Ceramic Core-Shell Particles for High Porosity and Strength
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Solution Overview
Problem
Conventional sintered ceramic honeycomb structures face limitations in achieving high porosity and strength simultaneously, as modifications to increase porosity or cell density often degrade material strength, and they lack multifunctionality for catalytic or chemical reactions.
Innovation Solution
The use of ceramic particles with a core/shell structure, where the core and shell differ in density, composition, or pore morphology, allows for the formation of sintered ceramic articles with increased porosity and strength, enabling greater surface area and multifunctionality through the selection of materials for the core and shell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If porosity is increased in conventional sintered ceramic honeycomb structures, then surface area and filtration capability are improved, but material strength deteriorates
Solution Approach 1:
The ceramic particle is segmented into a core and a shell, where the core provides structural strength and the shell provides porosity. This segmentation allows each part to optimize its function independently, resolving the contradiction between strength and porosity at the particle level.
Solution Approach 2:
Different regions of the ceramic particle are assigned different properties: the core has high density and strength characteristics, while the shell has high porosity and surface area characteristics. This local differentiation allows the composite particle to exhibit both high strength and high porosity simultaneously.
2Strength
If cell density is increased in conventional sintered ceramic honeycomb structures, then structural strength is improved, but porosity and surface area deteriorate
Solution Approach 1:
By segmenting the particle into core and shell, the structure can pack densely (high cell density) while the shell maintains high porosity. The dense core provides strength for structural integrity, while the porous shell preserves filtration surface area.
3Ease of manufacture
If conventional single-phase ceramic particles are used, then manufacturing simplicity is maintained, but multifunctionality for catalytic or chemical reactions is limited
Solution Approach 1:
The ceramic particle is formed as a composite material with a core of first ceramic phase and a shell of second ceramic phase. This composite structure enables multifunctionality: the core can provide structural support or one catalytic function, while the shell provides different catalytic activity or sorption capabilities, allowing the particle to perform multiple functions simultaneously.
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 approach results in sintered ceramic articles with enhanced strength and porosity, achieving higher modulus of rupture and coefficient of thermal expansion, while allowing for multifunctional applications such as catalytic and sorption reactions, particularly suitable for carbon capture technology.
Implementation Method 1
the green structure is fired to sinter the ceramic particles into a sintered ceramic article
Data Source
AI summary
Embodiments of the disclosure relate to a sintered ceramic article. The sintered ceramic article includes sintered ceramic particles. The sintered ceramic particles include a shell at least partially surrounding at least one core. The shell is made from a first ceramic phase, and the at least one core is made from a second ceramic phase. The first ceramic phase differs from the second ceramic phase in at least one of density, composition, or pore morphology.