Ceramic Filter Device with Viscous Intermediate Layer

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Solution Overview

Problem

Existing filter devices, particularly ceramic filters, are produced using complex and expensive methods, making them unsuitable for less complex applications due to high production costs.

Innovation Solution

A method for producing a ceramic filter device with at least two outer layers and an intermediate layer, where a viscous ceramic material is applied to partial areas of the first outer layer, forming separating elements that are then compressed between the layers before sintering, allowing for a simpler and more cost-effective manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If complex manufacturing methods are used to produce ceramic filters with high performance, then the filter quality and reliability are improved, but the production cost increases significantly

Engineering Contradiction:

Improvefilter qualityVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The filter device is divided into multiple functional layers (first outer layer, intermediate layer with separating elements, second outer layer), where each layer has a specific function. The intermediate layer is further segmented into multiple separating elements that can be independently formed and positioned, allowing for modular construction and simplified manufacturing of complex filter structures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The intermediate layer with separating elements is prepared in advance as a separate component before being integrated with the outer layers. The viscous ceramic material is applied to form separating elements with predetermined shapes and positions, allowing for pre-processing and quality control before final assembly and sintering.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If complex manufacturing methods are used to produce ceramic filters, then the filter performance is improved, but the manufacturing process complexity increases

Engineering Contradiction:

Improvefilter performanceVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple manufacturing operations are merged into a single sintering process. The outer layers and intermediate layer with separating elements are combined into one integrated structure that is sintered as a single unit, eliminating the need for separate assembly steps and reducing manufacturing process complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The ceramic material transitions from a viscous state during application and forming to a solid state during sintering. By controlling the viscosity of the ceramic material during the forming stage, the separating elements can be easily shaped and positioned, and then the material hardens during sintering to provide structural integrity.

Inventive Principle:

Principle #35Parameter changes

3Strength

If traditional ceramic filter manufacturing methods are used, then the structural integrity is maintained, but the production efficiency decreases

Engineering Contradiction:

Improvestructural integrityVSAvoidproduction efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The manufacturing process is designed as a continuous operation where outer layers and intermediate layers are sequentially applied and then sintered in one continuous process. The viscous ceramic material allows for continuous forming and shaping operations before the final sintering step, maximizing production efficiency.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

Traditional mechanical assembly methods are replaced by a chemical-bonding approach where ceramic materials are applied in viscous form and then bonded together through sintering. This eliminates complex mechanical fastening or joining operations and directly fuses the layers into a single integrated structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 enables the production of ceramic filter devices at a lower cost, making them suitable for less complex applications by simplifying the manufacturing process while maintaining adaptability to different filter tasks through adjustable shape and material properties.

Implementation Method 1

viscous ceramic material is applied to partial areas of the first outer layer

Methodology Applied

Scientific EffectViscous material application:

Implementation Method 2

The amount of compression or pinching is typically selected with regard to the desired dimensions of the filter device

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 3

two sintered ceramic outer layers are connected to one another via ceramic webs and a ceramic outer ring by sintering to form a homogeneous unit

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentEP3530343B1Method for producing a ceramic filter device

Publication Date: 2021.10.06 KERAFOL HLDG GMBH

Figure 1~2
Figure 3~4

AI summary

Method for manufacturing a ceramic filter device (10) comprising at least two outer layers (11, 12) between which an intermediate layer (13) connecting the two outer layers (11, 12) is arranged or formed, comprising the following steps: - providing a first outer layer (11), - applying an intermediate layer (13) to the first outer layer (11), - applying a second outer layer (12) to the intermediate layer (13), wherein the application of the intermediate layer (13) comprises a spot and/or web-shaped application of a viscous ceramic material.