PATENT DOCUMENT

Publication Number: US-10328605-B2
Application Number: US-201414172375-A
Country: US
Kind Code: B2

Title: Ceramic component casting

Abstract:
Methods for improved ceramics component casting. One such method may include vacuuming a ceramic-based slurry mixture and/or vacuuming a component mold. The vacuuming of the ceramic-based slurry mixture and the component mold may be to remove air bubbles from the respective elements. More specifically, the vacuuming may remove air bubbles from the ceramic-based slurry mixture and from a cavity of the component mold, respectively. The method may also include disposing the ceramic-based slurry mixture into the cavity of the component mold, and continuously vacuuming the cavity of the component mold including the ceramic-based slurry mixture for a predetermined time to remove any additional air bubbles included in the ceramic-based slurry mixture. Finally, the method may include forming a ceramic component within the continuously vacuumed cavity of the component mold over the duration of the predetermined time. The ceramic component formed from the ceramic-based slurry mixture.

Claims:
We claim: 
     
       1. A method comprising:
 vacuuming a ceramic-based slurry mixture to remove air bubbles from the ceramic-based slurry mixture; 
 establishing a vacuum state in a component mold to remove air bubbles from a cavity of the component mold; 
 introducing the ceramic-based slurry mixture into the component mold while maintaining the vacuum state; and 
 forming a ceramic component within the cavity of the component mold from the ceramic-based slurry mixture while maintaining the vacuum state for a period of time. 
 
     
     
       2. The method of  claim 1 , further comprising providing vibrations to the ceramic-based slurry mixture prior to the introducing of the ceramic-based slurry mixture. 
     
     
       3. The method of  claim 2 , further comprising providing the vibrations to the ceramic-based slurry mixture subsequent to the introducing of the ceramic-based slurry mixture into the cavity of the component mold. 
     
     
       4. The method of  claim 3 , wherein the provided vibrations include at least one of a physical vibration, an ultrasonic vibration, or a rotary vibration. 
     
     
       5. The method of  claim 1 , wherein the forming of the ceramic component includes forming a zirconia component. 
     
     
       6. The method of  claim 1 , wherein the introducing the ceramic-based slurry mixture further includes supplying a predetermined amount of the ceramic-based slurry mixture to the cavity of the component mold via a supply tank. 
     
     
       7. The method of  claim 1 , wherein the vacuuming of the component mold removes air bubbles from the ceramic-based slurry mixture as the ceramic-based slurry mixture fills the cavity of the component mold. 
     
     
       8. The method of  claim 1 , wherein the forming of the ceramic component within the cavity of the component mold comprises:
 reasonably maintaining an ambient temperature surrounding the component mold including the ceramic-based slurry mixture; and 
 reasonably maintaining a minimal compression force within the component mold including the ceramic-based slurry mixture. 
 
     
     
       9. The method of  claim 1 , wherein the cavity of the component mold is filled from a bottom portion of the cavity to a top portion of the cavity. 
     
     
       10. The method of  claim 1 , wherein:
 the component mold defines a non-horizontal sidewall adjacent to an opening and configured to direct air bubbles toward the opening, wherein the non-horizontal sidewall is a first non-horizontal sidewall positioned on a first side of the opening; and 
 the component mold further defines a second non-horizontal sidewall positioned on a second side of the opening. 
 
     
     
       11. A method comprising:
 vacuuming a chamber containing a ceramic-based slurry mixture to remove air bubbles from the ceramic-based slurry mixture; 
 while vacuuming the chamber, vacuuming a cavity of a component mold and introducing the ceramic-based slurry mixture into the cavity through a supply conduit fluidly coupling the chamber to an opening in a bottom portion of the cavity, such that the ceramic-based slurry mixture fills the cavity from the bottom portion to a top portion of the cavity; 
 continuing to vacuum the cavity including the ceramic-based slurry mixture for a predetermined time; and 
 forming a ceramic component within the cavity of the component mold over a duration of the predetermined time including curing the ceramic-based slurry mixture by chemically reacting a first material and a second material in the ceramic-based slurry mixture. 
 
     
     
       12. The method of  claim 11 , wherein:
 a first material comprises an epoxy material; 
 a second material comprises an epoxy hardener; and 
 at least one of the first material and the second material includes a plurality of zirconia particles. 
 
     
     
       13. The method of  claim 12 , wherein the zirconia particles are suspended within at least one of the first material and the second material and are distributed evenly throughout the respective first material and the second material. 
     
     
       14. The method of  claim 12 , wherein the introducing of the ceramic-based slurry mixture into the cavity of the component mold includes providing a combination of the first material and the second material into the cavity of the component mold. 
     
     
       15. The method of  claim 11 , wherein the cavity of the component mold is angularly oriented. 
     
     
       16. The method of  claim 11 , wherein the introducing of the ceramic-based slurry mixture into the cavity of the component mold includes forming a single air bubble only in a top portion of the cavity. 
     
     
       17. The method of  claim 11 , wherein the cavity of the component mold includes a coating.

Description:
TECHNICAL FIELD 
     The disclosure relates generally to manufacturing processes, and, more particularly, to methods of casting ceramic components. 
     BACKGROUND 
     Ceramic-based components can be used in a variety of products including structural/building materials, kitchen and tableware, automotive components, medical devices and electronic devices. These ceramic-based components may be used in such a variety of industries because of the desirable physical properties and characteristics. As one example, ceramic-based materials may include high strength properties (e.g., fracture toughness, ductility), include dielectric constant properties and may be substantially transparent, dependent on manufacture. Conventional ceramic-based components are typically made using two techniques: ceramic injection molding (CIM) and ceramic gel casting. 
     Conventional CIM processing typically involves the use of a mold and ceramic-based material that may be substantially liquid when heated. The ceramic-based material may be heated to a specific temperature to be completely liquefied, and then may be poured into the mold. The mold may then be mechanically pressed together using a high compression force, and rapidly cooled. The cooling of the mold, and liquid material within the mold, may cause the ceramic-based material to become substantially solid and take the shape of the mold. 
     The molds used in CIM can be very expensive, and very difficult to create. More specifically, at least partially due to the patterns that may be included in the mold and the required material composition that can withstand the rapid heating and cooling of CIM, the molds may be very expensive and may be difficult and time consuming to manufacture. Additionally, if a mold is defective, it typically cannot be corrected, and a new mold must be created. Furthermore, the rapid heating and cooling of the ceramic-based material used in the CIM process may ultimately have a negative effect on the physical properties of the ceramic component formed in the CIM process. For example, where the ceramic-based material is heated above a desired temperature during the CIM process, the final ceramic component formed using CIM may have a decreased ductility properties. 
     Ceramic gel casting is another conventional manufacturing process for creating ceramic components. In gel casting, a monomer is typically combined with a liquid mixture including a ceramic material, and the combination is disposed within a mold. Similar to CIM, once the liquid mixture and monomer are included in the mold, the mixture is heated to a predetermined temperature to polymerize the liquid and ultimately form a ceramic component. Also similar to CIM, the conventional gel casting process includes placing the mold under high pressure during the casting process and rapidly cooling the mixture to form the ceramic component. 
     Conventional gel casting may include additional complications. For example, conventional gel casting may cause air bubbles to be formed in the final ceramic component, which may substantially reduce the strength of the ceramic component and may cause undesirable cosmetic defects. Air bubbles may be present in the mixture prior to the pouring or otherwise placing the mixture into the mold, and/or air bubbles may be present within the mold during the casting process. Additionally, the ceramic material included in the mixture may not be evenly and/or completely combined with the monomer material during the gel casting process, which may result in a ceramic component having a varying density. That is, a portion of the ceramic component formed from the mixture having a high concentration of ceramic material may be substantially dense, where a portion of the ceramic component formed form the mixture having a low concentration of ceramic material may include minimal density. 
     SUMMARY 
     Generally, embodiments discussed herein are related to methods for improved ceramic component casting. The methods of casting may include combining two materials, where the combining of the two materials begin a curing process to form a ceramic component. At least one of the two materials may include zirconia particles. The combined materials, including the zirconia particles, may be disposed within a cavity of a ceramic component mold, and may cure over a predetermined time to form a ceramic component. The forming of the ceramic component may be accomplished by maintaining a minimal compression force and relatively constant temperature surrounding the two materials including the zirconia particles. That is, the formation may not require any additional pressure than the amount of pressure needed to hold the component mold together. Additionally, the formation may not require the addition of heat to the two materials including the zirconia to form the ceramic component. As a result, the mold need not withstand rapid heating and cooling, and may be made from a more cost-effective material. Additionally, through the casting process, the two materials including the zirconia and/or the mold may be subjected to a vacuum in order to remove air bubbles that may negatively affect the formed ceramic component. 
     One embodiment may include a method for improved ceramic casting. The method may include vacuuming at least one of: a ceramic-based slurry mixture to remove air bubbles from the ceramic-based slurry mixture, and a component mold to remove air bubbles from a cavity of the component mold. The method may also include disposing the ceramic-based slurry mixture into the cavity of the component mold, and forming a ceramic component within the cavity of the component mold over the duration of a predetermined time. The ceramic component may be formed from the ceramic-based slurry mixture. 
     A further embodiment may include an additional method for improved ceramic casting. The method may include vacuuming at least one of: a ceramic-based slurry mixture to remove air bubbles from the ceramic-based slurry mixture, and a component mold to remove air bubbles from a cavity of the component mold. The method may also include disposing the ceramic-based slurry mixture into the cavity of the component mold, and continuously vacuuming the cavity of the component mold including the ceramic-based slurry mixture for a predetermined time. Additionally, the method may include forming a ceramic component within the continuously vacuumed cavity of the component mold over the duration of the predetermined time. The ceramic component may be formed from the ceramic-based slurry mixture. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1A  shows an illustrative first material and a second material included in a ceramic-based slurry mixture, according to embodiments. 
         FIG. 1B  shows an illustrative ceramic-based slurry mixture including the combined first material and second material of  FIG. 1A , according to embodiments. 
         FIG. 2  is a flow chart illustrating a method for casting a ceramic component. This method may be performed using the ceramic-based slurry mixture as shown in  FIG. 1B . 
         FIGS. 3A-3G  show illustrative views of a casting system, including a ceramic-based slurry mixture, undergoing processes of casting as depicted in  FIG. 2 , according to embodiments. 
         FIGS. 3H and 3I  show an illustrative ceramic component formed by processes of casting as depicted in  FIG. 2 , according to embodiments. 
     
    
    
     It is noted that the drawings of the invention are not necessarily to scale. The drawings are intended to depict only typical aspects of the invention, and therefore should not be considered as limiting the scope of the invention. In the drawings, like numbering represents like elements between the drawings. 
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims. 
     The following disclosure relates generally to manufacturing process, and more particularly, to improved methods of ceramic component casting. 
     In a particular embodiment a method of casting may include combining two materials, where the combining of the two materials begin a curing process to form a ceramic component. At least one of the two materials may include zirconia particles. The combined materials, including the zirconia particles, may be disposed within a cavity of a ceramic component mold, and may cure over a predetermined time to form a ceramic component. The forming of the ceramic component may be accomplished by maintaining a minimal compression force and relatively constant temperature surrounding the two materials including the zirconia. That is, the formation may not require any additional pressure than the amount of pressure needed to hold the component mold together. Additionally, the formation may not require the addition of heat to the two materials including the zirconia to form the ceramic component. As a result, the mold need not withstand rapid heating and cooling, and may be made from a more cost-effective material. Additionally, through the casting process, the two materials including the zirconia and/or the mold may be subjected to a vacuum in order to remove air bubbles that may negatively affect the formed ceramic component. 
     One sample, non-limiting method for improved ceramic casting may include vacuuming at least one of: a ceramic-based slurry mixture to remove air bubbles from the ceramic-based slurry mixture; and a component mold to remove air bubbles from a cavity of the component mold. The method may also include disposing the ceramic-based slurry mixture into the cavity of the component mold, and forming a ceramic component within the cavity of the component mold over the duration of a predetermined time. The ceramic component may be formed from the ceramic-based slurry mixture. 
     An alternative method for improved ceramic casting may generally include the operations set forth above, as well as, continuously (or periodically) vacuuming the cavity of the component mold including the ceramic-based slurry mixture for a predetermined time. Additionally, the method may include forming a ceramic component within the continuously vacuumed cavity of the component mold over the duration of the predetermined time. The ceramic component may be formed from the ceramic-based slurry mixture. 
     These and other embodiments are discussed below with reference to  FIGS. 1-3I . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these Figures is for explanatory purposes only and should not be construed as limiting. 
     Referring now to  FIGS. 1A and 1B , a perspective view of one example of a ceramic-based slurry mixture  100  is shown. In an embodiment, as shown in  FIG. 1A , ceramic-based slurry mixture  100  may include a first material  102  and a second material  104 . More specifically, ceramic-based slurry mixture  100  may be made from the combination of first material  102  and second material  104 , as shown in  FIG. 1B . Each of first material  102  and second material  104  may be made from distinct materials that may chemically react with one another to begin a curing process of ceramic-based slurry mixture  100 , as discussed herein. That is, and as discussed herein, first material  102  and second material  104  may be combined to form ceramic-based slurry mixture  100 , which may subsequently begin to cure after and may ultimately form a ceramic component ( FIG. 3F ). In a non-limiting embodiment, first material  102  may include any conventional pre-mixed epoxy material. Additionally, and as discussed herein, first material  102  may also include any conventional dispensate material, which may aid in substantially even dispensing or dispersion of particles included within first material  102 . In a non-limiting example, second material  104  may include any conventional epoxy harder material. That is, second material  104  may include any conventional epoxy reactant material that may cause first material  102  to harden when second material  104  is mixed with first material  102 . In non-limiting examples, the first material  102  and second material  104  may include, or may be mixed to form a polyester-based epoxy or an acrylate epoxy. 
     As shown in  FIGS. 1A and 1B , at least one of first material  102  and second material  104  may include a plurality of zirconia particles  106 . More specifically, only first material  102  may include a plurality of zirconia particles  106  suspended within first material  102 . As shown in  FIG. 1A , the plurality of zirconia particles  106  may be distributed evenly throughout first material  102 , such that at any viscosity of first material  102 , a substantially homogenous dispersion of the plurality of zirconia particles  106  may be present within the materials. That is, the plurality of zirconia particles  106  may not be undesirably gathered at the top or bottom surface of first material  102 , dependent upon the buoyancy properties of first material  102 . Rather the plurality of zirconia particles  106  may evenly “float” throughout the material. The even distribution or dispersion of the plurality of zirconia particles  106  may be a result of the dispensate material included in first material  102 . That is, the dispensate material included in first material  102  may ensure that the plurality of zirconia particles  106  may be evenly distributed or dispersed throughout the entirety of first material  102 . 
     In an alternative embodiment, zirconia particles  106  may not be distributed evenly through at least one of first material  102  and second material  104 . In the alternative embodiment where zirconia particles  106  are not distributed evenly in first material  102  and/or second material  104 , zirconia particles  106  may be evenly distributed when combined to form ceramic-based slurry mixture  100 , as discussed herein. Additionally as discussed herein, homogenous dispersion of the plurality of zirconia particles  106  within first material  102  and/or second material  104  may aid in forming a rigid ceramic component having a substantially uniform density. 
     As shown in  FIG. 1B , when first material  102  and second material  104  are combined to form ceramic-based slurry mixture  100 , air bubbles  108  or small pockets of air may be formed in ceramic-based slurry mixture  100 . More specifically, as a result of combining and/or mixing first material  102 , including zirconia particles  106 , and second material  104 , a plurality of air bubbles  108  may be formed within and dispersed throughout ceramic-based slurry mixture  100 . As shown in  FIG. 1B , air bubbles  108  may be dispersed unevenly through ceramic-based slurry mixture  100 , and may be adjacent to and/or substantially surround zirconia particles  106  formed in ceramic-based slurry mixture  100 . 
     The air bubbles  108  may be formed within ceramic-based slurry mixture  100  as a result of air being trapped between or within first material  102  and second material  104  during the combining process to form ceramic-based slurry mixture  100 . For example, when first material  102  and second material  104  are poured into a mixing container  110  and stirred to form ceramic-based slurry mixture  100 , air bubbles  108  may be formed from air trapped in container  110  by the respective materials, or may enter into the material through the stirring action. As discussed herein, air bubbles  108  may cause undesirable defects (e.g., cosmetic, structural, etc.) in a ceramic component (discussed in more detail below with respect to  FIG. 3G ). 
     Turning to  FIG. 2 , a process of ceramic component casting may now be discussed. Specifically,  FIG. 2  is a flowchart depicting one sample method  200  for manufacturing or casting ceramic component. 
     In operation  202 , ceramic-based slurry mixture  100  may be provided to a casting system (see,  FIG. 3A ). More specifically, ceramic-based slurry mixture  100  may be poured or placed in a casting system for forming a ceramic component (one example of which is shown in  FIG. 3G ), as discussed herein. Ceramic-based slurry mixture  100  may be provided to casting system pre-mixed, or first material  102  and second material  104  (as shown in  FIGS. 1A and 1B ) forming ceramic-based slurry mixture  100  may be combined within the casting system. That is, ceramic-based slurry mixture  100  may be formed and subsequently disposed within the casting system, or ceramic-based slurry mixture  100  may be formed directly in the casting system. 
     In operation  204 , ceramic-based slurry mixture  100  may be vacuumed. More specifically, in operation  204 , ceramic-based slurry mixture  100  may be subject to a vacuum to cause a pressure differential. By subjecting ceramic-based slurry mixture  100  to a vacuum, air bubbles  108  may migrate through ceramic-based slurry mixture  100  to low pressure region, which may ultimately remove air bubbles  108  from ceramic-based slurry mixture  100 . As discussed herein, by removing air bubbles  108  prior to placing ceramic-based slurry mixture  100  into a ceramic component mold (as described in more detail below with respect to operation  208 ) of the casting system, defects (whether cosmetic or structural) of the ceramic component formed from ceramic-based slurry mixture  100  may be substantially minimized and/or eliminated. 
     In operation  206 , a vacuum or near-vacuum may be induced in the component mold of the casting system. More specifically, in operation  206 , a cavity of the component mold of the casting system may be subject to a vacuum to substantially remove air from the component mold. By initially removing air from the component mold before further operations are performed by casting system  300 , the risk of defects in ceramic component may be substantially minimized and/or eliminated, as discussed herein. 
     It is understood that operation  204  and operation  206  may be performed simultaneously within system  300 . That is, ceramic-based slurry mixture  100  may be subject to a vacuum at the same time that the component mold of the casting system is subject to a vacuum. Furthermore, it is understood that ceramic-based slurry mixture  100  may be vacuumed for a predetermined time to substantially remove air and/or air bubbles  108 , and may be subsequently plugged to prevent additional air and/or air bubbles  108  from forming within the casting system. 
     In operation  208 , ceramic-based slurry mixture  100  may be disposed into the cavity of the component mold of the casting system. The disposing or providing of ceramic-based slurry mixture  100  may include flowing ceramic-based slurry mixture  100  to the cavity from below the component mold. That is, the ceramic-based slurry mixture  100  may be provided in a manner to fill the cavity of the component mold of the casting system from the bottom of the cavity to the top of the cavity. The disposing of ceramic-based slurry mixture  100  in operation  208  may also include supplying a predetermined amount of ceramic-based slurry mixture  100  to the component mold of the casting system. That is, dependent upon the geometry of the cavity of the component mold, as discussed herein, a predetermined amount of ceramic-based slurry mixture  100  may be supplied to the component mold of the casting system. During the disposing process in operation  208 , air bubbles  108  may be formed in ceramic-based slurry mixture  100  disposed in the component mold of the casting system. That is, the disposing process in operation  208  may cause existing air bubbles  108  in the casting system or new air bubbles  108  to be formed in the predetermined amount of ceramic-based slurry mixture  100  disposed or provided to the component mold of the casting system. 
     In optional operation  210  (shown in phantom), the cavity of the component mold, including ceramic-based slurry mixture  100 , may be continuously vacuumed for a predetermined time. As similarly discussed with respect to operation  204 , in operation  210 , ceramic-based slurry mixture  100  included in the component mold of the casting system may be subject to a vacuum to cause a pressure differential. By subjecting ceramic-based slurry mixture  100  to a vacuum, air bubbles  108  may migrate through ceramic-based slurry mixture  100  to low pressure region, which may ultimately remove air bubbles  108  from ceramic-based slurry mixture  100  disposed in the component mold of the casting system. 
     In operation  212 , cavity  314  of component mold  316  may be vacuumed subsequent to the disposing of ceramic-based slurry mixture  100  in operation  208 . As similarly discussed above, in operation  212 , ceramic-based slurry mixture  100  included in the component mold of the casting system may be subject to a vacuum. In operation  212 , the subjecting of ceramic-based slurry mixture  100  to vacuum while in the mold  316  may substantially ensure that ceramic-based slurry mixture  100  is free from air bubbles  108  prior to further processing within the casting system. 
     In operation  214 , a ceramic component may be formed from ceramic-based slurry mixture  100  within the cavity of the component mold over a duration of predetermined time. More specifically, ceramic-based slurry mixture  100  including zirconia particles  106  may cure over a duration of predetermined time to form a substantially rigid, zirconia based component (e.g., ceramic component). The predetermined time for forming ceramic component  342  may be dependent, at least in part, on chemical properties of ceramic-based slurry mixture  100 . That is, the predetermined time for forming the ceramic component may be dependent upon the composition of first material  102  and second material  104  forming ceramic-based slurry mixture  100 , and the chemical reaction that may take place when combining first material  102  and second material  104  to form ceramic-based slurry mixture  100 , as discussed herein. The predetermined time may take an extended period of time because of its reliance of the reaction between first material  102  and second material  104 . For example, the predetermined time to form ceramic component  342  may include approximately thirty (30) minutes. 
     Turning to  FIGS. 3A-3G , a sample casting system  300  undergoing various operations of method  200  of  FIG. 2  may be depicted. Additionally,  FIGS. 3H and 3I  depict a sample ceramic component formed using casting system  300 . It is understood that similarly numbered components may function in a substantially similar fashion. Redundant explanation of these components has been omitted for clarity. 
     As shown in  FIG. 3A , ceramic-based slurry mixture  100  may be disposed, provided, and/or contained in a chamber  304  of a supply tank  302  of casting system  300 , to be used in casting ceramic component, as discussed herein. Ceramic-based slurry mixture  100  contained in supply tank  302 , as shown in  FIG. 3A , may correspond to operation  202  of  FIG. 2 . Ceramic-based slurry mixture  100  may be provided to supply tank  302  pre-mixed, or first material  102  and second material  104  may be combined within supply tank  302  to form ceramic-based slurry mixture  100 . That is, ceramic-based slurry mixture  100  may be formed and subsequently disposed within supply tank  302  of casting system  300 , or ceramic-based slurry mixture  100  may be formed directly in supply tank  302 . Supply tank  302  of casting system  300  may include any conventional storage component capable of storing substantially liquid material (e.g., ceramic-based slurry mixture  100 ). 
     As shown in  FIG. 3B , a supply tank vacuum  306  may be in fluid communication with chamber  304  via a tank opening  308  to subject ceramic-based slurry mixture  100  to a vacuum pressure, as referenced above with respect to operation  204  in  FIG. 2 . In an example embodiment, supply tank vacuum  306  may be positioned adjacent tank opening  308  of supply tank  302  to substantially vacuum ceramic-based slurry mixture  100  included in chamber  304  of supply tank  302 . Supply tank vacuum  306  may vacuum ceramic-based slurry mixture  100  to substantially remove air bubbles  108  that may be formed in ceramic-based slurry mixture  100 , as discussed herein. As shown in  FIG. 3B , supply tank vacuum  306  may simultaneously remove air within chamber  304  of supply tank  302  and remove air bubbles  108  formed in ceramic-based slurry mixture  100  by applying a vacuum force (F VAC ) within supply tank  302 . 
     As shown in  FIG. 3B , further operations may be performed on ceramic-based slurry mixture  100  of supply tank  302  during the vacuuming in operation  204  of  FIG. 2 . For example, supply tank  302  may be coupled to or positioned on a vibration component  310  of casting system  300 , where vibration component  310  may provide vibrations to ceramic-based slurry mixture  100  prior to the performance of additional operations of casting system  300  (e.g., disposing in operation  208 ). Vibration component  310  may provide a vibration to supply tank  302  including ceramic-based slurry mixture  100 , to aid in the removal of air bubbles  108  formed within ceramic-based slurry mixture  100 . More specifically, as shown in  FIG. 3B , vibration component  310  may provide a vibration to supply tank  302  and ceramic-based slurry mixture  100  included in supply tank  302  to move air bubbles  108  to the top surface  312  of ceramic-based slurry mixture  100 . By moving air bubbles  108  to top surface  312  of ceramic-based slurry mixture  100 , air bubbles  108  may dissipate into chamber  304  and/or be removed from ceramic-based slurry mixture  100  by the vacuum force (F VAC ) applied by supply tank vacuum  306 . The vibration component  310  may include any conventional vibration system which may provide vibrations to move air bubbles  108  of ceramic-based slurry mixture  100  to top surface  312 . For example, the provided vibration systems may include, but are not limited to: physical vibration system, ultrasonic vibration system, or rotary vibration system. 
     As shown in  FIG. 3B , mold vacuum  318  may be in fluid communication with cavity  314  of component mold  316  via a vacuum conduit  320  to vacuum air from cavity  314 . Subjecting cavity  314  of component mold  316  using mold vacuum  318  may correspond to operation  206  of  FIG. 2 . As similarly discussed with respect to supply tank  302  and supply tank vacuum  306 , mold vacuum  318  of casting system  300  may apply a vacuum force (F VAC ) to remove air from cavity  314 , prior to further operations being performed by casting system  300 . As shown in  FIG. 3B , vacuum conduit  320  may be positioned through a top portion  322  of component mold  316 , such that mold vacuum  318  may draw air included in cavity  314  of component mold  316  from vacuum conduit  320 . 
     As shown in  FIG. 3B , cavity  314  of component mold  316  may include a unique or custom geometry, that may be utilized to form a ceramic component ( FIG. 3G ). That is, cavity  314  may include an opening having a custom geometry that may shape ceramic-based slurry mixture  100  used to form ceramic component during the casting process discussed herein. Cavity  314 , as shown in  FIG. 3B , may be angularly oriented within component mold  316 . More specifically, cavity  314  may be formed or oriented within component mold  316  to include at least one angular sidewall  324  positioned adjacent vacuum conduit  320  of component mold  316 . As discussed herein, angular sidewall  324  of cavity  314  may aid in allowing air and/or air bubbles  108  to move within cavity  314  to be positioned adjacent vacuum conduit  320 , and be subsequently removed from cavity  314  via mold vacuum  318 . Additionally as shown in FIG.  3 B, cavity  314  may include a coating  326 . Coating  326  may include any conventional material having substantially hydrophobic properties. As discussed herein, coating  326  may also aid in allowing air bubbles  108  to move through ceramic-based slurry mixture  100  disposed in cavity  314  (e.g., operation  208 ), to be positioned adjacent vacuum conduit  320 , and be subsequently removed from cavity  314  via mold vacuum  318 . 
     Supply tank vacuum  306  and mold vacuum  318  may include distinct vacuum systems (not shown) or may be two distinct vacuum hoses included in a single-vacuum system (not shown). 
     As shown in  FIGS. 3C-3E , ceramic-based slurry mixture  100  included in supply tank  302  may be disposed within cavity  314  of component mold  316 , as similarly discussed with respect to operation  208  of  FIG. 2 . That is, and discussed herein, the combination of first material  102  and second material  104  forming ceramic-based slurry mixture  100 , may be provided to cavity  314  of component mold  316  via a supply conduit  328  of casting system  300 . As shown in  FIGS. 3C-3E , supply conduit  328  may fluidly couple chamber  304  of supply tank  302  including ceramic-based slurry mixture  100  and cavity  314  of component mold  316 . More specifically, as shown in  FIG. 3C-3E , component mold  316  may be elevated above supply conduit  328 , and/or supply conduit  328  may be coupled to a bottom portion  330  of component mold  316 . In coupling supply conduit  328  to bottom portion  330  of component mold  316 , cavity  314  of component mold  316  may be filled with ceramic-based slurry mixture  100  from bottom portion  330  to top portion  322 . That is,  FIGS. 3C-3E  may show a progression of ceramic-based slurry mixture  100  being disposed within cavity  314  of component mold  316  to fill cavity  314  from bottom portion  330  to top portion  322 . Ceramic-based slurry mixture  100  may be supplied from supply tank  302  to cavity  314  using any conventional fluid flow technique or device (not shown) including, but not limited to: gravity feed, fluid pump, and pressure flow. 
     As discussed with respect to operation  208  in  FIG. 2 , the predetermined amount of ceramic-based slurry mixture  100  supplied to cavity  314  may be measured and/or regulated using any conventional technique for controlling fluid flow within a system (e.g., casting system  300 ). For example, fluid control system  332  (hereafter, “control system  332 ”) may be utilized to supply the predetermined amount of ceramic-based slurry mixture  100  to cavity  314  of component mold  316 . As shown in  FIGS. 3C-3E , control system  332  may include a valve  334  in fluid communication with supply conduit  328 , and a flow sensor  336  positioned within supply conduit  328 , and in electronic communication with control system  332 . Valve  334  may be configured to substantially open and/or close supply conduit  328 , such that when valve  334  is open, ceramic-based slurry mixture  100  may flow to cavity  314 , and when valve  334  is closed, ceramic-based slurry mixture  100  may not flow to cavity  314 . Flow sensor  336  may be configured to determine flow characteristics of ceramic-based slurry mixture  100  flowing through supply conduit  328 . The flow characteristics of ceramic-based slurry mixture  100  may include, but are not limited to: flow volume of ceramic-based slurry mixture  100 , flow speed of ceramic-based slurry mixture  100 , and duration of flow time for ceramic-based slurry mixture  100 . Control system  332  may be configured to receive flow characteristics from sensor  336  and determine if the predetermined amount of ceramic-based slurry mixture  100  has been supplied to cavity  314 . When control system  332  determines that the predetermined amount of ceramic-based slurry mixture  100  is supplied to cavity  314 , as shown in  FIG. 3D , control system  332  may close valve  334  to prevent any additional ceramic-based slurry mixture  100  from entering cavity  314  of component mold  316 . As shown in  FIG. 3D , cavity  314  may be substantially supplied with the predetermined amount of ceramic-based slurry mixture  100 , and any remaining ceramic-based slurry mixture  100  within supply conduit  328  may backflow into supply tank  302 . 
     As shown in  FIGS. 3C-3E , during the disposing of ceramic-based slurry mixture  100  in operation  208  in  FIG. 2 , air bubbles  108  may be formed within ceramic-based slurry mixture  100  disposed in cavity  314 . More specifically, as ceramic-based slurry mixture  100  is disposed in cavity  314  of component mold  316 , air bubbles  108  may be included in and dispersed throughout the predetermined amount of ceramic-based slurry mixture  100  disposed in cavity  314 . Air bubbles  108  included in cavity  314  may include air bubbles  108  not substantially removed from ceramic-based slurry mixture  100  in chamber  304  of supply tank  302 , as discussed above. Additionally, air bubbles  108  may include new air bubbles  108  formed in the predetermined amount of ceramic-based slurry mixture  100  included in cavity  314 . The newly formed air bubbles  108  may be formed from air trapped in supply conduit  328 , air trapped in cavity  314  of component mold  316  and/or may be air bubbles  108  formed from ceramic-based slurry mixture  100  being disposed into cavity  314  with an undesirable flow rate (e.g., splashing in cavity  314 ). 
     Turning to  FIG. 3E , as result of the angular orientation of cavity  314  and/or coating  326  of cavity  314 , the plurality of air bubbles may be combined to form a single air bubble  340  positioned in top portion  322  of component mold  316 . More specifically, as a result of angled sidewalls  324  being angled toward vacuum conduit  320  of component mold  316  and coating  326  of cavity  314  including hydrophobic properties, the plurality of air bubbles  108  of ceramic-based slurry mixture  100  may move along angled sidewalls  324 , toward top portion  322 , and may be directed toward vacuum conduit  320  by angled sidewalls  324 . Where coating  326  includes hydrophobic properties, coating  326  of cavity  314  may repel air bubbles  108  away from coating  326 , and angled sidewalls  324  may carry air bubbles to the only portion of cavity  314  that does not include coating  326 —vacuum conduit  320 . As the plurality of air bubbles  108  are positioned adjacent vacuum conduit  320 , they may combine to form a single, large air bubble  340 , that may be adjacent to, or substantially positioned in alignment with vacuum conduit  320 . As shown in  FIG. 3E , once air bubbles  108  move toward vacuum conduit  320  of component mold  316  and form single air bubble  340 , the remainder of cavity  314 , including ceramic-based slurry mixture  100 , may be substantially free from air bubbles  108 . As such, ceramic-based slurry mixture  100  in cavity  314  may substantially prevent defects from being formed within ceramic component, as a result of the removal of all air bubbles  108  and single air bubble  340 . 
     Also shown in  FIGS. 3D and 3E , component mold  316  including ceramic-based slurry mixture  100  within cavity  314  may be substantially vibrated. That is, and as similarly discussed with respect to supply tank  302  as shown in  FIG. 3B , a vibration may be provided to ceramic-based slurry mixture  100  subsequent to the disposing of ceramic-based slurry mixture  100  into cavity  314  of component mold  316 . The vibrations provided to component mold  316  including ceramic-based slurry mixture  100  may aid in allowing the plurality of air bubbles  108  formed in cavity  314  ( FIG. 3D ), move along angled sidewalls  324  of cavity  314  and collect/form single air bubble  340  adjacent vacuum conduit  320  of component mold  316  ( FIG. 3E ). The vibrations may be provided to component mold  316  using any conventional device and/or conventional technique as discussed herein. For example, and similarly discussed with respect to  FIG. 3B , component mold  316  may be coupled to a distinct vibration component  310  (not shown) to provide vibrations to ceramic-based slurry mixture  100  include in cavity  314  of component mold  316 . 
     As shown in  FIGS. 3C-3E , mold vacuum  318  may continuously apply a vacuum force (F VAC )(shown in phantom) for removing air/air bubbles  108  formed within cavity  314  during the disposing of ceramic-based slurry mixture  100  within cavity  314  of component mold  316 . The continuous vacuuming of mold vacuum  318  may correspond to optional operation  210  of  FIG. 2 . The vacuuming of cavity  314  of component mold  316  in operation  206  may be continuous, and may continue through the disposing of ceramic-based slurry mixture  100  into cavity  314  of component mold  316 , such that a vacuuming of cavity  314  and the disposing of ceramic-based slurry mixture  100  into cavity  314  occur simultaneously. The predetermined time for continuously vacuuming cavity  314  may be dependent upon a number of factors including, but not limited to: flow volume of ceramic-based slurry mixture  100 , flow speed of ceramic-based slurry mixture  100 , and duration of flow time for the predetermined amount of ceramic-based slurry mixture  100  provided to cavity  314 . As discussed herein, the continuous vacuuming of cavity  314  including ceramic-based slurry mixture  100  may aid in the removal of undesirable air bubbles  108  that may be formed during the disposing process 
     As shown in  FIG. 3F , mold vacuum  318  may apply a final vacuum force (F VAC ) to cavity  314  including the predetermined amount of ceramic-based slurry mixture  100 , to substantially ensure that ceramic-based slurry mixture  100  is free from air bubbles  108 . Applying the final vacuum force (F VAC ) using mold vacuum  318  may correspond to operation  212  of  FIG. 2 . After the predetermined amount of ceramic-based slurry mixture  100  is disposed or flowed to cavity  314 , mold vacuum  318  may apply a vacuum force (F VAC ) to remove single air bubble  340 . This final vacuum force (F VAC ) may substantially ensure that a ceramic component ( FIG. 3G ) formed from ceramic-based slurry mixture  100  in cavity  314  may be free from defects caused by air bubbles  108 /single air bubble  340 . As shown in  FIG. 3F , single air bubble  340 , and the plurality of air bubbles ( FIG. 3D ) forming single air bubble  340 , may be removed from cavity  314  via mold vacuum  318 . As a result, ceramic-based slurry mixture  100  included in cavity  314  of component mold  316  may be ready for further processing by casting system  300  to form ceramic component ( FIG. 3G ). 
       FIG. 3G  shows ceramic-based slurry mixture  100  included in cavity  314  curing to form substantially rigid ceramic component  342 , which may correspond to operation  214  of  FIG. 2 . More specifically, ceramic-based slurry mixture  100  including zirconia particles  106  may cure over a duration of predetermined time to form a substantially rigid, zirconia based component (e.g., ceramic component  342 ). In comparing  FIGS. 3F and 3G , during the curing process zirconia particles  106  may aid in the formation of ceramic component  342 . More specifically, as shown in  FIG. 3F , and discussed herein, zirconia particles  106  may be dispersed evenly throughout ceramic-based slurry mixture  100 . As the curing process becomes complete, and ceramic component  342  of  FIG. 3G  is formed, the plurality of evenly distributed zirconia particles  106  may aid in forming rigid ceramic component  342  to include a substantially uniform density. That is, and discussed herein, where zirconia particles  106  are evenly distributed throughout ceramic-based slurry mixture  100  during the forming or curing process, ceramic component  342  may include a substantially uniform density. 
     Because of ceramic-based slurry mixture  100  composition (e.g., first material  102 , second material  104 ) and the respective chemical reaction that takes place in combining the materials to form ceramic-based slurry mixture  100 , the forming of ceramic component  342  may occur without performing additional processes on ceramic-based slurry mixture  100 . More specifically, once ceramic-based slurry mixture  100  is disposed in cavity  314  of component mold  316  and air bubbles  108 /single air bubble  340  are vacuumed from cavity  314 , ceramic-based slurry mixture  100  used to form ceramic component  342  may only require curing time. As such, the forming of ceramic component  342  may include reasonably maintaining an ambient temperature surrounding component mold  316  including ceramic-based slurry mixture  100 , and reasonably maintaining a minimal compression force on ceramic-based slurry mixture  100  included in component mold  316 . That is, ceramic-based slurry mixture  100  does not require any heating or cooling to form ceramic component  342  during the forming process, nor does ceramic-based slurry mixture  100  require a large compression force after being disposed in cavity  314  to form ceramic component  342 . The minimal compression force on ceramic-based slurry mixture  100  may include a compression force that may hold a two-part component mold  316  together. Where component mold  316  includes a single, integral component, the minimal compression force on ceramic-based slurry mixture  100  may include atmospheric pressure. 
     It is understood that mold vacuum  318  may continuously vacuum cavity  314  during the forming of ceramic component  342  in operation  214 . That is, cavity  314  may be continuously vacuumed during the forming process to substantially prevent air bubbles  108  from being undesirably included in ceramic-based slurry mixture  100  and/or ceramic component  342 . Additionally, the continuous vacuuming during the forming process may substantially prevent or eliminate the risk of air becoming trapped in cavity  314  and negatively affecting ceramic component  342  by creating a cosmetic defect (e.g., bump or divot) and/or creating a variable density in ceramic component  342 , as discussed above. 
     Once formed, ceramic component  342  may be removed from component mold  316  and may be further processed if necessary. As shown in  FIG. 3H , substantially rigid ceramic component  342  formed from casting system  300  may be shown, subsequent to the removal from component mold  316 . Ceramic component  342  may be removed from component mold  316  and may be immediately implemented into a component, device or system that may utilize ceramic component  342 . Alternatively, and as shown in  FIGS. 3H and 3I , ceramic component  342  may require further machining. More specifically, as shown in  FIG. 3H , ceramic component  342  may include protrusions  346 ,  348 . Protrusion  346  may be formed from a portion of ceramic-based slurry mixture  100  that may be positioned within vacuum conduit  320  of component mold  316  during the forming process. Protrusion  348  may be formed from a portion of ceramic-based slurry mixture  100  that may be positioned in component mold  316  between cavity  314  and supply conduit  328  during the forming process. Where it is desired for ceramic component  342  to be substantially rectangular, these undesirable protrusions  346 ,  348  may be removed from ceramic component  342 . More specifically, a material removal process may be performed on ceramic component  342  to remove protrusions  346 ,  348 , and make ceramic component  342  into a desirable/required geometry, as shown in  FIG. 3I . The material removal process used on ceramic component  342  may include any conventional material removal process including, but not limited to: grinding, milling, turning, and cutting. 
     By utilizing ceramic-based slurry mixture  100 , which may cure itself based on the chemical reaction between first material  102  and second material  104 , ceramic component  342  may be formed without the manufacturing stresses (e.g., rapid heating-cooling, high compression force) typically associated with conventional ceramic casting. These stresses associated with conventional manufacturing processes typically attribute to the formation of defects in conventional ceramic components. By eliminating the use of rapid heating and cooling, and/or the use of high compression forces in forming ceramic component  342 , the risk in defects formed in ceramic component  342  may be substantially reduced and/or eliminated. 
     Additionally, by utilizing ceramic-based slurry mixture  100  to form ceramic component  342 , and eliminating the rapid heating-cooling and/or high compression force in the formation process, component mold  316  may be manufactured from less expensive and more easily manufactured material. That is, with respect to process of forming ceramic component  342  discussed above, component mold  316  may not undergo rapid temperature changes and/or high compression forces. As such, component mold  316  may not require materials that are resistant to rapid temperature changes and/or high compression forces, which typically includes very expensive and difficult material to machine. Rather, component mold  316  may be manufactured from easier machined material that is more cost effective. Additionally, because component mold  316  may be manufactured from material that is more easily machined and/or more cost effective, and because no heating-cooling and/or compression force is required, a plurality of component molds  316  may be manufactured. As a result, a large number of ceramic components  342  may be formed or manufactured simultaneously. 
     Furthermore, although only a basic, rectangular geometry is discussed above, it is understood that cavity  314  of component mold  316  may include more intricate geometric configurations for forming ceramic component  342 . More specifically, because component mold  316  may be formed from more easily machined material, as discussed above, cavity  314  used to form ceramic component  342  may be more intricate, and may include very specific geometries for ceramic component  342 . As such, ceramic component  342  may include exact or substantially precise, intricate geometries when removed from component mold  316 , and may require minimal or no additional machining prior to being implemented within a component, device or system. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not target to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20140204
Publication Date: 20190625
Grant Date: 20190625
Priority Date: 20140204
Inventors: WEBER, DOUGLAS
MATSUYUKI, NAOTO
Assignee: APPLE INC
CPC Classifications: [{"code": "B28B17/026", "inventive": true, "first": true, "tree": "[]"}, {"code": "B28B13/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "C04B2235/6027", "inventive": false, "first": false, "tree": "[]"}, {"code": "B28B13/0275", "inventive": true, "first": false, "tree": "[]"}, {"code": "B28B7/44", "inventive": true, "first": false, "tree": "[]"}, {"code": "C04B35/486", "inventive": true, "first": false, "tree": "[]"}, {"code": "B28B1/24", "inventive": true, "first": false, "tree": "[]"}, {"code": "B28B7/36", "inventive": true, "first": false, "tree": "[]"}, {"code": "B28B1/082", "inventive": true, "first": false, "tree": "[]"}, {"code": "B28B1/082", "inventive": true, "first": true, "tree": "[]"}, {"code": "C04B2235/6027", "inventive": false, "first": false, "tree": "[]"}, {"code": "B28B13/0275", "inventive": true, "first": false, "tree": "[]"}, {"code": "B28B1/24", "inventive": true, "first": false, "tree": "[]"}, {"code": "B28B1/082", "inventive": true, "first": false, "tree": "[]"}, {"code": "C04B35/486", "inventive": true, "first": false, "tree": "[]"}, {"code": "C04B2235/6027", "inventive": false, "first": false, "tree": "[]"}, {"code": "C04B35/486", "inventive": true, "first": false, "tree": "[]"}, {"code": "B28B13/0275", "inventive": true, "first": false, "tree": "[]"}, {"code": "B28B1/24", "inventive": true, "first": false, "tree": "[]"}, {"code": "B28B7/44", "inventive": true, "first": false, "tree": "[]"}, {"code": "B28B17/026", "inventive": true, "first": true, "tree": "[]"}, {"code": "B28B7/36", "inventive": true, "first": false, "tree": "[]"}, {"code": "B28B13/02", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 52469358