In the ceramic manufacturing industry, achieving a high firing yield is a constant pursuit. Composite corundum mullite trays have emerged as a crucial solution in this regard. These trays play a vital role in controlling the high - temperature deformation of ceramic products during the firing process, ultimately improving the overall firing yield.
The design of composite corundum mullite trays involves two main aspects: structural optimization and heat conduction matching. Geometric shape optimization is a key factor. For example, the distribution of grooves on the tray can significantly affect the heat flow around the ceramic products. A well - designed groove pattern can ensure more uniform heat distribution. Tests have shown that trays with optimized groove distributions can reduce the temperature difference across the ceramic surface by up to 15% during firing, which greatly reduces the risk of deformation.
The thickness gradient of the tray also matters. By adjusting the thickness at different parts of the tray, we can better control the heat transfer rate. A proper thickness gradient can make the ceramic products heat up more evenly, reducing the internal stress caused by uneven heating. In some production cases, after optimizing the thickness gradient, the deformation rate of ceramic products decreased from 8% to 3%.
The installation method of the trays is another important consideration. The stacking spacing between trays affects the air circulation and heat transfer in the kiln. If the spacing is too small, the heat transfer will be blocked, leading to uneven heating. On the other hand, if the spacing is too large, the energy efficiency will be reduced. Generally, a stacking spacing of 3 - 5 cm is recommended for most ceramic firing processes.
The design of positioning holes on the trays can ensure accurate placement on the kiln car. This helps to maintain a consistent relative position between the trays and the kiln car, which is beneficial for stable heat transfer. In a real - world production scenario, after improving the positioning hole design, the alignment accuracy of the trays increased from 90% to 98%, resulting in more stable firing results.
To achieve the best firing results, the trays need to be well - matched with the heat conduction characteristics of the kiln car. Different kiln cars have different heat transfer rates and heat storage capacities. By adjusting the material properties and design parameters of the trays, we can make them work in harmony with the kiln car. For example, in a kiln with a relatively high heat transfer rate, trays with lower heat capacity can be used to avoid over - heating of the ceramic products.
Let's take a look at a real - world case. A ceramic production company was facing a high deformation rate of about 12% in their firing process. After analyzing the problem, they optimized the design of their composite corundum mullite trays. They adjusted the groove distribution, thickness gradient, and installation method. As a result, the deformation rate dropped to 4% within a month, and the firing yield increased from 85% to 93%. This case clearly demonstrates the effectiveness of tray design optimization.
一线技术人员的现场检测和调试对于确保托盘的正常运行和提高烧成成品率至关重要。现场检测方法包括温度测量、变形检测等。通过定期测量陶瓷产品和托盘的温度，可以及时发现温度异常情况，并采取相应的措施进行调整。变形检测可以使用专业的测量工具，如卡尺、千分尺等，及时发现陶瓷产品的微小变形，并分析原因进行改进。
调试经验方面，技术人员需要根据不同的生产情况和检测结果，灵活调整托盘的安装方式、窑炉的温度曲线等。例如，如果发现某个区域的陶瓷产品变形较大，可以适当增加该区域托盘的通风量，或者调整该区域的温度设置。
If you are looking to improve your ceramic firing yield and reduce the deformation rate of your products, our composite corundum mullite trays are the ideal solution. With advanced design and proven performance, they can help your business achieve better results. Click here to learn more about our high - quality composite corundum mullite trays and take your ceramic production to the next level!
