Powder Composition for Thermal Expansion Control

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Solution Overview

Problem

Conventional materials fail to sufficiently lower the linear thermal expansion coefficient and achieve excellent coatability, which is necessary for forming a composition with improved thermal expansion control characteristics.

Innovation Solution

A powder with specific lattice constant and particle diameter distribution characteristics, such as titanium-containing metal oxide powder, is developed to satisfy the requirements of large temperature-dependent anisotropy and coatability, combined with a first material like resins or ceramics to form a solid composition.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional materials with negative linear thermal expansion coefficient are added to solid materials, then the linear thermal expansion coefficient is lowered, but the thermal expansion control characteristics are not sufficiently improved

Engineering Contradiction:

Improvethermal expansion control characteristicsVSAvoidlinear thermal expansion coefficient reduction

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent changes the particle size parameters of the powder material, specifically controlling D50 to be 0.5 μm or more and 60 μm or less, with specific D10/D50 and D90 ratios. This parameter optimization enables both sufficient thermal expansion control (|dA(T)/dT| ≥ 10 ppm/°C) and good coatability, resolving the contradiction between thermal expansion control effectiveness and manufacturing applicability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite system by combining powder with specific crystal structure characteristics (|dA(T)/dT| ≥ 10 ppm/°C) and optimized particle size distribution with a first material (resin, ceramic, metal, or alkali metal silicate). This composite approach achieves both excellent thermal expansion control and coatability that neither component alone could provide

Inventive Principle:

Principle #40Composite materials

2Reliability

If powder with specific crystal structure is used to achieve thermal expansion control, then thermal expansion coefficient is reduced, but coatability is compromised

Engineering Contradiction:

Improvethermal expansion control characteristicsVSAvoidcoatability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent optimizes particle size parameters (D50: 0.5-60 μm, D10/D50 ratio: 0.05-0.45, D90: 0.5-70 μm) to balance thermal expansion control performance with coatability. This parameter range allows the powder to maintain its crystal structure's thermal expansion properties while achieving smooth coating application without aggregation or poor adhesion

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies different particle size characteristics to different portions of the powder distribution. The controlled D10/D50 ratio ensures fine particles are present for good coating surface quality, while the D90 limit ensures most particles are small enough for good coatability, while the crystal structure provides the thermal expansion control

Inventive Principle:

Principle #3Local quality

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 resulting composition exhibits excellent thermal expansion control characteristics and coatability, effectively lowering the linear thermal expansion coefficient and reducing defects in coating processes.

Implementation Method 1

it has been known to add a solid material having a negative linear thermal expansion coefficient to a solid material having a positive linear thermal expansion coefficient in order to lower the linear thermal expansion coefficient of the latter solid material

Methodology Applied

Scientific EffectNegative linear thermal expansion: Negative Thermal Expansion

Implementation Method 2

each of the lattice constants is obtained by X-ray diffractometry of the powder

Methodology Applied

Scientific EffectX-ray diffraction: X-Ray

Implementation Method 3

a particle diameter D50 at a cumulative frequency of 50%, a particle diameter D10 at a cumulative frequency of 10%, and a particle diameter D90 at a cumulative frequency of 90% in a volume-based cumulative particle diameter distribution curve obtained by a laser diffraction scattering method

Methodology Applied

Scientific EffectLaser diffraction scattering: Diffraction

Data Source

PatentUS12187902B2Powder and solid composition

Publication Date: 2025.01.07 SUMITOMO CHEM CO LTD

AI summary

This powder satisfies requirements 1 and 2. Requirement 1: |dA(T)/dT| satisfies 10 ppm/° C. or more at at least one temperature T1 in a range of −200° C. to 1200° C. A is (a-axis (shorter axis) lattice constant) of a crystal in the powder)/(c-axis (longer axis) lattice constant of the crystal in the powder), and each of the lattice constants is obtained by X-ray diffractometry of the powder. Requirement 2: a particle diameter D50 at a cumulative frequency of 50%, a particle diameter D10 at a cumulative frequency of 10%, and a particle diameter D90 at a cumulative frequency of 90% in a volume-based cumulative particle diameter distribution curve obtained by a laser diffraction scattering method satisfy conditions (I) and (II): (I) D10/D50 is 0.05 or more and 0.45 or less; and (II) D90 is 0.5 μm or more and 70 μm or less.