Polyvinyl Acetal Resin Composition for Cleaner Ceramic Slurry Dissolution
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Solution Overview
Problem
Conventional polyvinyl acetal resins leave finer undissolved matter when dissolved in organic solvents, requiring additional filtration steps that lower productivity and affect the electrical characteristics of multilayer ceramic capacitors.
Innovation Solution
A polyvinyl acetal resin with specific IR absorption spectrum characteristics and hydroxy group content, satisfying certain relational formulas, reduces fine undissolved matter, improving productivity and enabling production of a ceramic green sheet with excellent toughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional polyvinyl acetal resin is used as binder resin, then the resin can be dissolved in organic solvent to form ceramic slurry, but fine undissolved matter remains in the solution requiring additional filtration steps
Solution Approach 1:
The patent changes the chemical composition parameters of the polyvinyl acetal resin by controlling the acetal group content (40-80 mol%) and hydroxy group content (10-40 mol%) to optimize solubility. This parameter optimization ensures complete dissolution in organic solvents without leaving fine undissolved matter, eliminating the need for filtration steps while maintaining excellent electrical characteristics of the final ceramic product
Solution Approach 2:
The patent performs preliminary optimization of the resin's molecular structure during manufacturing by controlling the acetalization reaction conditions. This preliminary action ensures that the resin is pre-configured with optimal solubility characteristics before use, preventing undissolved matter formation during the ceramic slurry preparation process
2Reliability
If filtration step is added to remove undissolved matter, then electrical characteristics improve, but productivity decreases due to additional processing time
Solution Approach 1:
The patent extracts the problematic fine undissolved matter from the system by optimizing the resin's dissolution properties. Through precise control of acetal and hydroxy group contents, the resin is engineered to completely dissolve in organic solvents, removing the source of undissolved matter that would otherwise require filtration to eliminate
Solution Approach 2:
The patent performs preliminary optimization of the resin's molecular structure during manufacturing by controlling the acetalization reaction conditions. This preliminary action ensures that the resin is pre-configured with optimal solubility characteristics before use, preventing undissolved matter formation during the ceramic slurry preparation process
3Productivity
If polyvinyl acetal resin with high solubility is used, then filtration is unnecessary improving productivity, but the resin may lack toughness required for ceramic green sheet
Solution Approach 1:
The patent employs parameter optimization by simultaneously controlling multiple composition parameters: acetal group content (40-80 mol%), hydroxy group content (10-40 mol%), and weight average molecular weight (10,000-1,000,000). This multi-parameter optimization achieves the difficult balance of complete solubility (eliminating filtration need) while maintaining sufficient toughness for ceramic green sheet formation
Solution Approach 2:
The patent creates a composite molecular structure within the polyvinyl acetal resin by incorporating both acetal groups (for solubility) and hydroxy groups (for toughness and green sheet formation). This composite functional approach allows the single resin to simultaneously provide both dissolution capability and mechanical strength
4Manufacturing precision
If finer undissolved matter is removed to meet smaller size requirements, then product quality improves, but more aggressive filtration is needed reducing productivity
Solution Approach 1:
The patent changes the fundamental parameter of resin solubility by optimizing acetal group content (40-80 mol%) and hydroxy group content (10-40 mol%). This parameter change ensures complete dissolution at the molecular level, eliminating fine undissolved matter formation and making filtration entirely unnecessary regardless of the required product size or quality level
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 resin results in a ceramic green sheet with reduced defects, enhancing the reliability and productivity of multilayer ceramic capacitors by minimizing undissolved matter and ensuring smooth production.
Implementation Method 1
conventional polyvinyl acetal resins may leave trace amounts of undissolved matter when dissolved in organic solvents
Implementation Method 2
using a polyvinyl acetal resin in a ceramic green sheet application requires removal of undissolved matter by a filtration step
Implementation Method 3
The slurry composition is subjected to heating or the like to remove the organic solvent and other volatile components
Data Source
AI summary
The present invention provides a polyvinyl acetal resin which leaves less fine undissolved matter when dissolved in an organic solvent and thus can improve productivity particularly when used as a binder for a ceramic green sheet, and which can also provide a ceramic green sheet having excellent toughness and enables production of a highly reliable multilayer ceramic capacitor. Provided is a polyvinyl acetal resin having: a wavenumber A (cm−1) of a peak within a range of 3,100 to 3,700 cm−1 in an IR absorption spectrum measured using an infrared spectrophotometer; and a hydroxy group content (mol %), the wavenumber A of the peak and the hydroxy group content satisfying relations of the following formulas (1) and (2):[(3,470−A)/Hydroxy group content]≤5.5 (1)(3,470−A)≤185 (2)wherein A is a wavenumber which is lower than 3,470 cm−1 and at which a transmittance a (%) satisfying [100−(100−X)/2] is exhibited, where X (%) is a minimum transmittance of the peak within the wavenumber range of 3,100 to 3,700 cm−1.