Extended Ceramic Tube Structures Sinter Bonding

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Solution Overview

Problem

Manufacturing large-sized, extended-length ceramic tube structures with high thermal mass is challenging due to sourcing issues and high thermal budgets, requiring segmented approaches and efficient joining methods to achieve strong and hermetic seals.

Innovation Solution

The development of extended-length tube structures formed by joining ceramic tube segments with a ceramic coupling component using sinter bonds, which provides a strong and hermetic seal with a shear strength of at least 25 MPa, achieved through specific silicon carbide-based materials and processing techniques like isopressing and multistep sintering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If large-sized ceramic tube structures with high thermal mass are manufactured as monolithic parts, then the structure integrity is improved, but the manufacturing becomes infeasible due to sourcing issues and high thermal budgets

Engineering Contradiction:

Improvestructure integrityVSAvoidmanufacturing feasibility

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent divides the large-sized ceramic tube structure into multiple smaller tube segments that can be manufactured separately using conventional sintering processes. These segments are then joined together using sinter bonds to form the extended-length tube structure, making manufacturing feasible while maintaining structural integrity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses composite material structures where ceramic tube segments are joined through sinter bonds to create an extended-length tube. The composite nature of the joined structure allows fabrication of large-scale components that would otherwise be impossible to manufacture as monolithic parts

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If ceramic tube segments are joined using conventional methods, then the joining process is simplified, but the seal quality deteriorates due to inability to achieve strong hermetic seals

Engineering Contradiction:

Improvejoining process simplicityVSAvoidseal quality

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces conventional mechanical joining methods with sinter bonding, a thermal process that fuses ceramic segments at the molecular level. This substitution achieves hermetic seals with shear strength of at least 25 MPa while maintaining relative simplicity in the joining process

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the bonding parameters by using sintering temperatures and pressures specific to ceramic materials. The sinter bond process uses controlled thermal and pressure parameters to create strong hermetic seals between segments, achieving shear strength of at least 25 MPa

Inventive Principle:

Principle #35Parameter changes

3Productivity

If extended-length tube structures are fabricated with high aspect ratios, then the structural efficiency is improved, but the manufacturing precision deteriorates due to challenges in maintaining alignment and seal integrity

Engineering Contradiction:

Improvestructural efficiencyVSAvoidalignment and seal integrity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent employs preliminary positioning and alignment of tube segments before the sinter bonding process. This preliminary action ensures proper alignment and spacing of segments, which is critical for maintaining manufacturing precision in extended-length structures with high aspect ratios

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sinter bond acts as an intermediary element that not only joins segments but also compensates for minor misalignments. The bonding process creates a transition zone that maintains seal integrity even when perfect alignment is difficult to achieve in high aspect ratio structures

Inventive Principle:

Principle #24Intermediary (Mediator)

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 method enables the creation of large-scale ceramic tube structures with high aspect ratios and robust seals, maintaining integrity under various conditions including thermal cycles and pressure tests, with minimal pressure loss and excellent nitrogen, helium, and vacuum seal performance.

Implementation Method 1

The ceramic coupling component is positioned so as to be sinter-bonded to the second end of the first tube segment and to the first end of the second tube segment

Methodology Applied

Scientific EffectSinter bonding: Sintering

Data Source

PatentEP2828222B1Extended length tube structures

Publication Date: 2019.05.01 SAINT GOBAIN CERAMICS & PLASTICS INC

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AI summary

An extended length tube structure includes a first ceramic tube segment having a first end and a second end, and a second ceramic tube segment having a first end and a second end, in which the second end of the first ceramic tube segment is arranged to face the first end of the second ceramic tube segment. A ceramic coupling component is positioned to circumscribe the end-to-end configuration of the tube segments, and is sinter-bonded to the tube segments to form an continuous, extended length tube structure having a seal, such as a sinter bond or an interference bond, that is free of bond materials.