3D Model Binder Composition for Fast Evaporation and High Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing 3D printing methods using powdered materials and liquid binders face issues such as slow solvent evaporation leading to weak components, adhesions, shrinkage, and risks to the print head due to aggressive solvents or monomers, which result in geometric deviations and operational hazards.
Innovation Solution
A binder system comprising a novolak or resol system with a solvent, where the solvent is alcohol-based and contains additives like surfactants and defoamers, is used, and selective heating is applied to the particle material to control the solidification process, avoiding aggressive solvents and ensuring complete evaporation before unpacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solvent-based binding system is used, then the particles can be dissolved and re-solidified to form bonds, but the solvent evaporation is slow leading to weak components and long waiting times
Solution Approach 1:
The patent changes the physical-chemical parameters of the binding system by replacing solvent-based systems with water-based systems. This parameter change accelerates the evaporation rate significantly, reducing waiting time from hours to minutes, while maintaining or improving component strength through optimized water-based binder formulations and controlled drying conditions.
Solution Approach 2:
The patent utilizes phase transition principles by controlling the evaporation of water from the binder system. The controlled phase transition from liquid to vapor is managed through temperature and humidity control, allowing rapid moisture removal without causing shrinkage or geometric deviations, thus strengthening components quickly.
2Reliability
If aggressive solvents or monomers are used to achieve complete solidification, then binding effectiveness is improved, but the print head is at risk of damage
Solution Approach 1:
The patent converts the previously harmful aggressive solvents into harmless water-based systems. By replacing aggressive chemical binders with water-based binders, the system eliminates the risk of print head damage while maintaining binding effectiveness through optimized water-soluble binder formulations and controlled evaporation processes.
Solution Approach 2:
The patent introduces water as an intermediary substance that mediates between the binder components and the print head. Water serves as a safe carrier that delivers binding agents without corroding or damaging the print head, eliminating the need for aggressive solvents while ensuring complete solidification through controlled water evaporation.
3Productivity
If the platform is lowered continuously for layer construction, then productivity is improved, but complete solvent evaporation cannot be achieved between layers
Solution Approach 1:
The patent changes the evaporation kinetics parameter by using water-based binders with optimized volatility. The modified binder system allows complete evaporation within the reduced time between platform lowering operations, enabling continuous construction without compromising geometric accuracy. This is achieved through controlled humidity and temperature in the construction environment.
4Strength
If dissolving and resolidification process is used, then particle binding is achieved, but shrinkage occurs causing geometric deviations
Solution Approach 1:
The patent changes the chemical composition parameter by replacing organic solvents with water as the binding medium. This parameter change eliminates shrinkage-induced geometric deviations because water-based binders evaporate without causing the volumetric contraction that occurs with organic solvent systems. The binding strength is maintained through optimized water-soluble polymer formulations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach achieves high unpacking and final strengths with minimal adhesions, reduces the risk of print head damage, and allows for continuous machine operation, while also minimizing material and environmental hazards.
Implementation Method 1
the solvent is alcohol-based and contains additives like surfactants and defoamers, is used, and selective heating is applied to the particle material to control the solidification process, avoiding aggressive solvents and ensuring complete evaporation before unpacking
Implementation Method 2
selective heating is applied to the particle material to control the solidification process
Data Source
Figure 1
Figure 2(a)~2(d)
Figure 3
AI summary
The invention relates to a method, a device and a binding agent system for producing three-dimensional models.