Cut-out Sintered Ceramic Sheet Shearing

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Solution Overview

Problem

Existing methods for processing sintered ceramic sheets into complex shapes suffer from dimensional inaccuracies and reduced production efficiency, as they require direct contact with rotary knives or generate heat during laser processing, limiting the ability to create intricate designs.

Innovation Solution

A method involving the formation of a ceramic green sheet, sintering, and subsequent shearing of a film-adhered ceramic sheet using dies with controlled clearance to achieve high-dimensional accuracy and rapid processing of complex shapes without deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If dicing with rotary knife is used to cut sintered ceramic sheet, then cutting can be performed, but direct contact between rotary knife and ceramic sheet causes inability to process complex shapes and generates burrs

Engineering Contradiction:

Improvecutting capabilityVSAvoiddimensional accuracy and shape complexity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent replaces the mechanical dicing system (rotary knife) with a laser processing system that uses optical energy to cut the sintered ceramic sheet. This substitution eliminates the need for direct mechanical contact, enabling complex shape processing while maintaining cutting capability. The laser beam can precisely follow complex paths without physical contact, resolving the contradiction between ease of manufacture and manufacturing precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If laser processing is used to cut sintered ceramic sheet, then complex shapes can be processed, but heat generation at laser focus changes properties of the ceramic sheet

Engineering Contradiction:

Improveshape complexityVSAvoidheat generation and property change

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent optimizes laser processing parameters including power, pulse duration, frequency, and scanning speed to minimize heat-affected zone while maintaining cutting effectiveness. By carefully controlling these parameters, the process achieves complex shape processing with minimal thermal damage to the ceramic properties.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If laser processing is used for complex shapes, then shape complexity is improved, but longer processing time reduces production efficiency

Engineering Contradiction:

Improveshape complexityVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent uses pulsed laser operation with optimized pulse duration and frequency to efficiently remove material while allowing thermal diffusion between pulses. This periodic action prevents heat accumulation and enables faster processing of complex shapes compared to continuous laser operation, thereby improving production efficiency while maintaining shape complexity capability.

Inventive Principle:

Principle #19Periodic action

4Ease of manufacture

If dicing process is used, then cutting can be performed, but direct contact requirement makes it impossible to process complex shapes

Engineering Contradiction:

Improvecutting capabilityVSAvoidshape processing capability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent replaces the mechanical dicing system with a non-contact laser processing system, enabling the processing of complex shapes that would be impossible with rotary knife contact. The laser beam can precisely follow complex two-dimensional paths without physical constraints, significantly enhancing adaptability and versatility for various shape requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach allows for the quick and efficient production of cut-out sintered ceramic sheets with superior dimensional accuracy and complex shapes, minimizing burrs and deformation, while maintaining the sintered state's properties.

Implementation Method 1

a second step of sintering the formed ceramic green sheet

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 2

when a ceramic green sheet 11 is sintered, the sintered ceramic sheet 12 shrinks be about 20%

Methodology Applied

Scientific EffectThermal shrinkage: Thermal Contraction

Implementation Method 3

a step of shearing a film-adhered ceramic sheet, the film-adhered ceramic sheet including a sintered ceramic sheet and a plastic film adhered to at least one surface of the sintered ceramic sheet

Methodology Applied

Scientific EffectShear stress: Shear Stress

Data Source

PatentUS8747590B2Cut-out sintered ceramic sheet and method of manufacturing the same

Publication Date: 2014.06.10 MARUWA

AI summary

A method of manufacturing a cut-out sintered ceramic sheet including forming a ceramic green sheet, sintering the formed ceramic green sheet, adhering a plastic resin film onto which adhesive is applied on at least one surface of the sintered ceramic sheet, and shearing the sintered ceramic sheet.