Pasty Composition for High Aspect Ratio 3D Structures
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Solution Overview
Problem
Current methods for manufacturing three-dimensional structures with high aspect ratios for electrochemical and electronic components are limited by the inability to achieve sufficient layer thickness and stability, leading to structural defects and increased production costs due to the limitations of printing technologies like silk screen and tampon printing.
Innovation Solution
A pasty composition comprising a heterogeneous mixture of powdery solids, organic polymers, solvents with controlled evaporation rates, and additives that allows for the formation of self-supporting structures with high aspect ratios through controlled evaporation and heat treatment, enabling precise shaping and mechanical stability before sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If silk screen printing or tampon printing is used to manufacture functional layers, then manufacturing cost is reduced, but aspect ratio and layer thickness are limited
Solution Approach 1:
The patent modifies the physical-chemical parameters of the paste composition by incorporating specific binders, solvents, and additives that control viscosity and drying behavior. This enables the paste to maintain stability during printing while achieving higher layer thicknesses and aspect ratios that would be impossible with conventional printing pastes
Solution Approach 2:
The invention uses composite paste formulations combining conductive powders (silver, copper, or electrically conductive ceramics) with specially designed polymer binders and solvent systems. This composite structure allows the paste to exhibit both printability and the mechanical strength needed to maintain high aspect ratios without collapsing during drying and sintering
2Manufacturing precision
If higher layer thickness is achieved to increase aspect ratio, then structural stability deteriorates due to collapse and formation of recesses
Solution Approach 1:
The patent applies preliminary protective actions by formulating the paste with binders and additives that create a stable green body structure before sintering. The paste composition is designed to maintain structural integrity during the critical drying phase, preventing collapse and recess formation that would otherwise occur with thick layers
Solution Approach 2:
The invention changes the rheological and drying parameters of the paste through careful selection of solvent evaporation rates and binder properties. This controlled parameter change allows thick layers to be deposited and maintained in a stable configuration throughout the drying and sintering processes
3Shape
If cutting machining is performed on sintered structures, then final shape is achieved, but material damage and structure failure occur due to brittleness
Solution Approach 1:
The patent performs preliminary shaping operations on the green body (unsintered) structure while it is still in a ductile, machinable state. This preliminary action allows complex three-dimensional shapes to be formed before sintering, eliminating the need for subsequent machining of brittle sintered parts and preventing structure failure
Solution Approach 2:
The invention replaces post-sintering mechanical machining with pre-sintering shaping operations. By performing formative operations while the material is in its green, ductile state rather than after sintering when it is brittle, the process eliminates the harmful mechanical stresses that cause cracking and failure
4Ease of operation
If conventional paste formulations are used, then application is simple, but mechanical properties of dried paste are insufficient requiring high processing effort
Solution Approach 1:
The patent uses composite paste formulations with specially designed polymer binders and additives that provide both ease of application and superior mechanical properties in the dried green body. The composite nature of the paste allows it to be easily printed while forming a structurally sound layer that requires minimal post-processing
Solution Approach 2:
The invention modifies the physical-chemical parameters of the paste composition to achieve optimal balance between printability and mechanical strength. By controlling viscosity, solvent evaporation rate, and binder properties, the paste applies easily but dries to a mechanically robust green body that resists damage during handling and requires minimal machining effort
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 creation of structures with improved mechanical properties and aspect ratios, reducing the risk of structural defects and production costs by allowing for precise shaping and stable formation of functional layers with enhanced adhesion and reduced material removal forces.
Implementation Method 1
a first solvent C1 having a boiling temperature at which an evaporation of the first solvent C1 takes place
Implementation Method 2
in a heat treatment in which a sintering of a solid contained in a pasty composition takes place
Data Source
AI summary
A pasty composition for the manufacture of three-dimensional structures or structural elements on the surface of a substrate is formed together with a polymer as an organic component B1, and a powdery material that makes up a proportion of solid in the range of 60 mass % to 95 mass % in the composition, andat least two mutually different solvents C1 and C2 that form a solvent mixture. A first solvent C1 has a boiling temperature here that is lower than the boiling temperature of the further solvent or solvents C2.