Ceramic Substrate Release Agent Distribution for Recycled Slurry
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Solution Overview
Problem
Conventional methods for producing ceramic substrates result in offcuts due to defects or excess release agent application, leading to reduced performance and difficulty in reusing these offcuts due to residual release agent, which affects yield and substrate performance.
Innovation Solution
A method for producing ceramic substrates with controlled release agent distribution, where the release agent is applied in specific amounts and cleaned from offcuts, allowing their reuse in a recycled slurry to maintain substrate performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If offcuts with residual release agent are reused as raw material, then yield is improved, but substrate performance deteriorates
Solution Approach 1:
The patent extracts and removes the release agent from offcuts through a cleaning process before reusing the offcuts as raw material. This separation allows the offcuts to be recycled without the harmful residual release agent that would otherwise degrade substrate performance, thereby resolving the contradiction between improving yield and maintaining substrate performance
Solution Approach 2:
The patent changes the physical or chemical state of the release agent through cleaning processes, transforming it from a residual contaminant on offcuts into a removable substance. By altering the state or concentration of the release agent, the offcuts can be successfully reused without compromising substrate performance, thus enabling both high yield and maintained performance
2Ease of manufacture
If release agent is applied to prevent adhesion during sintering, then manufacturing process is improved, but offcut reuse becomes difficult
Solution Approach 1:
The patent converts the harmful residual release agent on offcuts into a removable contaminant through systematic cleaning processes. By transforming the situation where release agent presence prevents reuse into a process where the release agent can be effectively removed, the patent enables offcut reuse while maintaining the manufacturing benefits of using release agent during sintering
Solution Approach 2:
The patent implements a recovery process for offcuts by removing the release agent through cleaning, then reusing the cleaned offcuts as raw material for new ceramic substrates. This discarding-and-recovering approach allows the offcuts to be regenerated into useful materials, thereby improving productivity through waste reduction while maintaining ease of manufacture
Data Source
AI summary
A ceramic substrate according to an embodiment has a first surface as a front surface and a second surface as a back surface, when a midpoint of a line segment connecting a central portion P1 of the first surface and a central portion P2 of the second surface is defined as a midpoint portion C1, an amount of a component of a release agent measured at the central portion P1 of the first surface or the central portion P2 of the second surface is five times or more an amount of the component of the release agent measured at the midpoint portion C1. A ratio P1/P2 between the amount of the component of the release agent measured at the central portion P1 and the amount of the component of the release agent measured at the central portion P2 preferably satisfies 0.5≤P1/P2≤2.


