Binder-Free Ceramic Compact Production via Low-Temperature Slurry Spraying
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Solution Overview
Problem
The existing methods for producing ceramic compacts require high-temperature baking to remove polymer binders, which is not economical and limits the efficiency of achieving high filling density of ceramic particles.
Innovation Solution
A method involving spraying a ceramic slurry containing ceramic particles and a dispersion medium onto a heated substrate at temperatures below 400°C, using a ceramic particle concentration of 20% to 40% by volume, with a dispersant in the medium, to efficiently produce ceramic compacts with high filling density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a slurry containing polymer binder is used and heated to remove the binder, then a ceramic compact can be formed, but the heating temperature must be 400°C or higher which increases production cost
Solution Approach 1:
The invention extracts and removes the polymer binder component from the slurry formulation, replacing it with a binder-free ceramic particle dispersion system. This eliminates the need for high-temperature binder removal while maintaining the ability to form ceramic compacts with high filling density
Solution Approach 2:
The invention changes the chemical composition parameters of the slurry by eliminating polymer binders and adjusting ceramic particle concentration to 20-40% by volume. This parameter change allows the system to achieve adequate green strength and packing density without requiring high-temperature binder combustion
2Reliability
If a slurry containing polymer binder is used, then a ceramic compact can be formed, but the production cost increases due to high-temperature baking requirement
Solution Approach 1:
The invention extracts and removes the polymer binder component from the slurry formulation, replacing it with a binder-free ceramic particle dispersion system. This eliminates the need for high-temperature binder removal while maintaining the ability to form ceramic compacts with high filling density
Solution Approach 2:
The invention uses a simple, inexpensive binder-free dispersion system that does not require complex binder chemistry or high-temperature processing infrastructure, thereby reducing manufacturing complexity and cost
3Ease of operation
If a slurry with low ceramic particle concentration is used, then the slurry is easier to apply, but the filling density of the ceramic compact decreases
Solution Approach 1:
The invention optimizes the ceramic particle concentration parameter to a specific range of 20-40% by volume in the slurry. This concentration range provides the optimal balance between slurry flowability for easy application and sufficient particle packing density to achieve high filling density in the final compact
Solution Approach 2:
The invention ensures uniform distribution of ceramic particles throughout the dispersion medium, creating consistent local packing characteristics that translate to high overall filling density while maintaining slurry processability
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 method allows for the efficient production of ceramic compacts with a filling density of 85% or more, reducing production costs and energy consumption by avoiding high-temperature baking.
Implementation Method 1
a ceramic particle dispersion consisting of ceramic particles and a dispersion medium containing a dispersant is sprayed onto a surface of a substrate heated at a temperature of 150°C or higher and under 400°C
Data Source
Figure 15
Figure 16~17
AI summary
The present invention is a sintering method of a ceramic for sintering characterized by forming a layer containing a carbon powder on a surface of an article consisting of a ceramic for sintering, and then irradiating with laser a surface of the carbon powder-containing layer of a lamination obtained.