Ceramic Tape Binder Burn-Off for Defect-Free Sintering
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Solution Overview
Problem
Existing methods for manufacturing ceramic tapes or sheets are inefficient, time-consuming, and prone to defects due to binder interaction during sintering, leading to low yield and surface imperfections.
Innovation Solution
A process involving the continuous removal of the organic binder before sintering, followed by controlled handling and sintering in a specially designed furnace, maintains the integrity and strength of the inorganic grains, allowing for efficient and defect-free manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the organic binder is removed before sintering, then the inorganic grains can sinter without binder interference and surface quality improves, but the grains become unsupported and the tape loses strength for handling
Solution Approach 1:
The patent applies preliminary action by removing the organic binder before sintering the inorganic grains. This preliminary binder removal prevents the binder from interfering with the sintering process and causes surface defects, thereby improving surface quality. The tape is designed to maintain structural integrity through the grain network alone after binder removal, enabling continuous processing without requiring binder presence during sintering.
2Productivity
If the green tape is handled continuously after binder removal, then productivity increases, but the tape may fracture due to lack of binder support
Solution Approach 1:
The patent applies parameter changes by controlling the physical and chemical state of the inorganic grain network after binder removal. The grains are sintered to a degree where they form a cohesive network with sufficient mechanical strength to support continuous handling. Temperature control and sintering duration are adjusted to achieve the optimal balance between grain bonding and tape flexibility, preventing fracture during continuous processing.
3Strength
If traditional setter boards are used during sintering, then support is provided during processing, but adhesion to refractory materials causes pinholes and surface defects
Solution Approach 1:
The patent applies the taking out principle by removing the setter board from the sintering process entirely. The green tape is sintered in a suspended state within the furnace, eliminating contact between the ceramic particles and refractory setter board surfaces. This extraction of the setter board prevents adhesion-related defects such as pinholes and surface imperfections, while the tape's own grain network provides the necessary structural support during sintering.
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 process enables high-yield, energy-efficient production of ceramic tapes or sheets with improved surface quality and reduced defects, suitable for various applications such as substrates in batteries and displays.
Implementation Method 1
preparing the tape for sintering by chemically changing the binder and/or removing the binder from the first portion of the tape
Implementation Method 2
sintering the inorganic grains to produce a sintered article
Data Source
AI summary
A method of manufacturing a ceramic tape includes advancing a tape through a binder burn-off station, where the tape entering the binder burn-off station comprises grains of polycrystalline ceramic bound by an organic binder. The binder burn-off station comprises an active heater that chemically changes the organic binder and/or removes the organic binder from the tape, leaving the tape with the grains of the polycrystalline ceramic exiting the binder burn-off station.