Photoreactive-photostable Hybrid Binders for Ceramic Slurries
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Solution Overview
Problem
Traditional organic binders in curable ceramic slurries result in weak brown ceramic parts during partial firing, limiting handling strength and part yields due to complete removal of the binder, which complicates handling before final firing.
Innovation Solution
The use of photoreactive-photostable hybrid binders, comprising a photoreactive organic resin component, a photoreactive siloxane component, and one or more photostable siloxane components, which convert to silica during firing, enhancing the adhesion between ceramic particles and improving the handling strength of brown ceramic parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional organic binders are used in curable ceramic slurries, then the binder can be completely removed during partial firing, but the resulting brown ceramic part becomes weak and susceptible to damage
Solution Approach 1:
The patent uses a hybrid binder system combining photoreactive organic resin with photostable siloxane components. The photostable siloxane remains after firing to provide structural support and improve handling strength of the brown ceramic part, while the photoreactive organic resin is removed during firing. This composite approach resolves the contradiction by maintaining strength during handling while still allowing binder removal.
Solution Approach 2:
The binder system is designed with different components having different stability characteristics. The photoreactive organic resin component is designed to be removed during partial firing, while the photostable siloxane component is designed to remain and provide strength. This local differentiation of binder properties allows simultaneous achievement of binder removal and strength maintenance.
2Ease of manufacture
If traditional organic binders are completely removed during partial firing, then the binder function is eliminated, but part yields are reduced due to handling difficulties
Solution Approach 1:
The hybrid binder system with photostable siloxane components provides structural integrity during handling, enabling successful completion of subsequent operations (transfer, inspection, modification) without part damage. This maintains high part yields while still achieving complete removal of the photoreactive organic resin binder component during firing.
Solution Approach 2:
The photostable siloxane component acts as a protective framework that cushions and supports the ceramic particles during handling operations between firing steps. This pre-established structural support prevents damage that would otherwise reduce part yields.
3Strength
If photostable siloxane components are used in the hybrid binder, then silica formation increases and handling strength improves, but the binder composition becomes more complex
Solution Approach 1:
The patent modifies the chemical composition parameters of the binder by incorporating photostable siloxane components with specific char yields (at least 20 wt%). This parameter change increases silica formation and handling strength while managing composition complexity through defined material specifications.
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 high char yield of the photostable siloxane components leads to significant silica formation, increasing the strength and yield of brown ceramic parts, and reaction bonding with ceramic particles further enhances the strength and reduces shrinkage of the sintered ceramic parts.
Implementation Method 1
photoreactive-photostable hybrid binders, comprising a photoreactive organic resin component, a photoreactive siloxane component, and one or more photostable siloxane components, which convert to silica during firing, enhancing the adhesion between ceramic particles
Implementation Method 2
reaction bonding with ceramic particles further enhances the strength and reduces shrinkage of the sintered ceramic parts
Data Source
AI summary
Ceramic slurries may include ceramic particles, a photoreactive-photostable hybrid binder, and a photoinitiator. The photoreactive-photostable hybrid binder may include a photoreactive organic resin component, a photoreactive siloxane component, and one or more photostable siloxane components. Methods of forming a ceramic part may include curing a portion of a ceramic slurry by exposing the portion of the ceramic slurry to light to form a green ceramic part, and partially firing the green ceramic part to form a brown ceramic part. The brown ceramic part may be sintered at or above a sintering temperature of the ceramic particles to form a ceramic part, wherein sintering includes heating the brown ceramic part to a sufficient temperature to promote reaction bonding that converts silica from the photoreactive-photostable hybrid binder into silicates that bond with the ceramic particles.