Piezoelectric Ceramic Structures with In-Situ Layer Alignment
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Solution Overview
Problem
The existing manufacturing processes for layered structures, particularly those involving ceramics or metals, are cumbersome and time-consuming due to the need to relocate and reposition layers at different stages, which can lead to misalignment and damage, especially when forming piezoelectric materials that do not self-set or partially set after application.
Innovation Solution
An in-situ additive manufacturing process where each subsequent layer is formed directly on the previous layer without relocation, using ceramic slurry that is sintered and then cut or diced, eliminating steps like etching and binder burnout, and allowing for the construction of layered structures with piezoelectric characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing processes are used for layered ceramic structures, then manufacturing precision can be maintained, but manufacturing time and process complexity increase significantly due to relocation and repositioning steps
Solution Approach 1:
The build plate is pre-patterned with alignment features and the first ceramic layer is deposited and sintered in advance to establish a precise reference surface. This preliminary preparation eliminates the need for subsequent relocation and repositioning operations, allowing direct deposition of subsequent layers while maintaining manufacturing precision and reducing overall manufacturing time.
Solution Approach 2:
The patent uses a master build plate with embedded alignment features that replicates the precise geometric pattern required for layer alignment. By copying this master pattern onto subsequent build plates and using it as a reference during deposition, the process eliminates time-consuming relocation steps while maintaining consistent layer alignment precision across all layers.
2Stability of the object's composition
If ceramic slurry is applied and sintered in traditional processes, then layer stability is achieved, but the process becomes cumbersome and time-consuming due to multiple relocation steps
Solution Approach 1:
The patent merges the deposition, sintering, and alignment operations into a single integrated process cycle. The build plate serves dual functions as both the deposition surface and the alignment reference, eliminating the need for separate relocation and repositioning steps. This consolidation maintains layer stability through controlled sintering while significantly reducing process complexity by eliminating multiple operational phases.
Solution Approach 2:
The build plate is designed with multi-functionality, serving as both the substrate for ceramic slurry deposition and the alignment reference for subsequent layers. This universal component eliminates the need for separate alignment fixtures and relocation mechanisms, reducing process complexity while maintaining layer stability through its dual role in the manufacturing process.
3Adaptability or versatility
If piezoelectric materials are used that do not self-set, then manufacturing flexibility is improved, but it becomes difficult to additively manufacture with additional layers
Solution Approach 1:
The first piezoelectric ceramic layer is deposited and sintered in advance to create a stable, self-supporting reference surface. This preliminary action provides a firm foundation for subsequent layer deposition, enabling the additive manufacturing process to continue with additional layers despite the materials lacking self-setting properties. The pre-sintered layer acts as a temporary support structure during the manufacturing process.
Solution Approach 2:
The sintered first ceramic layer serves as an intermediary support structure for subsequent piezoelectric material deposition. This intermediary layer provides the mechanical stability needed to support additional layers during manufacturing, enabling additive manufacturing feasibility while maintaining the flexibility of using piezoelectric materials that do not self-set. The intermediary layer is later removed or integrated into the final structure.
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 reduces manufacturing time and minimizes layer misalignment, enabling efficient production of layered composite structures with piezoelectric properties, suitable for applications in sensors, actuators, and transducers.
Implementation Method 1
sintering at least a portion of the first layer of the ceramic powder, wherein sintering the portion of the first layer of ceramic powder melts the plurality of ceramic particles
Implementation Method 2
The piezoelectric effect is a conversion of mechanical stress to electricity or electricity to mechanical stress
Data Source
AI summary
An additively manufactured multilayered structure including a first ceramic layer, the first ceramic layer including a ceramic powder having piezoelectric characteristics and a second ceramic layer built over the first ceramic layer, the second ceramic layer includes a second layer of ceramic powder has piezoelectric characteristics built on the first layer. At least a portion of the second ceramic layer is sintered and set over the first layer.