Template-Based Ceramic Solid Production via Hydrogel Gelation
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Solution Overview
Problem
There is a need for materials and devices that enable safe and high-performance energy storage and thermoelectric operations, as existing technologies face challenges in achieving efficient and cost-effective production of ceramic materials for energy storage devices and thermoelectric devices.
Innovation Solution
The development of template-based methods for producing ceramic solids, such as oxide ceramic solids, using a gelation process combined with precursor solution entrapping, which allows for molecular-level mixing and avoids phase segregation and impurity formation, utilizing hydrogel templates that can be processed without additional thermal energy and are bio-compatible.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to produce ceramic materials, then production cost and time are reduced, but phase purity and material quality deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-mixing precursor components at the molecular level in a gel matrix before ceramic formation. This preliminary molecular mixing ensures uniform distribution of elements, preventing phase segregation during subsequent heating processes and achieving high phase purity without requiring extended processing times or additional purification steps.
Solution Approach 2:
The patent utilizes parameter changes by controlling the gelation process and heating parameters to transform precursor materials into ceramic phases. By optimizing temperature profiles and holding times during calcination, the process achieves complete reaction and phase formation while maintaining high purity, resolving the contradiction between processing speed and material quality.
2Manufacturing precision
If molecular-level mixing is achieved through solution-based technology, then phase purity improves, but process complexity increases
Solution Approach 1:
The patent employs a gel matrix as an intermediary medium that facilitates molecular-level mixing of precursor components. The gel structure provides a homogeneous environment where precursors are uniformly distributed at the molecular level before ceramic formation. This intermediary approach simplifies the overall process by eliminating the need for complex mechanical mixing equipment or multiple processing steps, as the gelation process itself achieves uniform distribution.
3Use of energy by moving object
If traditional ceramic production methods are used, then equipment requirements are minimized, but energy consumption increases
Solution Approach 1:
The patent exploits phase transitions by utilizing the gelation process to transform liquid precursor solutions into a solid-like gel matrix, and then using controlled heating to transform the gel into ceramic material. This phase transition approach allows the process to proceed at lower temperatures compared to traditional ceramic sintering, significantly reducing energy consumption while requiring only simple heating equipment and eliminating the need for complex ceramic processing machinery.
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 efficient and cost-effective production of ceramic materials with desired properties for energy storage and thermoelectric devices, reducing process time and improving phase purity, while ensuring safety and performance.
Implementation Method 1
combining the ceramic precursor solution with a hydrogel precursor to produce a solubilized hydrogel template; gelling the solubilized hydrogel template to produce a wet gel comprising a hydrogel template containing an entrapped ceramic precursor solution
Implementation Method 2
When the formation is heated, only a single (desired) crystallographic phase is formed instead of multiple phases
Data Source
AI summary
Various embodiments relate to a method comprising forming a template from a template precursor, wherein the template contains an entrapped ceramic precursor, which can be further processed to form a ceramic solid, such as an oxide ceramic solid. In one embodiment, the template precursor is a hydrogel precursor and the template is a hydrogel template. The hydrogel template can include, for example, agarose, chitosan, alginate or a photo-initiating receptive hydrogel template such as a functionalized poly(ethylene glycol). Various devices, including electrolyte interfaces and energy storage devices, as well as thermoelectric devices are also provided. In one embodiment, the oxide ceramic solid is a cubic garnet having a nominal formula of Li7La3Zr2O12 (LLZO).