Polymer Microparticles for Ceramic Extrusion Moldability
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Solution Overview
Problem
Existing ceramic molding methods face challenges in achieving high flowability and shape-retaining ability due to insufficient water absorbing capacity of polymer microparticles, leading to suboptimal extrusion molding results.
Innovation Solution
The use of polymer microparticles with specific characteristics, including an average particle size between 10-150 µm, an ion exchange water absorbing amount between 10-60 mL/g, and electroconductivity of 1,500 µS/cm or less, which contain ionic functional groups and are produced through inverse suspension polymerization, enhance the water absorbing ability and moldability of ceramic materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a dispersant comprising a specific fatty acid salt is added to lower the viscosity of green ceramic clay, then the moldability is improved, but the dispersant obstructs the interaction between binder molecules, thereby deteriorating the shape-retaining ability and molded article strength
Solution Approach 1:
The patent introduces polymer microparticles as an intermediary substance that mediates between the ceramic powder and binder. These microparticles absorb excess water and improve flowability without interfering with binder molecule interactions, thus resolving the contradiction between moldability and shape-retaining ability
Solution Approach 2:
The patent changes the physical and chemical parameters of the additive by specifying polymer microparticles with particular properties: average particle size of 1-10 μm, water absorption capacity of 5-30 mL/g, and specific surface area of 10-100 m²/g. These parameter optimizations enable improved moldability while maintaining shape-retaining ability
2Ease of operation
If a large amount of dispersant is used to sufficiently lower the viscosity of green ceramic clay, then the flowability is improved, but the dispersant obstructs the interaction between binder molecules, thereby considerably deteriorating the shape-retaining ability and molded article strength
Solution Approach 1:
The polymer microparticles serve as an intermediary that absorbs water and improves flowability through physical absorption rather than chemical interaction. This mechanism allows sufficient flowability improvement without the harmful side effects of traditional dispersants that interfere with binder bonding
Solution Approach 2:
The patent utilizes the porous structure of polymer microparticles to absorb and retain water within their internal pore network. This porous architecture enables the microparticles to control water release and improve flowability while maintaining the integrity of binder interactions
3Reliability
If ionic impurities are released from polymer microparticles with residual monomers, then the water absorbing ability of the polymer microparticles is obstructed, but the flowability of green ceramic clay and shape-retaining ability of molded articles cannot be simultaneously achieved
Solution Approach 1:
The patent optimizes the electroconductivity parameter of the polymer microparticles to 1,500 μS/cm or less, which indicates controlled ionic content. This parameter control ensures that the microparticles maintain their water absorbing ability while providing sufficient moldability
Solution Approach 2:
The patent specifies using polymer microparticles with limited ionic functionality and controlled residual monomer content, effectively treating them as single-use additives that perform their water absorption and flowability enhancement function without long-term ionic interference in the ceramic matrix
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
These polymer microparticles significantly improve the flowability and shape-retaining ability of ceramic materials during extrusion molding, enabling the production of highly precise and reproducible ceramic articles with enhanced moldability and surface smoothness.
Implementation Method 1
an ion exchange water absorbing amount between 10 and 60 mL/g at an ordinary pressure
Implementation Method 2
the polymer microparticle is swollen with ion exchange water until the swollen polymer microparticle reaches a saturated state
Implementation Method 3
part of water is released from the polymer microparticle by a pressure applied upon extrusion molding, and then the polymer microparticle quickly absorb the water therearound after the pressure is released
Data Source
Figure 1
AI summary
The present invention relates to an additive for use in the molding of a ceramic material, which exhibits satisfactory water absorption performance in a ceramic green ceramic clay, can highly achieve both high fluidability and low loading performance during extrusion molding and high shape-retaining performance after extrusion at the same time, and comprises polymer microparticles. This additive for use in the molding of a ceramic material comprises polymer microparticles, is characterized in that the polymer microparticles have an average particle size between 10 and 150 µm when the polymer microparticles are swollen with ion exchange water until the swollen polymer microparticles reach a saturated state and can absorb 10-60 mL/g of ion exchange water under ordinary pressure, and is also characterized in that an aqueous dispersion prepared by dispersing 1 part by mass of the polymer microparticles in 110 parts by mass of ion exchange water has an electrical conductivity of 1500 µS/cm or less at 25°C.