Reactive Liquid Ceramic Binder for Low-Temperature Firing
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Solution Overview
Problem
Conventional refractory ceramic products require high firing temperatures, long burning times, and high pressures, leading to energy inefficiency and inadequate green strength without heat treatment, making it difficult to produce homogeneous mixtures and unshaped ceramic products.
Innovation Solution
The use of reactive, liquid ceramic binders with organomodified siloxane compounds, specifically designed to have organoalkoxysiloxane units, which can be mixed with ceramic powders at room temperature, providing high cold pressure resistance and allowing for the production of ceramic products with improved mechanical properties at lower firing temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional solid siloxane binders are used, then high firing temperatures (>1000°C) are required to achieve sufficient mechanical properties, but this leads to high energy consumption and long firing times
Solution Approach 1:
The invention changes the physical state parameter of the binder from solid to liquid, and modifies the chemical structure by introducing organoalkoxysiloxane units with reactive alkoxy groups. This allows the binder to remain liquid at room temperature for easy mixing, then undergo chemical reaction at lower temperatures to form strong bonds, eliminating the need for high-temperature firing >1000°C while achieving sufficient cold pressure resistance
Solution Approach 2:
The invention creates a composite binder system combining organomodified siloxane backbone with organoalkoxysiloxane units containing reactive alkoxy groups. This composite structure provides both the liquid state at room temperature for easy processing and the reactive functionality for low-temperature bonding, resolving the contradiction between ease of mixing and bond strength
2Stability of the object's composition
If conventional solid binders are used, then homogeneous mixtures with ceramic materials cannot be produced adequately, but switching to liquid binders requires high softening temperatures for plastic processing
Solution Approach 1:
The invention changes the physical state parameter of the binder from solid to liquid, and modifies the chemical structure by introducing organoalkoxysiloxane units with reactive alkoxy groups. This allows the binder to remain liquid at room temperature for easy mixing, then undergo chemical reaction at lower temperatures to form strong bonds, eliminating the need for high-temperature firing >1000°C while achieving sufficient cold pressure resistance
Solution Approach 2:
The invention replaces the mechanical plastic deformation process (requiring softening temperature for molding) with a chemical bonding process. The reactive alkoxy groups chemically react with ceramic surfaces to form strong bonds, allowing the green body to achieve sufficient strength without plastic processing, enabling uniaxial and isostatic pressing at room temperature
3Strength
If high firing temperatures and long burning times are used, then refractory ceramic products with sufficient mechanical properties are achieved, but energy consumption increases significantly
Solution Approach 1:
The invention changes the physical state parameter of the binder from solid to liquid, and modifies the chemical structure by introducing organoalkoxysiloxane units with reactive alkoxy groups. This allows the binder to remain liquid at room temperature for easy mixing, then undergo chemical reaction at lower temperatures to form strong bonds, eliminating the need for high-temperature firing >1000°C while achieving sufficient cold pressure resistance
Solution Approach 2:
The reactive alkoxy groups in the binder perform dual functionality: they provide liquid state at room temperature for easy mixing, and automatically react with ceramic surfaces during low-temperature firing to form strong bonds. This self-reacting capability eliminates the need for external high-energy input, reducing energy consumption while achieving sufficient mechanical properties
4Adaptability or versatility
If conventional binders are used, then unshaped ceramic products cannot be produced, but the invention enables production of unshaped refractory materials with high cold pressure resistance
Solution Approach 1:
The invention changes the physical state parameter of the binder from solid to liquid, and modifies the chemical structure by introducing organoalkoxysiloxane units with reactive alkoxy groups. This allows the binder to remain liquid at room temperature for easy mixing, then undergo chemical reaction at lower temperatures to form strong bonds, eliminating the need for high-temperature firing >1000°C while achieving sufficient cold pressure resistance
Solution Approach 2:
The invention replaces the mechanical plastic deformation process (requiring softening temperature for molding) with a chemical bonding process. The reactive alkoxy groups chemically react with ceramic surfaces to form strong bonds, allowing the green body to achieve sufficient strength without plastic processing, enabling uniaxial and isostatic pressing at room temperature
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 reduces energy requirements, shortens firing times, and maintains material strength, enabling the production of stable, fireproof ceramic products with enhanced cold compressive strength and dimensional stability, even at temperatures below 1000°C, while minimizing the formation of low-melting phases.
Implementation Method 1
reactive, liquid ceramic binders having organomodified siloxane compounds, the reactive liquid siloxane binder having organoalkoxysiloxane units according to the general formula (I)
Implementation Method 2
enabling the production of stable, fireproof ceramic products with enhanced cold compressive strength and dimensional stability, even at temperatures below 1000°C
Data Source
AI summary
The subject matter of the present patent application relates to a reactive ceramic binder in liquid form, suitable for the production of ceramic products from ceramic powder, characterized in that the reactive, liquid ceramic binder comprises liquid organomodified siloxane compounds, wherein the organomodified siloxane compounds comprise organoalkoxysiloxane units according to general formula (I), wherein R1 is independently identical or different alkyl, alkaryl or aryl groups, optionally interrupted by ether functions, R2 is independently identical or different groups from group H and/or an alkyl group with 1 to 6 carbon atoms, R3 is independently identical or different divalent, optionally unsaturated hydrocarbon groups with 1 to 30 carbon atoms, optionally interrupted by ether functions, and a is greater than or equal to 0 and less than or equal to 2.5 and b is greater than 0 and less than or equal to 3.provided that a + b is greater than or equal to 1 and less than or equal to 3.