Integrated Core Shaping Mold for Ceramic Hollow Bodies
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Solution Overview
Problem
Existing methods for manufacturing three-dimensional fired bodies require separate core installation and positioning within shaping molds, necessitating mold releasing agents and cleaning, which complicates the process.
Innovation Solution
A method involving a shaping mold with an integrated core, where the ceramic slurry is solidified and the mold is eliminated during drying or degreasing stages, eliminating the need for core positioning and mold cleaning, using a 3D printer for mold production and a ceramic slurry with a gelling agent for precise shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate core is installed in the shaping mold, then the hollow portion can be formed, but the process complexity increases due to core positioning and mold cleaning requirements
Solution Approach 1:
The core is integrated with the shaping mold to form a single unified structure. The core becomes an inherent part of the mold design, eliminating the need for separate core installation and positioning operations. This merging of the core and mold simplifies the manufacturing process while maintaining the accuracy of the hollow portion formation.
Solution Approach 2:
The core is pre-integrated into the shaping mold during mold fabrication, so that when the mold is used, the core is already in the correct position and configuration. This preliminary integration eliminates the need for subsequent core positioning operations and ensures consistent accuracy across multiple production cycles.
2Manufacturing precision
If a separate core is used in the shaping mold, then the hollow portion can be formed, but additional operations are required for mold releasing agent application and mold cleaning
Solution Approach 1:
By integrating the core with the shaping mold, the patent eliminates the need for separate mold maintenance operations. The unified structure removes the interface between the core and mold that would otherwise require releasing agents and cleaning, simplifying the manufacturing process while maintaining product quality.
3Ease of manufacture
If the shaping mold is eliminated by burning, then the mold can be removed, but the components in the shaped body may be burned causing surface unevenness
Solution Approach 1:
The patent changes the elimination method from thermal decomposition (burning) to melting. By controlling the temperature to be above the melting point of the organic material but below the degradation point of the ceramic components, the mold is removed through melting rather than burning. This parameter change prevents surface unevenness while maintaining ease of mold removal.
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 simplifies and enhances the accuracy of three-dimensional fired body manufacturing by eliminating the need for core positioning and mold cleaning, ensuring precise shape retention and preventing deformation during mold removal.
Implementation Method 1
producing the shaped body in the shaping mold by pouring a ceramic slurry into the shaping space of the shaping mold and solidifying the ceramic slurry
Implementation Method 2
the shaping mold may be eliminated by melting and removing the shaping mold
Implementation Method 3
a step of drying and then degreasing the shaped body
Implementation Method 4
the shaping mold may be eliminated by chemical decomposition (e.g., pyrolysis) of the shaping mold
Data Source
AI summary
A method for manufacturing a three-dimensional fired body includes (a) a step of producing a shaping mold using an organic material, the shaping mold having a shaping space which has the same shape as a shaped body having a hollow portion that opens to an outer surface thereof, in which a core corresponding to the hollow portion is integrated with the shaping mold; (b) a step of producing the shaped body in the shaping mold by pouring a ceramic slurry into the shaping space and solidifying the ceramic slurry; (c) a step of drying and then degreasing the shaped body, in which the shaping mold is eliminated in any one of the following stages: before drying, during drying, after drying and before degreasing, during degreasing, and after degreasing of the shaped body; and (d) a step of firing the shaped body to obtain a three-dimensional fired body.