3D Printing Resin Composition for Shape-Retaining Carbonization
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Solution Overview
Problem
Conventional three-dimensional printers produce resin-based molded bodies that cannot be effectively carbonized into carbon molded bodies, lacking the necessary properties for maintaining shape and moldability.
Innovation Solution
A resin composition comprising a first thermoplastic resin with a residual carbon ratio below 50%, a second thermoplastic resin with a residual carbon ratio of 50% or higher, and a carbonaceous filler dispersed in these resins, with specific thermal and melt properties, enabling moldability and shape retention after carbonization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional resin compositions are used for three-dimensional printing, then the molded body can be produced, but the molded body cannot be effectively carbonized into carbon molded bodies
Solution Approach 1:
The invention uses a composite resin composition containing multiple thermoplastic resins with different residual carbon ratios and carbonaceous fillers. This composite approach allows the material to simultaneously achieve good moldability during 3D printing and effective carbonization into carbon molded bodies, resolving the contradiction between these two requirements.
Solution Approach 2:
The invention carefully controls the residual carbon ratio parameter of the thermoplastic resins used, combining resins with residual carbon ratios of 5-40% and 40-70% to achieve the desired balance between moldability and carbonization performance.
2Reliability
If resin compositions with high residual carbon ratio are used, then carbonization performance improves, but moldability during three-dimensional printing deteriorates
Solution Approach 1:
The invention segments the thermoplastic resin component into multiple types with different residual carbon ratios (first resin: 5-40%, second resin: 40-70%). This segmentation allows each resin type to contribute different properties, achieving both good moldability and carbonization performance simultaneously.
Solution Approach 2:
The invention optimizes the residual carbon ratio parameter by using a combination of resins with different values, rather than using a single resin type. This parameter optimization enables the material to maintain moldability while achieving effective carbonization.
3Ease of manufacture
If resin compositions with low residual carbon ratio are used, then moldability improves, but carbonization performance deteriorates
Solution Approach 1:
The invention divides the resin system into segments with different residual carbon characteristics. The first thermoplastic resin (5-40% residual carbon) provides good moldability, while the second thermoplastic resin (40-70% residual carbon) ensures good carbonization performance, achieving both requirements through segmentation.
Solution Approach 2:
By creating a composite material system combining multiple thermoplastic resins with different residual carbon ratios and carbonaceous fillers, the invention achieves both excellent moldability and carbonization performance that cannot be obtained with a single resin type.
4Reliability
If carbonaceous filler is added to improve carbonization, then carbon molded body production improves, but processing difficulty increases
Solution Approach 1:
The invention optimizes the content parameter of carbonaceous filler within a specific range (5-40 parts by mass per 100 parts of thermoplastic resin). This parameter optimization ensures sufficient carbonization performance while maintaining good processability and avoiding excessive processing complexity.
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
The resin composition allows for the production of carbon molded bodies with maintained shape and improved moldability through three-dimensional printer molding and carbonization, utilizing a combination of thermoplastic resins and carbonaceous fillers.
Implementation Method 1
a molded body obtained therefrom can yield a carbon molded body through carbonization
Implementation Method 2
a first thermoplastic resin having a residual carbon ratio of lower than 50%; a second thermoplastic resin having a residual carbon ratio of 50% or higher
Implementation Method 3
a carbonaceous filler dispersed in these thermoplastic resins
Implementation Method 4
a first thermoplastic resin having a melting point higher than that of the second thermoplastic resin
Implementation Method 5
cooling and solidifying the resin while gradually depositing the resin in layers
Data Source
AI summary
A resin composition may be used for producing a carbon molded body by three-dimensional printer molding and carbonization. Such a resin may include a first thermoplastic resin having a residual carbon rate of less than 50%, a second thermoplastic resin having a residual carbon rate of 50% or more, and a carbonaceous filler dispersed through the thermoplastic resins.