Ceramic Clay Moldability via Inorganic Binder
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Solution Overview
Problem
Ceramic products face challenges with plasticity and shape retention due to the high amount of organic binders required, leading to defects like cracks and increased production costs, as well as environmental concerns from harmful gases generated during firing.
Innovation Solution
A ceramic clay with a layered double hydroxide in flake form, represented by specific formulas, is used in reduced amounts (0.01-5 mass%) to enhance moldability and formability, reducing the need for organic binders and minimizing environmental impact while maintaining product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a large amount of organic binder is added to improve plasticity and moldability, then the moldability and formability are improved, but the mechanical strength deteriorates due to defects and thermal stress during firing
Solution Approach 1:
The invention changes the chemical composition parameters by incorporating specific metal oxides (Al2O3: 20-40 wt%, SiO2: 30-50 wt%, MgO: 10-20 wt%) to replace organic binders. This parameter change maintains moldability while eliminating the strength deterioration caused by organic binder decomposition during firing.
Solution Approach 2:
The invention uses a composite inorganic binder system combining multiple metal oxides (alumina, silica, magnesia) that work synergistically to provide both plasticity for molding and structural strength. This composite approach replaces the single-component organic binder system, avoiding the defects associated with organic material decomposition.
2Ease of manufacture
If a large amount of organic binder is added to improve formability of large-sized structures, then the formability is improved, but harmful gases are generated during firing causing environmental pollution
Solution Approach 1:
The invention replaces long-lived organic binders that decompose and pollute with inorganic metal oxides that are thermally stable and environmentally benign. The inorganic binder system does not undergo decomposition reactions that release harmful gases, thus eliminating the environmental pollution problem while maintaining formability.
Solution Approach 2:
The invention changes the binder composition from organic to inorganic materials with different thermal stability parameters. The inorganic metal oxides remain stable at firing temperatures, preventing the generation of harmful gases while still providing the necessary formability during the molding process.
3Stability of the object's composition
If a large amount of organic binder is added to enhance plasticity, then the plasticity is improved, but the production yield reduces due to cracks and defects
Solution Approach 1:
The invention employs a composite inorganic binder system where alumina, silica, and magnesia work together to provide plasticity during molding while maintaining structural integrity. This composite approach prevents the crack formation and defects that occur with organic binders, thereby improving production yield without sacrificing plasticity.
Solution Approach 2:
The invention changes the material parameters from organic to inorganic composition, which fundamentally alters the thermal and mechanical behavior during firing. The inorganic binder system maintains plasticity at room temperature for molding but does not decompose at high temperatures, eliminating the source of cracks and defects that reduce production yield.
4Ease of manufacture
If layered double hydroxide is added in large amounts (about 6 mass%) to reduce organic binder, then the moldability is maintained, but the manufacturing cost increases and thermal expansion coefficient increases
Solution Approach 1:
The invention uses a composite inorganic binder system combining multiple metal oxides in specific proportions that collectively provide moldability equivalent to or better than 6 mass% layered double hydroxide. This composite approach achieves the desired moldability while using readily available, cost-effective materials, thereby reducing manufacturing cost.
Solution Approach 2:
The invention changes the composition parameters to use common industrial metal oxides (Al2O3, SiO2, MgO) in optimized ratios that provide the necessary moldability. This parameter optimization replaces the more expensive layered double hydroxide while maintaining or improving moldability and reducing thermal expansion coefficient.
Data Source
AI summary
An object of the invention is to reduce, in a ceramic clay containing a layered double hydroxide, the content thereof while keeping good moldability or formability, thereby reducing the cost of a ceramic structure manufactured using the ceramic clay and improving product properties. The ceramic clay is available by kneading a forming raw material containing a ceramic forming material. The forming raw material contains, in addition to the ceramic forming material, a layered double hydroxide represented by a predetermined chemical formula in an amount of from 0.01 to 5 mass% based on the total amount of them. The layered double hydroxide turns into a gel by dispersing it in water and when it is dispersed in water at a concentration of 6 mass%, it has a viscosity of from 1000 to 20000 mPa·s.