Ceramic Kneaded Clay Formulation for Low-Emission Firing
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Solution Overview
Problem
Conventional ceramic forming methods require organic binders and surfactants to achieve fluidity and shape retention, leading to environmental pollution, global warming, and structural defects like cracks due to the generation of CO2 and toxic gases during firing, especially in large-scale or complex structures.
Innovation Solution
A ceramic kneaded clay formulation incorporating a layered double hydroxide, a pore-forming agent, and a minimal amount of organic binder, which ensures fluidity and strength while reducing the amount of organic material used, thereby minimizing environmental impact and structural defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the additive amount of organic binder is increased to improve formability and fluidity, then the shape retention property is improved, but mechanical strength decreases and cracks are generated during firing
Solution Approach 1:
The patent changes the chemical composition parameters by introducing a specific organic binder system with controlled molecular weight and functional groups, optimizing the binder-to-substrate ratio to achieve sufficient formability while minimizing combustion-related defects and maintaining mechanical strength
Solution Approach 2:
The patent creates a composite binder system combining organic binder with specific additives that enhance both formability and strength retention, where the composite formulation allows the binder to perform multiple functions: providing plasticity during forming and maintaining structural integrity during firing
2Ease of operation
If the additive amount of organic binder is increased to improve formability, then the fluidity is improved, but CO2 and toxic gases are generated causing environmental pollution
Solution Approach 1:
The patent modifies the chemical composition by selecting organic binder(s) with specific combustion characteristics that produce fewer harmful emissions, and optimizes the binder quantity to the minimum necessary for achieving required fluidity and formability
Solution Approach 2:
The patent employs an organic binder formulation that is completely consumed during firing, transforming the binder from a permanent component into a temporary forming aid that decomposes cleanly, reducing residual harmful substances in the final product
3Ease of operation
If the amount of water is increased to ensure fluidity, then the formability is improved, but drying time is increased and cracks are generated during drying
Solution Approach 1:
The patent optimizes the water content parameter to the minimum level required for achieving adequate fluidity during forming, and adjusts the organic binder composition to maintain workability at lower water contents, thereby reducing drying time and minimizing drying-induced cracks
Solution Approach 2:
The organic binder acts as an intermediary substance that provides the necessary fluidity and plasticity without requiring excessive water, allowing the clay mixture to be formed properly while minimizing the free water that would need to be evaporated during drying
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 solution enables the production of ceramic structures with high strength, reduced defects, and desired porosity, while minimizing the generation of CO2 and toxic gases, contributing to environmental sustainability and cost-effectiveness.
Implementation Method 1
A ceramic kneaded clay of the present invention includes... a layered double hydroxide... which enables suppression of usage of an organic binder... and enables to obtain a honeycomb structure having smaller defects
Implementation Method 2
a pore-forming agent... enables usage of sufficient amount of pore-forming agent enough to realize desired porosity
Implementation Method 3
because the organic binder is burned in the firing, there is a problem that a space occupied by the organic binder in forming becomes a defect... CO2 or a toxic gas is generated by burning the organic binder in the firing
Data Source
AI summary
An oxide-ceramic forming clay comprising an oxide-ceramic forming material, a layered double hydroxide, a pore-forming agent, and water, wherein the amount of the pore-forming agent is between 3 and 50 parts by mass by superaddition to 100 parts by mass of a sum of the oxide-ceramic forming material and the layered double hydroxide and a sum of the pore-forming agent and an organic binder is between 5 and 55 parts by mass also by superaddition which has environment-friendly characteristics in a forming firing step, and usage thereof.