3D-Printed Carbon Graphite Articles with UV-Cured Preforms
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Solution Overview
Problem
Existing methods for producing carbon or graphite shaped articles are time-consuming and prone to damage during mold removal, limiting the production of complex, three-dimensional components.
Innovation Solution
A process involving a flowable polymeric mixture of UV permeable and polymerizable polymers, such as polyacrylonitrile, is used to create shaped articles through 3D printing, followed by UV crosslinking, stabilization, and high-temperature treatment to achieve carbonization or graphitization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional isostatic pressing and mold removal is used, then production time is reduced for simple shapes, but the blank is easily damaged and complex three-dimensional components cannot be produced
Solution Approach 1:
The patent replaces the mechanical isostatic pressing system with a 3D printing system that deposits carbonaceous material layer by layer according to digital models. This eliminates the mold removal problem entirely while enabling production of complex three-dimensional shapes with apertures and intricate geometries that cannot be achieved through traditional pressing methods
Solution Approach 2:
The patent changes the physical state and deposition parameters of the carbonaceous material by using it in a bindable form that can be deposited in thin layers and subsequently cured. This allows the material to be built up additively layer by layer, enabling complex geometries without the constraints of traditional mold-based forming
2Reliability
If traditional carbonization process is used, then binder decomposition is achieved, but the process is time-consuming and requires high temperatures
Solution Approach 1:
The patent applies preliminary action by curing the binder through UV irradiation or other activation methods immediately after material deposition, before the carbonization step. This pre-solidifies the structure, allowing subsequent handling and processing without requiring extended high-temperature treatment, thereby reducing overall process time while ensuring complete binder decomposition
Solution Approach 2:
The patent utilizes phase transitions by employing a binder that can be activated or cured through UV irradiation or thermal treatment to transition from a soft, workable state to a hardened, stable state. This allows the material to maintain structural integrity during processing while enabling faster cycle times compared to traditional prolonged carbonization
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
Enables the production of complex, three-dimensional carbon or graphite articles with enhanced stability, eliminating the need for mechanical aftertreatment and reducing production time.
Implementation Method 1
layerwise printing a shaped article with the 3D printer with simultaneous exposure to UV radiation for layerwise crosslinking of the UV crosslinkable resin
Implementation Method 2
introducing the shaped article into a furnace and stabilizing the UV precured shaped article in air at a predetermined stabilizing temperature until all volatile constituents have outgassed
Implementation Method 3
subsequently high temperature treating the shaped article for carbonization or graphitization in a furnace under protective gas
Data Source
AI summary
A process for 3D printing articles made of carbon or graphite includes producing a flowable polymeric mixture from a UV permeable and polymerizable polymer or cellulose and a UV crosslinkable resin, admixing the polymeric mixture with sugar and/or cellulose until the mixture has a consistency such that it can be filled into a 3D printer and processed thereby, homogenizing the mixture at room temperature or elevated temperature, filling a 3D printer with the mixture, layerwise printing a shaped article with simultaneous exposure to UV radiation for layerwise crosslinking of the UV crosslinkable resin, cleaning the shaped article, introducing the UV precured shaped article into a furnace and stabilizing the UV precured shaped article in air at a predetermined stabilizing temperature until all volatile constituents have outgassed from the prefabricated shaped article and subsequently high temperature treating the shaped article for carbonization or graphitization in a furnace under protective gas.