Thin Porous SiC Filter Plates with Carbon Filament Reinforcement
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Solution Overview
Problem
SiC membrane filter plates used in wastewater treatment are brittle and prone to breakage due to their slender shape, and adding reinforcements during manufacturing can increase costs and alter the ceramic structure, while conventional methods fail to effectively enhance tensile strength without increasing thickness.
Innovation Solution
Incorporating pre-formed carbon or ceramic filaments or filament-forming precursors into a pre-ceramic composition, which are embedded during the extrusion and sintering process to create porous ceramic with embedded carbon filaments, enhancing tensile strength without increasing thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the SiC membrane plates are made thicker to increase resistance to fracture, then the strength is improved, but the filtration area per volume decreases and manufacturing costs increase
Solution Approach 1:
The patent applies composite materials by incorporating carbon fiber reinforcements into the SiC ceramic matrix. This creates a composite structure where the carbon fibers provide tensile strength and fracture resistance, allowing the plates to maintain high strength at reduced thickness, thereby preserving filtration area per volume while improving mechanical durability
Solution Approach 2:
The patent changes the material composition parameters by adding carbon fiber content to the SiC extrusion mixture. This parameter change enables the plates to achieve enhanced mechanical properties without increasing thickness, resolving the contradiction between strength and filtration efficiency
2Strength
If additives are added to the SiC mixture to reinforce the material, then the strength is improved, but the manufacturing cost increases and the high sintering temperature burns away the additives
Solution Approach 1:
The patent changes the material parameter by selecting carbon fiber as the additive, which has the unique property of withstanding the high sintering temperatures required for SiC manufacturing. This parameter selection allows reinforcement without the additives being consumed during processing, reducing manufacturing complexity and cost
Solution Approach 2:
The patent uses carbon fiber, a relatively inexpensive material that can be readily incorporated into the SiC mixture. The carbon fiber provides cost-effective reinforcement compared to other potential additives, and its ability to survive the manufacturing process eliminates the need for complex protective measures or post-processing steps
3Strength
If pre-manufactured carbon fiber is added to the mixture to reinforce the plates, then the tensile strength is improved, but the cost increases due to the additional heating process already undergone by the carbon fiber
Solution Approach 1:
The patent changes the form of carbon reinforcement from pre-manufactured continuous fibers to chopped carbon fiber or carbonaceous precursors. This parameter change reduces the manufacturing cost by using materials that require less prior processing, while still achieving the desired tensile strength reinforcement in the final sintered product
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
The method results in SiC filtration plates with increased tensile strength and cost savings by using less expensive precursor materials that survive the high-temperature manufacturing process, maintaining filtration efficiency and reducing material density.
Implementation Method 1
subjecting the thin plate preform to elevated temperatures to convert the pre-ceramic raw material into porous ceramic with the filaments embedded therein
Implementation Method 2
extruding the flowable composition to form a thin plate preform
Data Source
AI summary
A method for manufacturing wastewater filtration plates uses a flowable composition including pre-ceramic raw material. The flowable composition is extruded to form a thin plate preform. Carbon-containing material is included in the flowable composition and/or added to the surface of the thin plate perform during or after extrusion thereof. The carbon-containing material is preformed carbon filaments or carbon-fiber precursor material. The thin plate preform is subjected to elevated temperatures to convert the pre-ceramic raw material into porous ceramic with carbon filaments embedded therein or disposed on the surface of the finished ceramic plate.