Device for Magnetic Freeze Casting of Ceramics and Method for Operating the Same

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This invention describes a device and method for freeze casting ceramic samples in a magnetic field. The core innovation is the use of a rotatable Halbach magnet array (a special arrangement of permanent magnets) to generate a highly homogeneous and adjustable magnetic field around the sample during the freeze casting process. This allows for precise control of the alignment of ceramic (and magnetizable) particles within the material, enabling the creation of porous ceramics with tailored microstructural properties and enhanced mechanical stability, especially in three spatial dimensions.

Use CasesContent extracted from patent full text and abstract with AI.

• Production of porous ceramic supports for gas separation membranes.
• Manufacture of mechanically stable substrates for solid oxide fuel cells or electrolyzers.
• Fabrication of advanced materials for filtration systems.
• Creation of high-performance porous ceramics for catalysis or chemical processing.
• Research and prototyping of novel ceramic-based devices with engineered porosity.
• Development of ceramic parts with improved gas transport and mechanical properties.

BenefitsContent extracted from patent full text and abstract with AI.

• Allows precise control and tailoring of the internal microstructure and porosity orientation of ceramics.
• Enables production of ceramics with both high porosity and improved mechanical stability in multiple directions.
• Improves gas diffusion capabilities of ceramic supports without compromising structural strength.
• Provides a highly homogeneous magnetic field for better particle alignment, even for larger samples.
• Offers flexibility via rotational and tilting mechanisms to optimize particle orientation for application-specific requirements.
• Reduces the need for extremely strong magnetic fields, lowering equipment costs and complexity.
• Compatible with a wide range of ceramic materials and various binder/solvent systems, including environmentally friendly water-based suspensions.

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Patent Abstract

The invention relates to a device for freeze casting a ceramic sample in a magnetic field, comprising a cooling means, a sample holder device connected to the cooling means, and a rotatably arranged permanent magnet, wherein according to the invention the permanent magnet is in the form of at least one annularly arranged Halbach magnet array and the Halbach magnet array is rotatably arranged in a plane (x–y) around the sample holder device. An advantageous embodiment of the invention provides for arranging two identical Halbach magnet arrays coupled in the z-direction, whereby a particularly homogeneous magnetic field in the z-direction is generated. A particular embodiment of the invention provides a means for tilting the Halbach magnet array out of the x–y-plane along the z-axis up to an angle of max. ±30°. This makes it possible in particular to set a homogeneous magnetic field in a third dimension (3-dimensional freeze casting) and thus to effect a targeted alignment of the particles during the production of the ceramic, also in accordance with the tilt angle.