Ceramic Sanitary Ware Bonding Zone Electric Charge Drying
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Solution Overview
Problem
Ceramic sanitary ware products face high risks of cracking during the drying process due to water content differences between joined parts and the bonding material, leading to tensile stresses and potential cracking, especially at the bonding line.
Innovation Solution
Applying a uniform electric charge along the joining zone of ceramic sanitary ware products during the drying process to increase mechanical strength, reduce moisture content, and achieve uniformity, thereby reducing the risk of cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a layer of bonding material with high water content is applied to join ceramic parts, then the parts can be bonded together in the green state, but differential shrinkage during drying causes high tensile stresses and cracking at the bonding line
Solution Approach 1:
The patent applies an electric field to change the physical-chemical parameters of the bonding material, accelerating water removal and reducing water content from up to 33% towards the 14-20% range of the ceramic parts. This parameter change reduces differential shrinkage and prevents cracking while maintaining bonding capability
Solution Approach 2:
The electric field treatment is applied preliminarily during the early drying stage, before significant shrinkage occurs. This preliminary action removes excess water from the bonding material in advance, preventing the development of high tensile stresses and cracking that would otherwise occur during subsequent drying
2Ease of operation
If the bonding material with higher water content is used to ensure proper bonding, then the joined parts can be finished in the green state, but the drying process creates tensile stresses that may lead to cracking
Solution Approach 1:
The electric field changes the water content parameter of the bonding material, reducing it from up to 33% towards the 14-20% range of the ceramic parts. This parameter change reduces differential shrinkage and the resulting tensile stresses, allowing finishing operations while preventing cracking
3Productivity
If traditional drying processes are used without intervention, then the production time remains traditional, but cracking occurs due to differential shrinkage between parts and bonding material
Solution Approach 1:
The electric field treatment is applied preliminarily during the early drying stage, before significant shrinkage and cracking occur. This preliminary water removal prevents cracking while the overall drying process and production time remain traditional
Solution Approach 2:
The patent replaces the traditional mechanical/thermal drying approach with an electric field-based water removal method. This substitution accelerates water removal from the bonding material without requiring increased thermal energy input or extended drying time, maintaining traditional production schedules while preventing cracking
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 enhances the mechanical strength and shrinkage resistance of the joined parts, reducing the risk of cracking without significantly affecting traditional production times or adding complex components to the manufacturing plant.
Implementation Method 1
the step of applying the flow of electric charge reduces the moisture content around the joining zone
Implementation Method 2
applying a bonding material (usually consisting of high-viscosity slip) uniformly to the surface to be joined to the rim
Data Source
Figure 1~3
AI summary
A method for making a ceramic sanitary ware product (M) comprises at least the following steps: applying a uniform layer (S) of bonding material comprising a high-viscosity fluid mixture to at least one surface (2) intended to be joined to at least a second part (M3) of the sanitary ware product (M); joining the second part (M3) of the sanitary ware product (M) to the first part (M2) along a joining zone defined by two respective contact surfaces (2, 3) of the selfsame parts (M2, M3) with the layer (S) of bonding material interposed between them; drying the sanitary ware product (M) thus obtained; immediately after the step of joining the two parts (M2, M3), there is a step of applying, through the agency of respective means (4), a flow (F) of electric charge uniformly distributed at least along the joining zone at a predefined intensity (A) and for a predetermined length of time (T) so as to increase mechanical strength at least at the joining zone.