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The Revolution of Film Manufacturing: How the 5-micron miracle promotes the development of energy and electronic technology?
With the continuous advancement of technology, traditional material manufacturing processes are also constantly evolving.Film manufacturing, especially the use of film casting technology (Tape Casting), has become a major innovation in the modern electronics and energy industries.During this process, the ceramic slurry is specially treated and eventually becomes a film with a thickness of only 5 microns. How does this remarkable technology affect the development of related industries?
Historical background of technological evolution
Film casting technology was first described in the 1940s, when it was used to produce capacitors on a large scale.Since then, with the continuous advancement of technology, film casting has achieved thin sheet production of less than 5 microns for the first time in the 1990s.This change not only improves manufacturing efficiency, but also opens new doors to the design of multi-layer structures.
The multi-layer film technology makes the design of electronic components more flexible and can achieve higher performance in a limited space.
Production process of film casting
The process of film casting is relatively complex and involves multiple critical steps.First, the raw material ceramic powder needs to be mixed with solvents, dispersants, binders, etc. to form a stable slurry.Next, the slurry is evenly applied to the plane by a casting machine to form a thin film.In this process, drying and sintering are crucial because this determines the strength and conductivity of the final product.
Composition and characteristics of slurry
The composition of the slurry directly affects the properties of the final film.Ceramic powder is the core component, while solvents enable it to be cast in liquid form.In addition, the selection of adhesive is crucial to the structure and mechanical properties of the film.
Each component has an impact on the rheological properties of the slurry, which is an important factor in controlling the casting process.
Technical Points of the Casting Process
In the casting process, it is first necessary to ensure the flatness of the film.For this reason, various casting machines such as blades, groove casters, etc. are widely used.When making films with a thickness of less than 50 microns, side casting or bottom casting is often used to achieve the best results.
The keyities of drying steps
The cast film is dried from only one side, which makes controlling the drying process the key to product quality.If the solvent volatilization is not uniform enough, it may cause the film to crack or deform.Therefore, air-aided treatment is usually performed during the drying process.
Wide application scenarios
The application range of thin film casting is very wide, including ceramic capacitors, polymer batteries, photovoltaic materials, and electrodes of molten carbonate fuel cells.These technological breakthroughs have led to significant progress in energy efficiency and electronic equipment performance.
To the point where the thinnest ceramic films as far as 5 microns can be produced, an achievement that has made many new technologies and applications come to light.
The potential for future development
In the future, with the further progress of material technology, thin film casting technology will continue to deepen its influence.This is not limited to electronics, but may also show greater potential in other high-tech products.Can this technological innovation continue to promote the progress of energy and electronic technology and lead a new chapter in future materials science?
