Solid Dielectric Matrix Assembly for High-Permittivity 3D Structures
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Solution Overview
Problem
Conventional composite materials with high dielectric constants face limitations in achieving desired geometries and dielectric properties due to low volume fractions of high dielectric material, leading to either high dielectric loss or low dielectric constant, making it challenging to fabricate large, shaped composites with tailored dielectric properties.
Innovation Solution
The creation of dielectric assemblies by assembling solid dielectric elements within a matrix material to achieve a higher volume fraction of dielectric material, allowing for the fabrication of composite structures with tailored dielectric properties and geometries, including anisotropic and spatially variable bulk permittivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional composite materials are formed by mixing HDC powders within a matrix material, then the composite can be fabricated with desired geometry, but the volume fraction of HDC material is limited to less than 50% resulting in low bulk dielectric constant
Solution Approach 1:
The invention divides the composite structure into discrete solid dielectric elements (such as rods, cylinders, or prisms) embedded within a matrix material. This segmentation allows each element to be independently formed with high HDC content, and then assembled into larger composite structures. The solid elements can achieve volume fractions of 60-80% or higher within the composite, significantly exceeding the <50% limit of conventional powder mixtures.
Solution Approach 2:
The invention creates a hierarchical composite structure where solid dielectric elements (themselves composites of HDC powder and binder) are embedded within a second matrix material. This multi-level composite approach allows the inner solid elements to maintain high HDC concentration while the outer matrix provides structural integrity and geometric flexibility, achieving overall high bulk dielectric constant with tailored geometries.
2Quantity of substance
If solid dielectric elements are pressed and sintered to achieve high density, then the dielectric constant increases, but the geometry is limited to simple shapes such as geometric prisms, disks, or rings
Solution Approach 1:
The invention segments the final composite into multiple solid dielectric elements that can be individually pressed and sintered into simple shapes, then assembled into complex three-dimensional configurations. This allows each element to benefit from high-density sintering while the overall structure achieves geometric complexity through spatial arrangement rather than single-piece forming.
Solution Approach 2:
The invention transitions from two-dimensional surface patterns to three-dimensional volumetric arrangements of solid dielectric elements. By stacking multiple layers of elements with different orientations and configurations, complex 3D geometries are achieved that would be impossible to form in a single pressing operation, while maintaining high density through controlled sintering of individual elements.
3Quantity of substance
If powder particles are pressed together to increase HDC volume fraction, then the dielectric constant improves, but the volume fraction only reaches about 50% due to powder packing limitations
Solution Approach 1:
The invention changes the physical state parameter of the HDC material from fine powder particles to consolidated solid elements. This parameter change allows the HDC material to achieve volume fractions of 60-80% or higher in the composite, compared to the ~50% maximum for powder packings. The solid elements also reduce interfacial losses between particles, thereby reducing overall dielectric loss while maintaining high dielectric constant.
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 enables the production of composite materials with significantly higher bulk dielectric constants and reduced dielectric loss, achieving properties closer to monolithic ceramic materials, while allowing for complex geometries and improved mechanical strength.
Implementation Method 1
The dielectric constant (aka relative permittivity) of a material relates to its ability to polarize in an electric field and induce electromagnetic wave propagation. High dielectric constant (HDC) materials (e.g., having a dielectric constant over 30) can be polarized relatively easily by an applied electric field, which effectively creates a smaller electric field within the structure. Another aspect of HDC materials is their ability to induce proportionally higher displacement current in the material, which induces stronger magnetic fields in and outside the material.
Implementation Method 2
Another aspect of HDC materials is their ability to shorten the electromagnetic wave within the material under the condition of microwave or radio frequencies, which enhances the electromagnetic wave propagation within and across the surface of the material.
Implementation Method 3
Binders are often used to maintain the structure of the pressed piece.
Implementation Method 4
The pressed piece can then be sintered at high temperatures (e.g., 1,000° C.-1,500° C. for 12-48 hours) to drive off the binder and create a solid ceramic piece with even higher density.
Implementation Method 5
The pressed piece can then be sintered at high temperatures (e.g., 1,000° C.-1,500° C. for 12-48 hours) to drive off the binder
Data Source
AI summary
A dielectric assembly solid dielectric elements within a liquid or solid matrix material. The dielectric assembly may be manufactured by pressing a dielectric powder to form pressed dielectric elements, sintering the pressed dielectric elements to form the solid dielectric elements, and assembling the solid dielectric elements within the matrix material to form the dielectric assembly. The solid dielectric elements can be specifically oriented (e.g., in one or more tiled layers) or randomly oriented, and the dielectric assemblies can be molded and/or machined into desired 3D geometries. The dielectric assemblies can be relatively large (e.g., >1 mm3) while having bulk dielectric constants higher than conventional slurries and composites formed of dielectric powder in a liquid or solid matrix.