SiC Fluidic Module with Tortuous Passages
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Solution Overview
Problem
The practical production of silicon carbide (SiC) structures with internal features, such as tortuous fluid passages, is challenging due to its high hardness and abrasiveness, which complicates the formation of complex structures like fluidic modules with integrated fluid separation and temperature regulation.
Innovation Solution
A method involving the use of positive passage molds and porous ceramic powders within a binder-coated ceramic powder, where the powder interconnects are pressed and then sintered to create closed-porosity ceramic bodies with tortuous fluid passages and open-porosity regions, enabling fluid separation and temperature regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machining methods are used to create internal features in SiC, then manufacturing precision can be achieved, but the difficulty of manufacture increases significantly due to high hardness and abrasiveness
Solution Approach 1:
The patent applies preliminary action by forming the internal passage features before the ceramic material hardens. Molds are embedded in the green (unfired) ceramic body, allowing complex internal geometries to be created during forming rather than requiring difficult post-sintering machining operations on the hard, brittle sintered material.
Solution Approach 2:
The patent replaces mechanical machining operations with a molding process. Instead of using cutting tools to remove material from hard SiC, the invention uses molds to shape the ceramic material in its soft, binder-coated state, thereby avoiding the challenges of machining abrasive, hardened ceramic material.
2Adaptability or versatility
If complex internal structures like tortuous passages are formed in SiC, then functionality is improved, but manufacturing complexity increases
Solution Approach 1:
Complex tortuous passage geometries are predetermined and formed in the mold before ceramic fabrication. The molds themselves contain the complex internal geometries, allowing these intricate structures to be replicated in the green ceramic body without requiring complex assembly or post-processing operations.
Solution Approach 2:
The patent embeds molds within the green ceramic body matrix. The molds are nested inside the ceramic powder volume, allowing the formation of internal passages that are surrounded by and integrated into the ceramic structure. This nesting approach enables complex internal geometries to be created as part of a monolithic structure.
3Adaptability or versatility
If integrated fluid separation and temperature regulation features are incorporated, then system functionality is enhanced, but manufacturing difficulty increases
Solution Approach 1:
The patent combines multiple functional features (fluid passages, porous regions for separation, and temperature regulation channels) into a single integrated ceramic body. All these features are formed simultaneously during one molding and sintering process, eliminating the need for separate manufacturing steps and assembly operations for each function.
Solution Approach 2:
The ceramic body is designed to perform multiple functions simultaneously: fluid transport through tortuous passages, fluid separation through porous regions, and temperature regulation through integrated channels. This multi-functional integration is achieved through a universal molding approach that creates all features in a single manufacturing process.
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 the effective formation of monolithic ceramic fluidic modules with integrated fluid separation and temperature regulation, enhancing the structural integrity and functionality of SiC-based fluidic systems.
Implementation Method 1
pressing the volume of ceramic powder with the first and second positive passage molds and the powder interconnect inside to form a pressed body
Implementation Method 2
heating the pressed body to remove the first and second positive passage molds
Implementation Method 3
sintering the pressed body to form a closed-porosity ceramic body
Data Source
AI summary
A process for forming a fluidic module (150) with integrated fluid separation includes positioning a first positive passage mold (115A) of a first fluid passage (170) having a tortuous shape within a volume of binder-coated ceramic powder (110A) and positioning a second positive passage mold (115B) of a second fluid passage (175) having a tortuous shape within the volume of ceramic powder (110A) and spaced apart from the first positive passage mold (115A). The process further includes positioning a powder interconnect (120) adjacent to a portion of each of the first (115A) and second positive passage molds (115B) within the volume of ceramic powder (110A), pressing the volume of ceramic powder (110A, HOB) with the first and second positive passage molds (115A, 115B) and the powder interconnect (120) inside to form a pressed body (148), heating the pressed body to remove the first and second positive passage molds (115A, 115B), and sintering the pressed body (148) to form a closed-porosity ceramic body (150).