Abstract: Tray assemblies and methods for manufacturing ceramic articles are provided. In one embodiment, a tray assembly includes a tray body having a supporting surface operable to support a ceramic article for passage through a microwave drying apparatus during a microwave drying process and a microwave coupling cover associated with the tray body. The microwave coupling cover envelopes at least a portion of the ceramic article during the microwave drying process. The microwave coupling cover has a dielectric property such that a greater percentage of microwave energy is coupled into the ceramic article with the microwave coupling cover present during the microwave drying process than with the microwave coupling cover not present. Methods may include rotating the ceramic article when the ceramic article is about 40%-60 dry.

Abstract: Electromagnetic (EM) drying of a plugged ware is provided that includes subjecting the ware to an axially non-uniform EM radiation field that causes more EM radiation to be dissipated in either of the plugged regions than in the unplugged region. The EM radiation field is provided by a configurable applicator system that includes a feed waveguide and a conveyor path. The feed waveguide includes configurable slots. The configurable applicator system can be set to selectively vary the amount of EM radiation dissipated by each ware along the longitudinal axis of each ware as a function of ware position along the conveying path, thereby enhancing the EM drying process.

Abstract: Methods for drying ceramic greenware in a manner that substantially compensates for otherwise non-uniform drying are disclosed. The methods generally include partially drying a piece (22) of greenware such that its end portions (22E) are drier than its middle portion (22C). The method also includes further drying the piece with radio-frequency (RF) radiation (88) generated by an electrode system (130) by conveying the piece through the electrode system. The electrode system has a main planar electrode (131E) with a longitudinal axis (AE), and an electrode concentrator (131C) formed thereon or attached thereto. The electrode concentrator has a central section (140) that runs in the direction of the longitudinal axis of the electrode and is configured so that when the piece is conveyed through the electrode system, the electrode system concentrates more RF radiation at the center portion of the piece than at the end portions of the piece.

Abstract: A method and system for drying a honeycomb structure having an original liquid vehicle content includes exposing the honeycomb structure to a first electromagnetic radiation source until the liquid vehicle content is between about 20% and about 60% of the original liquid vehicle content, exposing the honeycomb structure to a second electromagnetic radiation source different from the first electromagnetic radiation source until the liquid vehicle content is between about 0% and about 30% of the original liquid vehicle content, and exposing the honeycomb structure to convection heating until the liquid vehicle content is between about 0% and about 30% of the original liquid vehicle content.

Abstract: Systems and methods for controlling drying of ceramic greenwares in a manner that accounts for the load presented to a radio-frequency (RF) source of an RF applicator to reduce the risk of overheating greenware during drying. The method includes partially drying the greenware and then substantially drying the greenware with RF radiation. The amount of RF radiation provided to an electrode region is controlled based on the number of greenware pieces within the electrode region at a given time. The system includes a control unit electrically connected to the electrode and configured to provide a select RF voltage to the electrode based on the number of greenwares within the electrode region. The system adjusts at least one input voltage from a power supply. The adjusted voltage is stepped-up, DC-rectified to form a plate voltage, and then is converted by a high-frequency DC/AC convertor to the select high-frequency AC RF voltage needed to dry the greenwares without overheating.

Abstract: A method for drying a ceramic article comprises providing microwave radiation from a microwave generating source, providing a ceramic honeycomb structure having a middle portion and at least one end, and exposing the ceramic honeycomb structure to the microwave radiation while shielding the at least one end from directly receiving the microwave radiation, such that the radiation absorbed by the middle portion is equal to or greater than the radiation absorbed by the at least one end, and the proper drying of the entire honeycomb structure without heat-induced structural degradation is thus ensured.

Abstract: Electromagnetic (EM) drying of a plugged ware is provided that includes subjecting the ware to an axially non-uniform EM radiation field that causes more EM radiation to be dissipated in either of the plugged regions than in the unplugged region. The EM radiation field is provided by a configurable applicator system that includes a feed waveguide and a conveyor path. The feed waveguide includes configurable slots. The configurable applicator system can be set to selectively vary the amount of EM radiation dissipated by each ware along the longitudinal axis of each ware as a function of ware position along the conveying path, thereby enhancing the EM drying process.

Abstract: A method for drying a ceramic article comprises providing microwave radiation from a microwave generating source, providing a ceramic honeycomb structure having a middle portion and at least one end, and exposing the ceramic honeycomb structure to the microwave radiation while shielding the at least one end from directly receiving the microwave radiation, such that the radiation absorbed by the middle portion is equal to or greater than the radiation absorbed by the at least one end, and the proper drying of the entire honeycomb structure without heat-induced structural degradation is thus ensured.