Ceramic Filtration Disc Manufacturing via Segmented Base and Membrane Sintering
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Solution Overview
Problem
The production of ceramic filtration discs is complex, expensive, and limited in geometry, making it difficult to achieve cost-effective and flexible filtration solutions with existing methods.
Innovation Solution
A method involving the separate shaping and sintering of a porous ceramic base body followed by the application and sintering of ceramic membrane layers, using techniques like casting or dry pressing, allowing for increased flexibility and cost-effectiveness in producing filtration discs with optimized geometry and surface features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ceramic filtration discs are manufactured by laminating unsintered green films, then the disc structure can be formed with internal channels, but the production process becomes complex and expensive
Solution Approach 1:
The manufacturing process is divided into two independent stages: first forming the base body with internal channels, then applying the membrane layer separately. This segmentation allows each component to be optimized independently and simplifies the overall production process by avoiding complex lamination of unsintered films.
Solution Approach 2:
The base body is formed and sintered completely before the membrane layer is applied. This preliminary action eliminates the need to handle and laminate unsintered green films, significantly simplifying the manufacturing process and reducing complexity.
2Adaptability or versatility
If ceramic filtration discs are manufactured by laminating unsintered green films, then the disc structure can be formed, but the achievable disc geometry is limited
Solution Approach 1:
By separating the base body formation from the membrane application, the invention allows independent optimization of geometry. The base body can be formed with any geometry using conventional ceramic shaping techniques, while the membrane is applied as a separate layer, enabling complex geometries that would be difficult to achieve through lamination.
3Quantity of substance
If the base body is produced by casting from ceramic foam, then high porosity is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The invention utilizes ceramic foam as a starting material for the base body, which inherently provides high porosity. This approach leverages the excellent porous structure of foam ceramics to achieve the desired permeate drainage capability without requiring additional pore-forming steps in the membrane layer.
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 significantly reduces production costs, expands geometric possibilities, and enhances filtration performance by increasing the surface area and turbulence, leading to improved filtration efficiency and broader applications, such as in water purification.
Implementation Method 1
the ceramic foam is produced by using a ceramic slurry which foams up to a ceramic foam upon the addition of metal pastes and/or metal powders
Implementation Method 2
the green body for the base body is sintered at a temperature between 1,200°C and 2,000°C, more preferably between 1,200°C and 1,800°C
Implementation Method 3
applying the membrane in one or more layers as a slurry to the already sintered base body and sintering it again together with the base body
Implementation Method 4
the liquid is pumped through the membrane-coated outer layer of a porous ceramic body. The permeate permeates the membrane from the outside to the inside
Data Source
AI summary
The present application relates to a method for producing a ceramic filtration disc, which has a porous ceramic base body and a ceramic membrane arranged on the outer surfaces of the base body, wherein the ceramic filtration disc has an axial bore which forms the permeate outflow of the filtration disc, wherein in a first step the base body is formed and sintered, and that in a second step the membrane is applied in one or more layers as a slurry to the already sintered base body and sintered again together with the base body.