic via Emulsion Binder and Magnetic Field
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Solution Overview
Problem
Existing methods for producing orientational ceramics, particularly those with perovskite-type compounds like PZT, face challenges in achieving desired orientational control due to the brittleness of ceramic slurries without binder resins and aggregation issues with commonly used binder resins, which decrease magnetic anisotropy and hinder effective orientation.
Innovation Solution
The use of an emulsion binder resin, such as emulsion acrylic resin, which minimizes aggregation and maintains magnetic anisotropy, allowing for desired orientational control by applying a magnetic field during the forming process and subsequent drying, thereby producing ceramic compacts with oriented particles and sufficient strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If no binder resin is added to ceramic raw material powder, then magnetic anisotropy is maintained, but the ceramic slurry becomes too brittle to be handled for forming into sheet shape
Solution Approach 1:
An emulsion binder resin is introduced as an intermediary substance that does not significantly interact with ceramic particles through adsorption. This emulsion resin provides the necessary binding capability for sheet formation while maintaining the magnetic anisotropy of the ceramic particles, as it does not form aggregates that would cancel out magnetic orientation effects.
Solution Approach 2:
The type of binder resin is changed from conventional non-emulsion resins to emulsion binder resin. This parameter change in the binder resin's physical and chemical properties (emulsion vs. non-emulsion state) fundamentally alters its interaction with ceramic particles, enabling both formability and magnetic anisotropy preservation simultaneously.
2Ease of manufacture
If conventional binder resins are added to ceramic raw material powder, then the ceramic slurry becomes handleable for forming, but the ceramic particles aggregate and magnetic anisotropy decreases
Solution Approach 1:
The emulsion binder resin acts as a neutral intermediary that facilitates particle aggregation for formability without causing the ceramic particles to aggregate through resin adsorption. This unique property allows the resin to provide mechanical binding while preserving the magnetic orientation of individual ceramic particles.
Solution Approach 2:
Changing the binder resin from conventional types to emulsion binder resin fundamentally changes the aggregation behavior of ceramic particles. The emulsion resin's physical state and chemical properties prevent the formation of aggregates that would cancel magnetic anisotropy, while still providing sufficient binding for sheet formation.
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 orientational ceramics with desired orientational control and maintained magnetic anisotropy, even for perovskite-type compounds with small magnetic anisotropy like PZT, resulting in ceramic electronic components with favorable electrical properties.
Implementation Method 1
the accessory constituent is at least one Group III transition metal ions with a non-zero magnetic moment and rare-earth transition metal ions with a non-zero magnetic moment
Implementation Method 2
subjected to forming in a magnetic field
Data Source
AI summary
An additive that contains an emulsion binder resin substantially free of non-emulsion binder resin, such as an emulsion acrylic resin, is mixed into a ceramic raw material powder containing, as its main constituent, a perovskite-type compound to form a ceramic slurry. Then, an orientational ceramic is prepared by subjecting the slurry to a forming process while simultaneously or sequentially applying a magnetic field and drying the slurry. An orientational ceramic, even formed from a substance which has small magnetic anisotropy, such as PZT, is obtained.