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Seneca Ceramics
Technology that Makes the Impossible Possible
Applications

Seneca Ceramics’ technology and expertise offers extraordinary opportunities—opportunities for ground-shifting applications across the ceramics industry and beyond.

The solutions we deliver to most of our existing partners are built from the ground up. Our partners came to us with a problem to be solved, and leveraging our beyond-the-leading-edge technology, we developed a specific solution to their problem.

Having leveraged our technology, most of Seneca Ceramics’ current partners enjoy commanding technological advantages in their respective markets—a position of substantial value that they go to greath lengths to safeguard. Due to agreements with these partners, this website studiously avoids discussion of most of what Seneca Ceramics actually does on a daily basis—we avoid discussing what we believe are extraordinary technological achievements. 

Recognizing limits on what we are free to discuss, in this space we look to highlight new and extraordinary applications of our technology that we can talk about.

The following discussion of applications focuses on a handful of new and groundbreaking solutions that apply to broad industries—emergent solutions that we believe will be ground-shifting for the industries involved. These solutions have to potential to fundamentally change the state-of-the-art in the affected industries—allowing them to achieve better and lower-total-cost processes for doing the things they do.

Highligted Applications

  • Ceramic Hooks (Velcro-like material)
  • Ceramic Molds (for pressing and jiggering)
  • Ceramic Bolts
  • Diffusers
  • Investment Casting Cores/Sacrificial Inserts
 

Ceramic Hooks (a Velcro-like attachment system)

Seneca Ceramics has developed (and is in the process of patenting) a hook system to vastly simplify attaching and removing ceramic fiber insulation from virtually any surface.

The technology works exactly as it sounds. Seneca Ceramics has developed and patented ceramic plates populated with a field of ceramic hooks—plates that can be easily attached to virtually any frame or surface, and which hold ceramic fiber modules in place.

These plates will be easily replaceable if damaged, and they can be manufactured with a wide range of holding strengths and characteristics, to fit a range of needs. In the end, they will make it far easier to attach, maintain, and replace ceramic fiber insulation in a wide range of current uses.

For ceramic fiber users, availability of a clearly-superior attachment technology will simplify their lives; help them achieve greater energy efficiency; and ultimately, save them time and money. For ceramic fiber manufacturers, the company that is able to bring the clearly-superior solution to market will benefit from a vastly-strengthened position in the industry, with an opportunity to capture a large portion of the market for product-attachment solutions.

Seneca Ceramics is currently reaching out to and negotiating with players in the ceramic fiber industry to identify a strategic partner in the market. These conversations may result in developing an exclusive-supplier relationship, exclusive licensing of the technology, or outright sale of the patent rights.

Ceramic Molds

Seneca Ceramics has developed technology that allows us to produce high-durability ceramic molds for pressing and jiggering—industries that today rely almost exclusively on plaster molds that exhibit significant shortcomings. Our ceramic molds allow:

·      Extreme Increases in Durability: Plaster molds have an average life of less than 500 cycles for a standard clay body. Our ceramic molds have demonstrated lifespans in excess of 7,000 cycles.

·      High Resolution: Molds can be created with high resolution and, due to the inherent strength of the ceramic medium, allow deep surface relief (with the capacity for narrow cross-sections) in the formed body.

·      Increased Cycle Speeds: Our ceramic molds have demonstrated release times of less than one second on non-symmetrical bodies, with almost no dwell time under pressure and no tearing or sticking at the mold surface.   

The mullite pour cup shown in the picture below was formed with a ceramic mold. When looking at the picture, note in particular the zero draft angle on one side of the cup; the sharp edges of the external transitions; and the flatness of the pressed exterior, which was maintained even after firing.


In producing these pour cups, we achieved near-instantaneous release (less than one-half second) after pressing.

Taken together, the benefits of our ceramic molds translate into substantially-reduced production costs compared to plaster molds, while at the same time allowing higher-quality outcomes. Our ceramic molds allow more than a ten-fold increase in the number of cycles per mold; vastly reduced time lost to mold changeovers; and vast increases in cycle speeds (with virtually zero dwell time under pressure).

Note, too, that the benefits of ceramic molds extend beyond pressing and jiggering. Because we are able to tailor the porosity of the molds to specific needs, we can create molds that would allow pressure ejection of film-molded products (like a latex glove), and our molds would allow creation of extremely fine surface features.

See our demonstration of this technology in action.

Ceramic Bolts

Seneca Ceramics' beyond-the-leading-edge forming technologies and our ability to manage and tailor body chemistry and body structure allows us to produce hardware like nuts and bolts—hardware with a game-changing combination of high-quality and low cost.

While bolts made from materials like aluminum oxide are not new, technological limits to their production have resulted in (1) limits to their size and (2) onerous trade-offs between quality and cost. Up to now, even if ceramic bolts were available in the sizes you might want, a high-quality bolt was prohibitively expensive for everything but the most specialized use.

Seneca Ceramics' technological advances have wiped away these limitations. We have the capacity to produce hardware of virtually any size, with the highest quality, at only a fraction of historical costs.

Diffusers

Seneca Ceramics’ ability to tailor body structure, porosity and surface chemistry is unparalleled, and this capability allows us to produce diffusers that out-perform any in the industry.

Among other things, diffusers are used for:

·         Aeration of wastewater or aquaculture systems;

·         Oxygenation or ozonation of fluids for purification; and

·        Production of precisely-engineered bubble streams to support mixing processes.

Ceramic diffusers are highly desirable due to their durability and corrosion-resistance. And the very best ceramic diffusers exhibit two characteristics:

1.       They have the ability to create specific and uniform bubble sizes (a bubble size that optimizes the process of introducing air, or oxygen, or ozone into the liquid); and

2.       They achieve this outcome with a relatively low pressure gradient.

The best diffusers in the world—the diffusers that Seneca Ceramics makes—produce a uniform, milky cloud of bubbles, and they do so while consuming relatively little energy to generate a pressure gradient. As we noted at the top, the reason Seneca Ceramics can do this is because we possess unparalleled expertise in tailoring and managing body structure, pore sizes, and surface chemistry. 

Seneca Ceramics diffusers are in use today in various applications in the US and Northern Europe, but the vast majority of users across the world are currently using diffusers that offer an unfortunate combination of higher-cost and lower-quality—a circumstance we would very much like to remedy.

Investment Casting Cores/Sacrificial Inserts

The process of investment casting and powder metals pressing often rely on sacrificial inserts (or cores) to create internal features in the final part. The part is cast or pressed around the sacrificial core, and then the core is removed through a process of chemical leaching.

As is true for many of the above applications, Seneca Ceramics combination of unique forming technology and expertise in managing body structure, body and surface chemistry, and porosity allow us to produce investment casting cores that represent a quantum leap in the industry, with a combination of advantages:

  • Wide range of core sizes;
  • Extraordinary high dimensional tolerances;
  • High-resolution surfaces;
  • High dimensional stability at casting temperatures;
  • Inertness to molten alloys;
  • Core-leaching speeds optimized through management of body structure.
Moreover, because of our extraordinary technology, we can deliver these outcomes at lower unit cost while simultaneously enabling vastly-reduced core failure rates.
 


If you would like to talk about applications discussed above, or if you need a solution to an entirely different problem, give us a call.

Phone: (315) 781-0100
Email: customerservice@senecaceramics.com
Technical Contact: Chad Sheckler

 

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