Ceramic Green Ware Body for Honeycomb Structures
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Solution Overview
Problem
The challenge lies in producing ceramic honeycomb structures with thin walls and high cell density, as existing extrusion aids often hinder economic drying and extrusion due to soluble ions, leading to inefficiencies and difficulties in achieving the desired structural properties.
Innovation Solution
A ceramic precursor batch composition with a soluble ion concentration of less than 0.75 molar, primarily composed of inorganic oxide and a temperature gelling cellulose ether, is used to facilitate extrusion and drying, eliminating soluble ions and enabling the production of honeycomb structures with thin walls and high cell density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional extrusion aids with soluble ions are used, then extrusion process is facilitated, but drying efficiency decreases and HSE requirements increase
Solution Approach 1:
The patent changes the chemical composition parameters of the extrusion aid by limiting soluble ion concentration to less than 0.75 molar and specifying particular ion ratios (Na+/K+ less than 0.1, Ca2+/Mg2+ less than 0.1). This parameter optimization enables both good extrusion processability and high drying efficiency by eliminating ions that interfere with microwave drying while maintaining workable slurry rheology.
Solution Approach 2:
The patent employs a composite extrusion aid system combining temperature-gelling cellulose ether (0.5-5 wt%) with controlled inorganic ion concentrations. This composite approach provides both the binding necessary for extrusion and the low soluble ion content required for efficient microwave drying, resolving the contradiction between manufacturability and productivity.
2Productivity
If soluble ion concentration is reduced, then drying efficiency improves, but extrusion processability may deteriorate
Solution Approach 1:
The patent optimizes multiple parameters simultaneously: soluble ion concentration (<0.75 M), specific ion ratios (Na+/K+ <0.1, Ca2+/Mg2+ <0.1), and cellulose ether content (0.5-5 wt%). This multi-parameter optimization ensures that even with low soluble ions, the slurry maintains adequate viscosity and binding properties for extrusion while enabling rapid microwave drying.
Solution Approach 2:
The temperature-gelling cellulose ether acts as an intermediary substance that compensates for the reduced soluble ion content. It provides the necessary binding and rheological control for extrusion processability while not interfering with microwave drying, thus mediating between the conflicting requirements of manufacturability and drying efficiency.
3Manufacturing precision
If thin-walled high cell density honeycomb structures are produced, then structural performance improves, but manufacturing difficulty increases due to soluble ion interference
Solution Approach 1:
The patent achieves thin-walled high cell density structures by optimizing extrusion parameters including soluble ion concentration (<0.75 M), cellulose ether content (0.5-5 wt%), and extrusion conditions. These parameter changes enable the formation of delicate thin walls that maintain structural integrity while achieving high cell densities (e.g., 200-400 cells per linear inch), resolving the contradiction between structural performance and manufacturing difficulty.
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 enhances drying efficiency and facilitates the extrusion of honeycomb structures with improved structural properties, reducing the risk of defects and lowering Health, Safety, and Environment (HSE) requirements, while allowing for microwave drying and reducing drying time by 70%.
Implementation Method 1
a temperature gelling cellulose ether
Implementation Method 2
allowing for microwave drying
Data Source
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AI summary
A ceramic precursor batch composition, green ware formed thereof, porous ceramic honeycomb article formed thereof, and methods of making same.