Ceramic Substrate Release Agent Distribution for Recycled Slurry

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

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

VSEngineering Contradiction Analysis

1Productivity

If offcuts with residual release agent are reused as raw material, then yield is improved, but substrate performance deteriorates

Engineering Contradiction:
ImproveyieldVSAvoidsubstrate performance
Core Design Contradiction:
ProductivityVSReliability

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

Inventive Principle:
Principle #2Taking out (Extraction)

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

Inventive Principle:
Principle #35Parameter changes

2Ease of manufacture

If release agent is applied to prevent adhesion during sintering, then manufacturing process is improved, but offcut reuse becomes difficult

Engineering Contradiction:
Improvemanufacturing processVSAvoidoffcut reuse
Core Design Contradiction:
Ease of manufactureVSProductivity

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

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

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

Inventive Principle:
Principle #34Discarding and recovering

Data Source

PatentUS20260001819A1Ceramic substrate, ceramic circuit board, semiconductor device, method for producing slurry, and method for applying release agent
Publication Date: 2026.01.01 NITERRA MATERIALS CO LTD
  • US20260001819A1 patent drawing
  • US20260001819A1 patent drawing
  • US20260001819A1 patent drawing

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.