Ceramic Tape Manufacturing Line for Setter-Free Sintering
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Solution Overview
Problem
Conventional sintering processes result in surface defects on ceramic articles due to contact with setter boards, which are difficult to polish and affect mechanical properties, especially in thin and large-surface-area articles.
Innovation Solution
A continuous manufacturing line process that removes the setter board by burning off the binder and sintering the green tape without support, using tension to maintain the tape's integrity and achieve flatness, reducing surface defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional sintering with setter board support is used, then the green tape is supported during sintering, but surface defects are introduced on the supported side
Solution Approach 1:
The invention removes the setter board from the sintering process entirely. The green tape is suspended in a furnace without contacting any support surfaces during sintering, thereby eliminating the source of surface defects while maintaining structural support through the suspension mechanism.
Solution Approach 2:
The invention introduces an intermediary suspension mechanism (such as hooks, clips, or suspension fibers) that holds the green tape without direct contact. This intermediary system provides the necessary support while preventing the tape from contacting harmful surfaces, thus avoiding surface defect formation.
2Object-affected harmful factors
If the tape is suspended without support during sintering, then surface defects are avoided, but the tape may lack structural support
Solution Approach 1:
The invention employs an intermediary suspension system that provides structural support without direct contact. The suspension mechanism (hooks, clips, or fibers) acts as a mediator that holds the tape in place during sintering, preventing both surface defects and structural collapse.
Solution Approach 2:
The invention may use thin film or fiber-like suspension elements that provide adequate structural support while maintaining minimal contact with the tape surface. These flexible support elements prevent tape collapse during sintering without introducing surface defects.
3Loss of substance
If thin sintered articles are manufactured, then the articles can be produced with reduced material usage, but they become difficult to polish and may have excessive surface area to process
Solution Approach 1:
The invention prevents surface defect formation during sintering by using a non-contact suspension method. By eliminating the setter board contact that causes defects in the first place, the invention makes thin articles easier to manufacture without requiring extensive polishing to remove defects.
Solution Approach 2:
The invention converts the potential harm of needing support during sintering into a benefit by using a non-contact suspension system. This approach avoids the surface defects that would normally require polishing, thereby simplifying the manufacturing of thin articles.
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 produces sintered articles with improved mechanical properties and consistent surface quality, free from contact-induced defects, enabling efficient production of thin, large-surface-area ceramics.
Implementation Method 1
a first heated location to burn off or char the binder
Implementation Method 2
a second heated location for at least partial sintering of the inorganic particles
Data Source
AI summary
A method of manufacturing ceramic tape includes a step of directing a tape of partially-sintered ceramic into a furnace. The tape is partially-sintered such that grains of the ceramic are fused to one another yet the tape still includes at least 10% porosity by volume, where the porosity refers to volume of the tape unoccupied by the ceramic. The method further includes steps of conveying the tape through the furnace and further sintering the tape as the tape is conveyed through the furnace. The porosity of the tape decreases during the further sintering step.