Ceramic Ball CIP Reorientation for Uniform Density

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Solution Overview

Problem

Existing methods for manufacturing ceramic ball materials result in density unevenness due to fixed positioning during CIP forming, leading to polishing inefficiencies and density variations in the sintered compacts.

Innovation Solution

Perform multiple CIP processes on ceramic green compacts, changing the orientation of the compacts between each process to uniformly apply pressure and reduce density unevenness, followed by sintering and optional HIP processing to achieve high relative densities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If CIP forming is performed multiple times with fixed positioning, then the green compact density increases, but density unevenness persists and polishing efficiency decreases

Engineering Contradiction:
Improvedensity uniformityVSAvoidpolishing efficiency
Core Design Contradiction:
Manufacturing precisionVSProductivity

Solution Approach 1:

The patent applies the dynamics principle by changing the positioning orientation of the green compact between CIP forming cycles. Instead of maintaining a fixed position, the compact is reoriented (e.g., rotated 90 degrees or flipped) before subsequent CIP forming operations. This dynamic adjustment ensures that density unevenness developed in one orientation is compensated in the next orientation, achieving uniform density distribution throughout the compact while maintaining high polishing efficiency.

Inventive Principle:
Principle #15Dynamics

2Manufacturing precision

If CIP forming is repeated many times to resolve density unevenness, then density uniformity improves, but manufacturing time increases

Engineering Contradiction:
Improvedensity uniformityVSAvoidmanufacturing time
Core Design Contradiction:
Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent implements periodic action by performing CIP forming in cycles with periodic reorientation of the green compact. Instead of continuous forming in one position, the process alternates between forming operations and reorientation steps. This periodic intervention efficiently eliminates density unevenness in fewer cycles compared to continuous forming, thereby reducing total manufacturing time while achieving uniform density.

Inventive Principle:
Principle #19Periodic action

3Ease of manufacture

If the green compact position remains fixed during CIP process, then the forming process is simple, but density unevenness is generated

Engineering Contradiction:
Improveforming process simplicityVSAvoiddensity uniformity
Core Design Contradiction:
Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent resolves this contradiction by introducing dynamic repositioning into the otherwise simple CIP forming process. The green compact is periodically reoriented between forming cycles, adding a simple rotational or flipping operation that maintains process ease while eliminating density unevenness. This dynamic adjustment requires minimal additional complexity but dramatically improves density uniformity.

Inventive Principle:
Principle #15Dynamics

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 method significantly reduces density variations in the ceramic ball materials, improving polishing efficiency and reducing the time required for finishing, making them suitable for high-quality bearing balls.

Implementation Method 1

CIP (cold isostatic pressing) forming is performed on a ceramic green compact that has been molded by using a mold in a molding step

Methodology Applied
Scientific EffectCold isostatic pressing: Pressurisation

Implementation Method 2

a step of sintering a CIP green compact produced by a final CIP process among the plurality of times of the CIP process to produce a ceramic sintered compact

Methodology Applied
Scientific EffectSintering: Sintering

Implementation Method 3

performing a HIP (hot isostatic pressing) process on the ceramic sintered compact

Methodology Applied
Scientific EffectHot isostatic pressing: Hot Isostatic Pressing

Data Source

PatentEP4650334A1Ceramic ball material production method and ceramic ball production method
Publication Date: 2025.11.19 NITERRA MATERIALS CO LTD
  • EP4650334A1 patent drawingFigure 1~3
  • EP4650334A1 patent drawingFigure 4(A)~5
  • EP4650334A1 patent drawing

AI summary

A method for manufacturing a ceramic ball material according to an embodiment, includes: a step of producing a ceramic green compact; a step of performing a plurality of times of a CIP process on the ceramic green compact to produce a CIP (cold isostatic pressing) green compact; and a step of sintering a CIP green compact produced by a final CIP process among the plurality of times of the CIP process to produce a ceramic sintered compact. In the step of producing the CIP green compact, after a former CIP process among the plurality of times of the CIP process is performed, an orientation of a CIP green compact produced by the former CIP process is changed, and a latter CIP process is performed.