Composite Electroceramics from Waste via Lithium Molybdate Bonding
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Solution Overview
Problem
Current methods for manufacturing composite electroceramics face challenges such as low ceramic content, high energy consumption, and inefficient recycling of ceramic waste, leading to suboptimal electrical performance and significant material loss in the electronics industry.
Innovation Solution
A method involving the use of sintered electroceramic waste material, ground into a specific particle size, mixed with a binder like lithium molybdate or organometallic precursors, and compressed under controlled temperature and pressure to form high-performance electroceramic composites with a high ceramic content, reducing energy consumption and waste disposal costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional thermally driven sintering or melting assisted mechanism is used, then ceramic particles are bonded together, but energy consumption is high and ceramic content remains low
Solution Approach 1:
The patent changes the bonding mechanism from thermal-driven to aqueous solution-driven by using lithium molybdate aqueous solution as a binder. This parameter change allows ceramic particles to bond together at lower temperatures while maintaining bonding strength, thereby resolving the contradiction between bonding strength and energy consumption
Solution Approach 2:
The patent replaces the thermal field (conventional sintering) with a chemical field (aqueous solution bonding). The lithium molybdate aqueous solution acts as a binder that chemically bonds ceramic particles together, substituting the high-energy thermal process with a lower-energy chemical bonding process, thus reducing energy consumption while maintaining bonding strength
2Loss of substance
If ceramic waste is not recycled, then material loss is high, but recycling processes are complex and energy-intensive
Solution Approach 1:
The patent implements a recycling approach where ceramic waste material is recovered and reused as the primary ceramic particles in the composite electroceramics. The waste ceramic material is ground into powder and then bonded with lithium molybdate aqueous solution to form new electroceramic products, thereby reducing material loss while avoiding complex recycling processes
Solution Approach 2:
The patent enables the ceramic waste material to serve itself by using the waste ceramic particles as the base material for new electroceramic composites. The process requires minimal additional processing - mainly grinding and bonding with aqueous solution - allowing the waste material to be upcycled with simple operations, thus reducing both material loss and process complexity
3Reliability
If high ceramic content is achieved, then electrical performance is improved, but manufacturing precision becomes difficult to control
Solution Approach 1:
The patent changes the manufacturing approach by using aqueous solution bonding instead of thermal sintering, which allows for better control of composition and particle distribution. The lithium molybdate aqueous solution penetrates between ceramic particles and forms strong bonds, enabling high ceramic content (up to 95-98 wt%) while maintaining manufacturing precision through controlled solution concentration and bonding conditions
Solution Approach 2:
The lithium molybdate aqueous solution acts as an intermediary that facilitates bonding between ceramic particles without requiring high temperatures. This intermediary enables precise control over the bonding process and composition, allowing high ceramic content to be achieved while maintaining manufacturing precision through controlled solution application and evaporation parameters
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 enables the production of electroceramic composites with exceptional electrical performance, utilizing recycled materials efficiently, reducing energy consumption, and minimizing waste treatment costs while enhancing material utilization and productivity.
Implementation Method 1
aqueous solution of lithium molybdate (LMO, Li2MoO4) powder or the like has recently been used as a binder between particles
Implementation Method 2
The obtained homogeneous mass is dried, thereby obtaining an electroceramic composite material
Data Source
AI summary
A method for manufacturing composite electroceramics comprises obtaining sintered electroceramic waste material. The waste material is grinded to obtain first ceramic powder having a particle size of 10-400 micron. The first ceramic powder is mixed with NaCl, Li2MoO4 or other ceramic powder having a particle size of 0.5-20 micron, in a ratio of 60-90 vol-% said first ceramic powder and 10-40 vol-% NaCl, Li2MoO4 or other ceramic powder. The obtained ceramic powder mixture is mixed with aqueous solution of NaCl, Li2MoO4 or said other ceramic, in a ratio of 70-90 wt-% the ceramic powder mixture, and 10-30 wt-% the aqueous solution. The obtained homogeneous mass is compressed in a mould for 2-10 min in room temperature and in a pressure of 100-400 MPa. The compressed homogeneous mass is removed from the mould, thereby obtaining electroceramic composite material. Alternatively to the use of the water soluble salt an organometallic precursor compound can be used.