Inorganic Hydroxide in Ceramic Tape for Burnout Ignition Control
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Solution Overview
Problem
The rapid decomposition of binders in ceramic tape green bodies during the binder burnout process can lead to exothermic reactions, causing the tape green body to ignite and resulting in manufacturing failures, especially when using materials like lithium manganese oxide (LiMn2O4) or lithium cobalt oxide (LiCoO2).
Innovation Solution
Incorporating an inorganic hydroxide into the tape green body, which undergoes endothermic decomposition, absorbs heat and reduces the risk of ignition, allowing for faster binder removal and continuous processing without fracturing or cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the binder burnout rate is increased to quicken the continuous manufacturing process, then productivity is improved, but the tape green body is more likely to ignite due to higher temperatures
Solution Approach 1:
An inorganic hydroxide intermediary substance is introduced into the tape green body. This intermediary undergoes endothermic decomposition during binder burnout, absorbing excess heat and preventing the temperature from reaching ignition levels, thereby enabling faster conveyance rates without increasing ignition risk
Solution Approach 2:
The inorganic hydroxide utilizes phase transition (decomposition) to absorb heat. The decomposition reaction transitions the hydroxide from a stable compound to its decomposed state, consuming thermal energy in the process and thereby controlling the temperature during binder burnout to prevent ignition
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 use of inorganic hydroxides like magnesium hydroxide (Mg(OH)2) or calcium hydroxide (Ca(OH)2) in the tape green body reduces peak heat release, enabling higher conveyance rates through the burnout zone without ignition, thus enhancing the efficiency and reliability of the continuous ceramic tape manufacturing process.
Implementation Method 1
Incorporating an inorganic hydroxide into the tape green body, which undergoes endothermic decomposition, absorbs heat and reduces the risk of ignition
Data Source
AI summary
A tape green body including (i) inorganic sinterable material; (ii) an inorganic hydroxide; and (iii) a binder. The inorganic sinterable material can include a lithium-containing ceramic material. The inorganic hydroxide can be less than or equal 20 wt % of the tape green body. The inorganic hydroxide exhibits an endothermic decomposition. The tape green body exhibits a lack of ignition during a continuous process of transforming the tape green body into a ceramic tape at a conveyance rate of greater than or equal to 70 mm/min, or even greater than or equal to 100 mm/min. A method of manufacturing the ceramic tape from the tape green body includes a continuous binder burnout step that includes feeding the tape green body through a burnout heating zone having a burnout temperature sufficient to burn out at least a portion of the binder from the tape green body without igniting the tape green body.