Oxygen Swing Firing for Ceramic Green Body Debinder
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Solution Overview
Problem
Firing ceramic green bodies in low-oxygen atmospheres can lead to increased carbon content, causing cracks in the resulting ceramic articles due to sudden carbon burning when the atmosphere shifts to air, necessitating a method to remove carbon content effectively.
Innovation Solution
Controlling oxygen concentration in the kiln to swing during heating, alternating between different oxygen concentrations to facilitate and suppress the burning of carbon content, thereby ensuring complete debindering without cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ceramic green body is fired in a low-oxygen atmosphere, then the carbon content of the organic binder burns moderately suppressing cracks, but the amount of carbon remaining in the green body increases causing sudden burning and cracks in the fired article
Solution Approach 1:
The patent applies periodic action by alternately switching between low-oxygen atmosphere (to suppress crack formation) and air atmosphere (to burn off remaining carbon) during the firing process. This periodic switching of oxygen concentration enables controlled removal of carbon while preventing crack formation, resolving the contradiction between crack suppression and carbon removal.
2Quantity of substance
If the atmosphere is shifted from low-oxygen to air atmosphere, then the remaining carbon burns off, but sudden burning occurs causing cracks in the fired ceramic article
Solution Approach 1:
The patent applies preliminary action by gradually increasing the oxygen concentration over time rather than abruptly switching from low-oxygen to air atmosphere. This gradual transition allows the carbon to burn off slowly and controlledly, preventing sudden temperature spikes that would cause cracks, while still achieving complete carbon removal.
3Productivity
If the oxygen concentration is controlled to swing during heating, then complete debindering is achieved in shorter time, but the process complexity increases
Solution Approach 1:
The patent applies feedback by using oxygen concentration sensors to monitor the atmosphere in real-time and automatically adjusting the oxygen supply based on detected carbon content and temperature conditions. This closed-loop control system achieves complete debindering efficiently while maintaining manageable process complexity through automated regulation.
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 effectively removes the carbon content of organic binders, preventing cracks in fired ceramic articles by managing temperature peaks and ensuring thorough debindering in a shorter time, resulting in a more stable firing process.
Implementation Method 1
heating a ceramic green body in a kiln
Implementation Method 2
carbon content of an organic binder in a ceramic green body burns
Data Source
AI summary
The present disclosure is related to a method of producing a fired ceramic article. The method may include: heating a ceramic green body in a kiln, and controlling oxygen concentration in the kiln such that the oxygen concentration swings during the heating of the ceramic green body.