Ceramic Extrusion Torque Stability via Continuous Wet Mixing
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Solution Overview
Problem
The variability in bulk density of wet mixtures during batch processing in ceramic formed body manufacturing leads to inconsistent viscosity and shape defects, affecting production efficiency and product quality.
Innovation Solution
Implementing continuous wet mixing to stabilize bulk density and viscosity, with real-time shape measurement and feedback to adjust the liquid addition at the wet mixing and kneading steps, ensuring consistent extrusion behavior and product shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If batch-type wet mixing is used to add liquid to ceramic raw materials, then the mixing process can be performed in discrete units, but the bulk density of wet mixture varies between batches leading to inconsistent viscosity
Solution Approach 1:
The patent transitions from batch-type wet mixing to continuous wet mixing, where liquid is continuously added to ceramic raw materials during the mixing process. This continuous action eliminates the start-stop nature of batch processing, ensuring uniform bulk density and consistent viscosity throughout production, thereby resolving the contradiction between ease of manufacture and manufacturing precision.
Solution Approach 2:
The patent modifies the operational parameters of the mixing process by maintaining continuous operation and controlling the rate of liquid addition. By changing from discrete batch parameters to continuous flow parameters, the system achieves stable bulk density and consistent viscosity, solving the precision issue while preserving manufacturing efficiency.
2Productivity
If batch switching is performed during wet mixing, then production can proceed in manageable units, but the wet mixture immediately after switching has different bulk density compared to wet mixture before switching
Solution Approach 1:
The patent implements continuous wet mixing that eliminates batch switching entirely. Liquid is continuously added to the moving ceramic raw materials through the mixing chamber, ensuring that the bulk density remains stable throughout the entire production process without the fluctuations that occur during batch transitions, thus maintaining both productivity and composition stability.
Solution Approach 2:
The continuous mixing system is designed so that liquid addition is preliminarily established as a continuous process rather than being introduced in discrete batches. This preliminary design choice prevents the composition instability that would otherwise occur at batch transition points, maintaining steady bulk density throughout production.
3Ease of operation
If viscosity of forming raw material is not controlled, then extrusion can proceed without strict parameter management, but the mechanical load (torque) on extrusion machine and product shape become inconsistent
Solution Approach 1:
The patent incorporates a feedback mechanism where the viscosity of the forming raw material is monitored and controlled through continuous wet mixing. By regulating liquid addition based on material properties, the system maintains consistent viscosity that ensures uniform torque during extrusion and precise product shape control, while the automated nature of this control preserves operational simplicity.
Solution Approach 2:
The patent controls viscosity by precisely managing the liquid addition rate in the continuous mixing process. By adjusting this critical parameter, the system achieves optimal and consistent material flow characteristics that simplify extrusion operation while ensuring high manufacturing precision for product shape.
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 stabilizes the torque applied to the extrusion machine and maintains well-balanced fluidity and shape-retaining properties, resulting in a consistent ceramic formed body shape and improved production efficiency.
Implementation Method 1
a wet mixing step (second mixing) to add liquid (5) to the obtained dry mixture (4), while wet mixing by continuous processing
Implementation Method 2
The viscosity of a forming raw material is affected by the amount of liquid added to the forming raw material, and it is known that the viscosity of the forming raw material greatly affects the mechanical load (torque) applied to the extrusion machine or the shape of the ceramic formed body after extrusion
Implementation Method 3
a forming step to extrude a forming raw material, which is prepared by degassing and consolidating the obtained kneaded mixture (7), using an extrusion machine
Data Source
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AI summary
Provided is a method for manufacturing a ceramic formed body enabling the manufacturing of a ceramic formed body having a controlled product shape, such as roundness, by keeping the torque applied to the extrusion machine stable and low, using a forming raw material having well-balanced fluidity and shape-retaining property. A manufacturing method 1 includes: a dry mixing step S1 of dry mixing a raw material 3 by batch processing; a wet mixing step S2 of adding liquid 5 to a dry mixture 4 obtained at the dry mixing step S1 by continuous processing, the liquid including at least one type of water, surfactant, lubricant and plasticizer, while wet mixing; a kneading step S3 of kneading a wet mixture 6 obtained at the wet mixing step S2; and a forming step S4 of extruding a kneaded mixture (forming raw material) obtained at the kneading step S3 to make a ceramic formed body 2.