3D Structure Binding Resin Prevents Solvent Deformation
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Solution Overview
Problem
Existing methods for forming three-dimensional structures using powder binding technologies suffer from inadequate dimensional accuracy due to the melting of water-soluble polymer binding agents by water-based solvents, leading to shape deformation and reduced precision.
Innovation Solution
A three-dimensional formation composition comprising particles, a binding resin with an ammonium salt of a carboxyl group, and a water-based solvent, where the binding resin undergoes a chemical change from a hydrophilic to a hydrophobic state upon heating, preventing deformation and enhancing dimensional accuracy, durability, and water resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a water-soluble polymer binding agent is used to bind powder particles, then the particles can be bound together to form a three-dimensional structure, but the water-soluble polymer is melted by water-based solvent and the shape of the lower layer is changed, resulting in poor dimensional accuracy
Solution Approach 1:
The patent changes the chemical parameters of the binding resin by selecting specific types (polyvinyl alcohol, carboxymethyl cellulose, starch, or gelatin) that can withstand water-based solvents without melting. These resins are chosen for their chemical stability in aqueous environments, allowing them to maintain binding strength while preventing shape deformation when upper layers are formed.
Solution Approach 2:
The patent creates a composite material system consisting of powder particles bound with water-resistant binding resin. This composite structure maintains the binding function while adding resistance to water-based solvents, thereby preventing the lower layer from deforming when subsequent layers are applied with water-based slurries.
2Ease of manufacture
If a binding solution is discharged onto the powder layer to bind particles, then a thin plate-like member is formed, but the binding solution penetrates the layer and reaches the previously-formed section member, causing the newly-formed section member to attach to the previously-formed section member
Solution Approach 1:
The patent modifies the viscosity and composition parameters of the binding solution to control its penetration behavior. By adjusting these parameters, the binding solution remains localized on the current layer being formed and does not penetrate through to previously formed layers, thereby preventing unintended attachment between sections.
3Adaptability or versatility
If layers are laminated one by one to form a three-dimensional object, then complex objects with complicated internal structures can be formed as integrally-formed structures, but the water-based solvent in the forming slurry melts the water-soluble polymer and changes the shape of the lower layer
Solution Approach 1:
The patent changes the chemical composition parameters of the binding resin to use water-resistant materials. This allows the multi-layer lamination process to proceed without the lower layers deforming when water-based solvents are introduced in subsequent layers, thereby maintaining dimensional accuracy while forming complex three-dimensional structures.
Solution Approach 2:
The patent applies preliminary protection to the lower layers by using water-resistant binding resins before the water-based solvent from upper layers is applied. This preliminary protective measure ensures that the lower layers maintain their shape and position throughout the multi-layer formation process.
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 method achieves high dimensional accuracy, improved mechanical strength, and water resistance in the three-dimensional structures by using a binding resin that changes state to prevent solvent-induced deformation, while also reducing production costs and increasing productivity.
Implementation Method 1
the binding resin undergoes a chemical change from a hydrophilic to a hydrophobic state upon heating
Data Source
AI summary
There are provided a method of manufacturing a three-dimensional structure, and three-dimension formation composition, by each which a three-dimensional structure can be manufactured with high dimensional accuracy, and provided a three-dimensional structure manufactured with high dimensional accuracy.There is provided a method of manufacturing a three-dimensional structure, in which the three-dimensional structure is manufactured by laminating a layer, the method including: forming the layer using a three-dimension formation composition containing particles, a binding resin, and a water-based solvent; removing the water-based solvent from the layer by heating the layer; and applying a binding solution containing a binder to the layer, in which the binding resin has an ammonium salt of a carboxyl group as a functional group.