Spherical Titanium Oxide Filler for Low-Loss High-k Resin Composites
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Solution Overview
Problem
Current materials used in high-frequency band devices suffer from significant signal transmission losses due to high dielectric dissipation factors, and existing methods for producing spherical titanium oxide powders with stable dielectric properties are inadequate for achieving both high dielectric constants and low dissipation factors.
Innovation Solution
An inorganic oxide powder comprising a combination of spherical titanium oxide and aluminum oxide, with specific aluminum content, average circularity, and specific surface area, produced through a powder melting method, spheroidization, and heat-treatment, is used to achieve a high dielectric constant and low dielectric dissipation factor when filled in a resin material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If gas phase method is used to synthesize titanium oxide powder, then small average particle diameter is obtained and specific surface area becomes large, but dielectric dissipation factor deteriorates due to adsorbed water or hydroxyl groups
Solution Approach 1:
The patent converts the harmful effect of large specific surface area (which causes adsorbed water and high dielectric dissipation) into a benefit by carefully controlling and utilizing the surface properties. The flame fusion method produces spherical particles with controlled surface characteristics, and the subsequent heat treatment removes adsorbed water while maintaining the beneficial spherical shape and surface area for dispersibility.
Solution Approach 2:
The patent changes the physical and chemical parameters of the titanium oxide powder through controlled synthesis and heat treatment. By adjusting the synthesis conditions (flame fusion temperature, atmosphere) and heat treatment parameters (temperature, duration, atmosphere), the patent optimizes the balance between specific surface area, spherical shape, and dielectric dissipation factor to achieve the desired performance.
2Ease of manufacture
If wet method is used to synthesize titanium oxide powder, then production is easier, but water content ratio becomes high and dielectric dissipation factor deteriorates
Solution Approach 1:
The patent replaces the wet chemical synthesis method with a dry flame fusion method. This substitution eliminates the need for drying and water removal steps, directly producing powder with low water content. The flame fusion process uses combustion chemistry to form spherical titanium oxide particles in a dry state, avoiding the fundamental problem of residual water from wet methods.
Solution Approach 2:
The patent utilizes phase transitions during the flame fusion process. The titanium oxide powder undergoes melting and resolidification in the flame, transitioning from solid to liquid and back to solid, which forms spherical particles. This phase transition mechanism inherently produces dry particles without residual water, solving the dielectric dissipation problem associated with wet methods.
3Shape
If flame fusion method or thermal plasma method is used to obtain spherical titanium oxide powder, then shape is spherical and specific surface area is adjustable, but dielectric properties are not stable
Solution Approach 1:
The patent applies preliminary heat treatment to the spherical titanium oxide powder before final use. This pre-treatment step, performed at controlled temperatures in controlled atmospheres, stabilizes the dielectric properties by removing surface moisture and hydroxyl groups, and by establishing a consistent surface chemistry. This preliminary action ensures stable dielectric properties while preserving the spherical shape achieved during synthesis.
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 inorganic oxide powder effectively miniaturizes communication instruments by maintaining stable dielectric properties and improving dispersibility in resin materials, reducing fluidity issues and enhancing workability and filling properties.
Implementation Method 1
a powder melting method, spheroidization, and heat-treatment
Implementation Method 2
a powder melting method, spheroidization, and heat-treatment
Implementation Method 3
materials having a high dielectric constant and a low dielectric dissipation factor are sought
Data Source
AI summary
To provide: an inorganic oxide powder which, when filled in a resin material, can simultaneously achieve a high dielectric constant and a low dielectric dissipation factor; a method for producing the same; and a resin composition comprising the inorganic oxide powder.Provided is an inorganic oxide powder comprising a spherical titanium oxide powder and an aluminum oxide powder, wherein the aluminum content in the inorganic oxide powder is 20-50,000 mass ppm. Further provided is a resin composition comprising the inorganic oxide powder and at least one resin material selected from a thermoplastic resin and a thermosetting resin.