A new energy ceramic device pre-treatment method and device before metallization sintering

Abstract

This invention discloses a pretreatment method and apparatus for metallization sintering of new energy ceramic devices, relating to the field of ceramic metallization technology. The pretreatment method includes: S1, installation of the pretreatment device; S2, adjustment of the heat insulation baffle; S3, product movement control; S4, preheating process and temperature control; and S5, continuous entry into the kiln for sintering. This invention preheats the ceramic devices by installing a heating device on the inlet track of a continuous kiln, ensuring no condensation adheres and avoiding surface condensation and impurity adsorption caused by a humid hydrogen atmosphere. This significantly improves product cleanliness and metal layer adhesion, preventing cracking or detachment. Simultaneously, the direct installation of the pretreatment device avoids additional equipment requirements, allowing the ceramic devices to enter the kiln smoothly and efficiently, reducing stagnation and heat loss, and ensuring they reach the ideal temperature upon entering the sintering stage, thereby optimizing overall production efficiency and product quality.

Description

Technical Field

[0001] This invention relates to the field of ceramic metallization technology, specifically to a pretreatment method and apparatus for metallization sintering of new energy ceramic devices. Background Technology

[0002] Currently, the metallization sintering of new energy ceramic devices in the industry mainly adopts continuous kilns and bell-type kilns, and generally uses a wet hydrogen atmosphere for sintering. Among them, continuous kilns are widely used due to their high efficiency and good adaptability.

[0003] However, ceramic components are introduced into the kiln in a cold state after being coated with a metal layer paste. Contact with water vapor in the humid hydrogen atmosphere causes condensation. This not only forms watermarks on the surfaces of the ceramic components and the metal layer paste but also easily adsorbs impurities from the kiln, resulting in black spots and dirt on the ceramic surface. Furthermore, the watermarks evaporate rapidly during heating, potentially causing cracks in the metal layer, thus affecting product quality and reliability. These problems severely impact production efficiency and product yield. Therefore, effective solutions to these issues are urgently needed. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a pretreatment method and apparatus for metallization sintering of new energy ceramic devices, which solves the technical problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] This invention discloses a pretreatment method for metallization sintering of new energy ceramic devices, comprising the following steps:

[0007] S1. Installation of pretreatment device: Install the ceramic pretreatment device on the inlet track of the continuous kiln, ensuring good connection with the kiln and avoiding heat loss;

[0008] S2. Heat insulation baffle adjustment: Adjust the height of the heat insulation baffles at the inlet and outlet of the pretreatment device according to the size of the ceramic components and the height of the tray to ensure that the high-temperature resistant tray carrying the ceramic components can pass smoothly while minimizing heat loss.

[0009] S3. Product movement control: The ceramic components are loaded onto a high-temperature resistant tray and moved slowly along the preheating device and kiln via a track system, so that the products are moved at a uniform speed and the products stay in the preheating zone for a sufficient time.

[0010] S4. Preheating process and temperature control: The ceramic components are fed into the preheating device installed on the kiln inlet track. The ceramic components are heated in stages from 100℃ to 150℃, so that the ceramic components and metal layer reach above 100℃. Then the temperature is gradually reduced to cool down to about 60℃.

[0011] S5. Continuous entry into the kiln for sintering: The preheated ceramic parts continue to move along the track and gradually enter the continuous kiln for sintering.

[0012] As a further preferred embodiment of this technical solution, in step S3, the ceramic device advances at a speed of 200 mm every 15 minutes, with a total advancement time of 75 minutes.

[0013] As a further preferred embodiment of this technical solution, in step S4, the relative humidity in the device needs to be controlled at 30-40% during the preheating stage.

[0014] As a further preferred embodiment of this technical solution, the specific method for heating the ceramic device in stages at 100℃-150℃ in step S4 is as follows:

[0015] Preliminary drying stage: First, heat the ceramic parts at 100-120℃ for 30-40 minutes;

[0016] Uniform temperature drying stage: After the initial drying, raise the temperature to 140-150℃ and keep it at that temperature for 30-35 minutes to ensure that the main components of the metal paste are fully dried, while evaporating any residual trace solvents.

[0017] Cooling stage: After the ceramic device has been dried at a uniform temperature, the temperature is gradually reduced for 5-10 minutes to bring the ceramic device and metal layer to about 60°C, so as to avoid thermal stress caused by a sudden drop in temperature.

[0018] The present invention also provides a pretreatment device for metallization sintering of new energy ceramic devices, which is used to implement the pretreatment method described above, including a device body, a temperature controller, a heating device, an adjusting baffle and a thermocouple;

[0019] The main body of the device, which serves as the frame and support structure for the entire device, has a hollow interior.

[0020] The temperature controller is installed on top of the main body of the device and is electrically connected to the heating element and thermocouple. The temperature controller receives temperature feedback signals from the thermocouple and controls the power output of the heating element according to the set temperature parameters, thereby regulating the temperature of the device.

[0021] The heating element is installed on the inner wall of the main body of the device. The heating element is electrically connected to the temperature controller and is controlled by the temperature controller to achieve the preset temperature requirement.

[0022] Adjustable heat insulation baffles are located at the front and rear ends of the inner cavity of the main body of the device, and their height or position can be adjusted according to the size of the ceramic components or heating requirements.

[0023] Thermocouples are installed on the inner wall of the device body to monitor the internal temperature of the device in real time. The measurement data of the thermocouples is transmitted to the temperature controller, which can adjust the output of the heating element according to the actual temperature.

[0024] As a further preferred embodiment of this technical solution, the main body of the device has a shell size of 1000*320*300mm and an inner cavity size of 900*420*350mm.

[0025] As a further preferred embodiment of this technical solution, the inner wall of the main body of the device is coated with an alumina ceramic heat-insulating coating.

[0026] As a further preferred embodiment of this technical solution, the heating device is a heating tube, and two heating tubes are installed on each of the left and right walls of the inner cavity of the main body of the device.

[0027] Compared with the prior art, the present invention has the following beneficial effects:

[0028] 1. This invention installs the heating device on the inlet track of a continuous kiln, preheating the ceramic components before they enter the metallization kiln to ensure that there is no condensation on their surface. This effectively avoids the condensation phenomenon on the surface of the workpiece caused by the wet hydrogen atmosphere, thereby reducing the risk of impurity adsorption and improving the cleanliness of the product.

[0029] 2. During the pretreatment process, since the metal layer paste does not come into contact with condensate, the adhesion of the metal layer is enhanced, effectively preventing cracking and peeling caused by moisture, making the metallization layer of the ceramic device more stable and improving its overall performance.

[0030] 3. The ceramic pretreatment device is directly installed on the inlet track of the continuous kiln, which avoids the need for additional track equipment installation, saves production space, and allows ceramic parts to enter the kiln quickly and efficiently without changing tracks or waiting during transportation. This reduces downtime, reduces heat loss, and ensures that the ceramic parts reach the required temperature when entering the kiln. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the steps of the pretreatment method of the present invention;

[0032] Figure 2 This is one of the structural schematic diagrams of the pretreatment device of the present invention;

[0033] Figure 3This is a second schematic diagram of the pretreatment device of the present invention;

[0034] Figure 4 This is the third schematic diagram of the pretreatment device of the present invention;

[0035] Figure 5 This is the fourth schematic diagram of the pretreatment device of the present invention;

[0036] In the diagram: 1. Main body of the device, 2. Temperature controller, 3. Adjustable heat insulation baffle, 4. Heating element, 5. Thermocouple. Detailed Implementation

[0037] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0038] Example 1

[0039] Please see Figure 1 In this embodiment, a pretreatment method for metallization sintering of new energy ceramic devices includes the following steps:

[0040] S1. Installation of pretreatment device: Install the ceramic pretreatment device on the inlet track of the continuous kiln, ensuring good connection with the kiln and avoiding heat loss;

[0041] S2. Heat insulation baffle adjustment: Adjust the height of the heat insulation baffles at the inlet and outlet of the pretreatment device according to the size of the ceramic components and the height of the tray to ensure that the high-temperature resistant tray carrying the ceramic components can pass smoothly while minimizing heat loss.

[0042] S3. Product Movement Control: The ceramic components are loaded onto a high-temperature resistant tray and slowly moved along the preheating device and kiln via a track system, ensuring that the products are moved at a uniform speed and that they remain in the preheating zone for a sufficient amount of time. Uniform movement ensures that each ceramic component receives the same preheating conditions, improving the consistency of product quality.

[0043] S4. Preheating process and temperature control: The ceramic components are fed into the preheating device installed on the kiln inlet track. The ceramic components are heated in stages from 100℃ to 150℃, so that the ceramic components and metal layer reach above 100℃. Then the temperature is gradually reduced to cool down to about 60℃.

[0044] S5. Continuous entry into the kiln for sintering: The preheated ceramic components continue to move along the track and gradually enter the continuous kiln for sintering. The preheated ceramic components can enter the kiln for sintering smoothly, reducing the impact of sudden temperature changes. Entering the sintering stage under optimal conditions helps improve the uniformity of the sintering process and product quality, and enhances the strength and performance of the final product.

[0045] Furthermore, in step S3, the ceramic device advances at a speed of 200 mm every 15 minutes, with a total advancement time of 75 minutes.

[0046] Furthermore, in step S4, the relative humidity in the device needs to be controlled at 30-40% during the preheating stage.

[0047] Furthermore, in step S4, the specific method for heating the ceramic device in stages from 100℃ to 150℃ is as follows:

[0048] Preliminary drying stage: The ceramic parts are initially heated at 100-120℃ for 30-40 minutes. Preliminary heating can effectively remove moisture from the surface of the ceramic parts, reduce the impact of moisture on subsequent drying and sintering, lay the foundation for the subsequent drying of the metal paste, ensure that it can effectively adhere in subsequent processes, reduce residual solvent in the ceramic parts, and avoid bubbles or cracks caused by its volatilization in subsequent stages.

[0049] Uniform temperature drying stage: After the initial drying, the temperature is raised to 140-150℃ and kept at that temperature for 30-35 minutes to ensure that the main components of the metal paste are fully dried and to evaporate any residual trace solvents. The higher temperature ensures that the main components of the metal paste are fully dried, improving its adhesion and durability, evaporating residual solvents, and reducing the risk of defects in the subsequent sintering process.

[0050] Cooling Stage: After the ceramic components have completed uniform drying, the temperature is gradually reduced over 5-10 minutes until the ceramic components and metal layer reach approximately 60°C. This avoids thermal stress caused by sudden temperature drops. Slow cooling effectively prevents thermal stress caused by sudden temperature drops, reduces the risk of cracking in the ceramic components, and ensures a stronger bond between the metal layer and the ceramic, reducing the risk of peeling or detachment.

[0051] By employing the above steps and specific methods, rationally designing the pretreatment device, adjusting the heat insulation baffles, and controlling the movement of ceramic components, thermal efficiency and production efficiency were significantly improved, ensuring uniform heating and reducing the risk of thermal stress and product defects. Furthermore, staged heating and appropriate humidity control effectively enhanced the quality of the metal layer, ensuring that the ceramic components were in optimal condition before entering the sintering stage.

[0052] Example 2

[0053] Please see Figure 2-5 In this embodiment, a pretreatment device for metallization sintering of new energy ceramic devices is used to implement the pretreatment method of Embodiment 1, including a device body, a temperature controller, a heating device, an adjusting baffle and a thermocouple.

[0054] The main body of the device, which serves as the frame and support structure for the entire device, has a hollow interior.

[0055] The temperature controller is installed on top of the main body of the device and is electrically connected to the heating element and thermocouple. The temperature controller receives temperature feedback signals from the thermocouple and controls the power output of the heating element according to the set temperature parameters, thereby regulating the temperature of the device.

[0056] The heating element is installed on the inner wall of the main body of the device. The heating element is electrically connected to the temperature controller and is controlled by the temperature controller to achieve the preset temperature requirement.

[0057] Adjustable heat insulation baffles are located at the front and rear ends of the inner cavity of the main body of the device, and their height or position can be adjusted according to the size of the ceramic components or heating requirements.

[0058] Thermocouples are installed on the inner wall of the device body to monitor the internal temperature of the device in real time. The measurement data of the thermocouples is transmitted to the temperature controller, which can adjust the output of the heating element according to the actual temperature.

[0059] This pretreatment device achieves efficient and uniform heating through real-time monitoring and feedback control by a temperature controller and thermocouples, ensuring sufficient heat distribution for the ceramic components. Simultaneously, adjustable heat-insulating baffles and an alumina ceramic insulation coating within the cavity enhance the device's adaptability and thermal efficiency, strengthen structural stability and durability, and thus significantly improve the pretreatment effect of the ceramic components, laying the foundation for the quality and efficiency of the subsequent sintering process.

[0060] Furthermore, the main body of the device has outer shell dimensions of 1000*320*300mm and inner cavity dimensions of 900*420*350mm.

[0061] Furthermore, the inner wall of the main body of the device is coated with an alumina ceramic insulation coating. The application of the alumina ceramic insulation coating improves the thermal efficiency and durability of the device, and provides a more reliable guarantee for the pretreatment of ceramic components.

[0062] Furthermore, the heating device is a heating tube, with two heating tubes installed on each of the left and right walls of the inner cavity of the main body of the device. This configuration of two heating tubes on each side of the inner cavity enables uniform heating, improves heating efficiency, and enhances the flexibility of temperature control and system reliability. In addition, the multi-heating tube configuration can accommodate ceramic devices of different sizes and thermal requirements, providing an efficient and reliable solution for pretreatment before metallization sintering.

[0063] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A pretreatment method for metallization sintering of new energy ceramic devices, characterized in that, Includes the following steps: S1. Installation of pretreatment device: Install the ceramic pretreatment device on the inlet track of the continuous kiln, ensuring good connection with the kiln and avoiding heat loss; S2. Heat insulation baffle adjustment: Adjust the height of the heat insulation baffles at the inlet and outlet of the pretreatment device according to the size of the ceramic components and the height of the tray to ensure that the high-temperature resistant tray carrying the ceramic components can pass smoothly while minimizing heat loss. S3. Product movement control: The ceramic components are loaded onto a high-temperature resistant tray and moved slowly along the preheating device and kiln via a track system, so that the products are moved at a uniform speed and the products stay in the preheating zone for a sufficient time. S4. Preheating process and temperature control: The ceramic components are fed into the preheating device installed on the kiln inlet track. The ceramic components are heated in stages from 100℃ to 150℃, so that the ceramic components and metal layer reach above 100℃. Then the temperature is gradually reduced and cooled to about 60℃. The specific method for heating the ceramic device in stages from 100℃ to 150℃ is as follows: Preliminary drying stage: First, heat the ceramic parts at 100-120℃ for 30-40 minutes; Uniform temperature drying stage: After the initial drying, raise the temperature to 140-150℃ and keep it at that temperature for 30-35 minutes to ensure that the main components of the metal paste are fully dried, while evaporating any residual trace solvents. Cooling stage: After the ceramic device has been dried at a uniform temperature, the temperature is gradually reduced for 5-10 minutes to bring the ceramic device and metal layer to about 60°C, so as to avoid thermal stress caused by a sudden drop in temperature. S5. Continuous entry into the kiln for sintering: The preheated ceramic parts continue to move along the track and gradually enter the continuous kiln for sintering.

2. The pretreatment method for metallization sintering of new energy ceramic devices according to claim 1, characterized in that, In step S3, the ceramic device advances at a speed of 200 mm every 15 minutes, with a total advancement time of 75 minutes.

3. The pretreatment method for metallization sintering of new energy ceramic devices according to claim 1, characterized in that, In step S4, the relative humidity in the device needs to be controlled at 30-40% during the preheating stage.

4. A pretreatment apparatus for metallization sintering of new energy ceramic devices for implementing the pretreatment method according to any one of claims 1-3, characterized in that, It includes the main body of the device, temperature controller, heating element, regulating baffle and thermocouple; The main body of the device, which serves as the frame and support structure for the entire device, has a hollow interior. The temperature controller is installed on top of the main body of the device and is electrically connected to the heating element and thermocouple. The temperature controller receives temperature feedback signals from the thermocouple and controls the power output of the heating element according to the set temperature parameters, thereby regulating the temperature of the device. The heating element is installed on the inner wall of the main body of the device. The heating element is electrically connected to the temperature controller and is controlled by the temperature controller to achieve the preset temperature requirement. Adjustable heat insulation baffles are located at the front and rear ends of the inner cavity of the main body of the device, and their height or position can be adjusted according to the size of the ceramic components or heating requirements. Thermocouples are installed on the inner wall of the device body to monitor the internal temperature of the device in real time. The measurement data of the thermocouples is transmitted to the temperature controller, which can adjust the output of the heating element according to the actual temperature.

5. The pretreatment device for metallization sintering of new energy ceramic devices according to claim 4, characterized in that, The main body of the device has outer shell dimensions of 1000*320*300mm and inner cavity dimensions of 900*420*350mm.

6. The pretreatment device for metallization sintering of new energy ceramic devices according to claim 4, characterized in that, The inner wall of the main body of the device is coated with an alumina ceramic heat-insulating coating.

7. The pretreatment device for metallization sintering of new energy ceramic devices according to claim 4, characterized in that, The heating device is a heating tube, and two heating tubes are installed on each of the left and right walls of the inner cavity of the main body of the device.

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