Inorganic Sheet Forming via Indented Rollers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional methods for forming large sintered ceramic sheets are inefficient, as they result in fragile green bodies, require low solid loading slurries, generate significant waste water, and incorporate high amounts of organic materials, limiting sheet thickness and mechanical strength.
Innovation Solution
A method involving passing a ceramic precursor composition through indented rollers to form a board, which is then processed through finishing rollers to produce a sheet with enhanced mechanical integrity, allowing for larger and thicker sheets with improved mechanical properties, and optionally forming multilayered composites by stacking and sintering green sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional methods (slip casting, extrusion, pressing) are used to form inorganic sheets, then shaping is achieved, but the green bodies become fragile and difficult to handle, limiting the ability to form large size sheets
Solution Approach 1:
The invention changes the physical and chemical parameters of the forming mixture by using a specific composition ratio of ceramic powder to organic binder (1:0.01 to 1:0.5), along with controlled plasticizer and solvent content. This parameter optimization creates a green body with enhanced flexibility and strength, enabling large sheet formation without fragility
Solution Approach 2:
The invention uses a composite organic binder system combining multiple components (binder, plasticizer, solvent) that work synergistically to provide both structural integrity and flexibility to the green body, allowing large sheets to be formed and handled without breaking
2Volume of moving object
If tape casting is used to produce ceramic thin layers, then thickness control down to microns is achieved, but it is difficult to maintain thickness and inhibit sedimentation during drying, preventing thick sheet production
Solution Approach 1:
The invention optimizes the slurry parameters including solid loading (30-70 wt%), binder content (1-20 wt%), and plasticizer-solvent ratio to achieve a composition that maintains uniform thickness during drying. The specific parameter range prevents sedimentation while enabling thick sheet production up to several millimeters
Solution Approach 2:
The organic binder acts as an intermediary that holds ceramic particles in suspension and maintains uniform distribution during the drying process, preventing sedimentation and ensuring thickness uniformity throughout the sheet
3Ease of operation
If tape casting uses high amounts of organics (binder, plasticizer, solvent), then slurry flowability is improved, but economical and environmental problems arise
Solution Approach 1:
The invention reduces organic content by optimizing the binder to ceramic powder ratio to 0.01-0.5, and carefully controlling plasticizer and solvent amounts. This minimized organic formulation maintains adequate slurry processability while significantly reducing waste and environmental impact
Solution Approach 2:
The invention uses minimal organic additives only where strictly necessary for processability, rather than uniform high organic content throughout. The organic materials are concentrated in small amounts at critical interfaces and regions needed for flow and bonding
4Productivity
If extrusion methods are used to produce ceramic sheets, then continuous production is achieved, but the width of extruded sheet is curtailed by extruder and die size, making large sheets problematic
Solution Approach 1:
The invention transitions from extrusion (linear dimension constraint) to a sheet forming process where the mixture is spread and dried to achieve desired dimensions. This dimensional change allows production of large area sheets without being constrained by extruder diameter or die width
5Ease of manufacture
If traditional methods are used to form inorganic sheets, then shaping is achieved, but significant waste water is generated
Solution Approach 1:
The invention uses a controlled slurry formulation with optimized solvent content (10-50 wt%) that can be efficiently recovered and reused. The specific parameter range allows for reduced water consumption and easier waste water treatment compared to traditional low solid loading slurries
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 production of larger, thicker ceramic sheets with superior mechanical strength and reduced organic content, facilitating further processing and environmental sustainability by minimizing waste and organic additives.
Implementation Method 1
passing a sheet-forming composition comprising a major amount of inorganic particulate material through at least one pair of indented rollers forming an inorganic board
Implementation Method 2
passing said inorganic board through at least one pair of finishing rollers, thereby forming an inorganic sheet
Implementation Method 3
sintering the green ceramic sheet to form a sintered ceramic sheet
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Methods for making an inorganic sheet (7), a sintered ceramic sheet and a sintered multilayered ceramic composite, an inorganic sheet (7), sintered ceramic sheet and a sintered multilayered ceramic composite obtainable by such methods, and an apparatus configured to carry out such methods.