Segmented Ceramic Elements for Roller Kiln Firing

Solution Overview

Problem

Existing methods for firing clay or ceramic elements in a kiln often result in damaged outer surfaces due to production marks and uneven firing, particularly for elements with irregular shapes that cannot be stably balanced on rollers, preventing successful glazing and uniform extrusion.

Innovation Solution

Securing complementary ceramic elements together after passing through the kiln, with the inner surfaces contacting the rollers to avoid damaging the outer surfaces, allowing for glazing before or after firing and ensuring uniform firing of irregular shapes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ceramic elements are passed through the kiln on rollers, then the firing process can be completed, but the outer surface becomes damaged with production marks and uneven firing

Engineering Contradiction:

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The ceramic element is divided into two halves that are fired separately on the rollers, then joined together. This segmentation allows the outer surfaces to be protected from roller contact during firing, eliminating production marks while completing the firing process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of firing the complete ceramic element on rollers (conventional approach), the invention inverts the approach by firing two separate halves and joining them afterward. This inversion protects the outer surfaces from roller damage while achieving complete firing.

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If ceramic elements with irregular shapes (curved, V-shaped, rippled, or corrugated) are passed through the kiln on rollers, then the firing process can be attempted, but the elements rock unevenly resulting in non-uniform firing and glazing

Engineering Contradiction:

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

Irregularly shaped ceramic elements are segmented into two halves for separate firing on rollers. This segmentation eliminates the rocking problem during firing, as each half can be stabilized independently, resulting in uniform firing and glazing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The conventional approach of firing complete irregular shapes on rollers is inverted by firing separate halves and joining them afterward. This inversion eliminates stability issues during firing while achieving complete and uniform firing of the final assembled piece.

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of manufacture

If the outer surface of ceramic elements is glazed before passing through the kiln on rollers, then the glazing can be applied, but the production marks from rollers damage the glazed surface

Engineering Contradiction:

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The ceramic element is segmented into halves that are glazed before being fired separately on rollers. The glazing is applied to the outer surfaces of the halves, which are then protected from roller contact during firing, preventing damage to the glazed surface.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The outer surfaces of the ceramic halves are glazed before the firing process. This preliminary glazing action allows the glaze to be applied undamaged, and the subsequent firing of separate halves prevents roller marks from contaminating the glazed surfaces.

Inventive Principle:

Principle #10Preliminary action

4Reliability

If complete ceramic elements are fired in the kiln, then the firing process can be completed, but unique shapes cannot be stably balanced and passed along the rollers

Engineering Contradiction:

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The invention segments complete ceramic elements into halves that are fired separately on rollers. This segmentation enables the firing of diverse and unique shapes that would otherwise be unstable on rollers, as the segmented halves can be more easily stabilized during the firing process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The conventional approach of firing complete unique shapes on rollers is inverted by firing separate halves and joining them afterward. This inversion enables greater shape variety and versatility, as irregular and unique shapes can be stabilized and fired as segments rather than complete forms.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS11027456B2Ceramic composite

Publication Date: 2021.06.08

AI summary

A composite ceramic element and method of firing clay or ceramic elements in a roller kiln, comprising the steps of passing a first ceramic element on rollers through the roller kiln, passing a second ceramic element on rollers through the roller kiln, and mating and securing the first and second ceramic elements together after passing each said ceramic element through the roller kiln.