CFC Workpiece Carrier with Ceramic Positioning Devices
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Solution Overview
Problem
Existing workpiece carriers for high-temperature treatments face issues with dimensional stability and contamination prevention, as metal support struts can warp or sag, and ceramic coatings are prone to cracking and wear due to thermal expansion differences.
Innovation Solution
A workpiece carrier with a support grid of carbon fiber-reinforced carbon (CFC) struts and positioning devices made of ceramic fiber composite material, which are thicker, stable, and resistant to temperature changes, preventing contamination by allowing workpieces to rest exclusively on the ceramic elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal support struts are used in workpiece carriers, then ease of manufacture is improved, but dimensional stability deteriorates at high temperatures due to warping and bending
Solution Approach 1:
The patent applies composite materials by using carbon fiber reinforced carbon (CFC) for support struts requiring high-temperature dimensional stability, while using ceramic materials for positioning devices requiring chemical inertness. This composite approach allows each material to be used where its properties are most beneficial, resolving the contradiction between ease of manufacture and dimensional stability at high temperatures.
2Object-affected harmful factors
If ceramic coatings are applied to CFC support struts to prevent contamination, then contamination prevention is improved, but reliability deteriorates due to cracking and flaking from thermal expansion differences
Solution Approach 1:
The patent extracts the contamination prevention function from the support struts and relocates it to dedicated positioning devices made entirely of ceramic materials. This separation eliminates the thermal expansion mismatch problem that caused coating failure, while still achieving contamination prevention through the chemically inert ceramic positioning devices that contact the workpieces.
Solution Approach 2:
The patent introduces ceramic positioning devices as intermediary elements between the CFC support struts and the metal workpieces. These positioning devices serve as a mediator that prevents direct contact between carbon-containing struts and metal workpieces, thereby preventing carburization without requiring thermal expansion-matched coatings on the struts themselves.
3Object-affected harmful factors
If ceramic positioning devices are used to prevent contamination, then contamination prevention is improved, but mechanical strength deteriorates due to brittleness and susceptibility to thermal shock
Solution Approach 1:
The patent applies local quality by using ceramic materials specifically for the positioning devices where chemical inertness is critical for contamination prevention, while using CFC for the support struts where mechanical strength and thermal shock resistance are paramount. This localized material assignment optimizes both contamination prevention and mechanical strength in their respective locations.
4Stability of the object's composition
If CFC support struts are used to ensure dimensional stability, then dimensional stability is improved, but object-generated harmful factors worsen due to potential carburization of workpieces
Solution Approach 1:
The patent introduces ceramic positioning devices as intermediary elements between the CFC support struts and the metal workpieces. These positioning devices serve as a mediator that prevents direct contact between carbon-containing struts and metal workpieces, thereby preventing carburization while maintaining the dimensional stability benefits of CFC struts.
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 provides a cost-effective, dimensionally stable, and contamination-free workpiece carrier that maintains structural integrity and prevents undesired material transfer during high-temperature treatments, allowing for efficient and secure handling of workpieces.
Implementation Method 1
Support struts made of carbon fiber reinforced carbon (CFC), on the other hand, are dimensionally stable and sufficiently strong even at high temperatures.
Implementation Method 2
The round bars are made of an extruded ceramic material and are not thermal shock resistant, meaning that the round bars can be easily damaged by the formation of cracks during rapid temperature changes.
Implementation Method 3
For example, undesirable carburization of steel, a workpiece material, can occur if it rests directly against a positioning device made of carbon fiber reinforced carbon.
Data Source
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AI summary
The invention relates to a workpiece carrier and a method for manufacturing a workpiece carrier (10) for providing and handling workpieces in high-temperature furnaces for high-temperature treatment or the like, wherein the workpiece carrier is formed from a support grid (11) with workpiece receptacles (12) for positioning workpieces on the workpiece carrier, wherein the support grid is formed from support struts (14, 15, 16, 17, 19, 20) forming a grid structure (21), wherein the support struts are made of carbon fiber reinforced carbon (CFC), wherein the workpiece receptacles are formed from positioning devices (22) of the workpiece carrier arranged on the support struts, wherein the positioning devices are designed and arranged on the support struts such that workpieces can be arranged on the workpiece receptacles in a predetermined position, wherein the positioning devices have a support element (24) for arranging workpieces.wherein the support element is made of a ceramic fiber composite material, wherein the positioning device has a support element (23) arranged on a support strut for arranging the support element.