Silicon Carbide Fluidic Modules: Crack-Free Demolding
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Solution Overview
Problem
The existing powder pressing process for producing ceramic structures with internal cavities, such as channels or chambers, faces challenges in maintaining structural integrity during mold removal due to variations in commercially available ceramic powder and binder mixtures, often resulting in small cracks in the cavity walls.
Innovation Solution
A method and apparatus are developed to remove an internal mold from a green state powder-pressed ceramic body by applying energy to melt the mold material while using fluid pressure through flexible membranes on the external surfaces of the ceramic body, preventing crack formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If heating is applied to remove the internal mold by melting, then the mold can be removed from the green state ceramic body, but cracks can form in the cavity walls due to thermal stress and structural weakness
Solution Approach 1:
The patent applies fluid pressure through flexible membranes to the external surfaces of the green state ceramic body before and during the heating process. This preliminary application of supportive pressure prevents crack formation in the cavity walls when thermal stress is applied during mold removal, thereby maintaining manufacturing precision while enabling ease of manufacture
Solution Approach 2:
The flexible membranes filled with pressurized fluid provide beforehand cushioning to the external surfaces of the ceramic body. This cushioning effect counteracts the thermal stress and structural weakness that would otherwise cause cracks during mold removal, resolving the contradiction between easy mold removal and cavity wall integrity
2Adaptability or versatility
If commercially available powder and binder mixtures are used, then the production process can proceed with standard materials, but structural integrity cannot be maintained during mold removal due to batch-to-batch variations
Solution Approach 1:
The patent changes the physical state parameters of the support system by using flexible membranes filled with pressurized fluid. This allows the system to adapt to variations in commercially available powder and binder mixtures while maintaining reliable structural integrity during mold removal, resolving the contradiction between material adaptability and process reliability
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 allows for successful demolding of ceramic structures with internal cavities without producing significant interior surface cracks, ensuring the structural integrity of the ceramic body.
Implementation Method 1
applying a fluid pressure through a flexible membrane to at least two opposite external surfaces of the green state powder pressed ceramic body
Implementation Method 2
applying energy to an internal mold the body to melt a material of the mold
Data Source
AI summary
A silicon carbide flow reactor fluidic module comprises a monolithic closed-porosity silicon carbide body and a tortuous fluid passage extending through the silicon carbide body, the tortuous fluid passage lying within two or more layers with the silicon carbide body, the tortuous passage having an interior surface, the interior surface having a surface roughness of less than 10 μm Ra. A method of forming the fluidic module is also disclosed.