Acid-Coated Granular Material for 3D Mold Fluidity
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Solution Overview
Problem
The existing three-dimensional laminated and shaped mold manufacturing techniques using two-component self-hardening molds face challenges with low fluidity of kneaded sand in unprinted portions, requiring regeneration through calcination, which is time-consuming and inefficient.
Innovation Solution
A method involving a granular material coated with an acid catalyst that activates and hardens an organic binder, incorporating magnesium sulfate to enhance hydration reactions and catalytic effects, allowing for direct reuse of refractory aggregates without regeneration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If liquid hardener is contained in kneaded sand in unprinted portion, then the binder is activated and hardens, but the fluidity of the kneaded sand becomes low and the mold cannot be used for recoater
Solution Approach 1:
The invention separates the catalyst (acid) from the hardener (liquid component) by coating the acid on granular material particles. This segmentation allows the granular material to maintain fluidity while the binder is selectively activated only where the binder is applied, not in unprinted portions.
Solution Approach 2:
The acid catalyst is locally applied only to the surface of granular material particles through coating, rather than being uniformly distributed in the entire kneaded sand mixture. This local quality ensures that binder hardening occurs only where binder is present, preserving fluidity in unprinted areas.
2Productivity
If the kneaded sand is regenerated by calcination to reuse, then the sand can be reused, but the process becomes time-consuming
Solution Approach 1:
The invention extracts the liquid hardener from unprinted portions through the moisture-absorbing properties of magnesium sulfate and the catalytic action of the acid coating. This allows the sand to be directly reused without time-consuming calcination processes, as the liquid components are already removed or deactivated.
Solution Approach 2:
The acid-coated granular material and magnesium sulfate combination automatically manages the liquid hardener through hydration reactions and catalytic effects, eliminating the need for external regeneration processes. The system self-regulates the liquid content, enabling direct reuse of the sand.
3Ease of operation
If acid catalyst is coated on granular material and mixed with magnesium sulfate, then fluidity improves and recoating becomes feasible, but the manufacturing process becomes more complex
Solution Approach 1:
The acid catalyst is pre-coated on the granular material particles before the molding process. This preliminary action ensures that when binder is applied, the catalytic reaction occurs immediately at the particle surface, maintaining fluidity during recoating operations without requiring complex real-time control systems.
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 enables high-speed, efficient manufacturing of three-dimensional laminated and shaped molds with improved fluidity and reduced veining defects, allowing for the direct reuse of refractory aggregates without regeneration, and maintaining mold strength and accuracy.
Implementation Method 1
a material that causes a hydration reaction having a moisture absorbing function and generates a catalytic effect
Implementation Method 2
an acid as a catalyst which activates and hardens an organic binder for binding the granular material
Data Source
AI summary
The present invention is a granular material that can be well recoated regardless of the type of the granular material, and enables a refractory aggregate in an unprinted portion to be used without any regeneration process, in the manufacture of a three-dimensional laminated and shaped mold. This granular material is a granular material for use in three-dimensional laminated mold shaping, and obtained by adding a material that causes a hydration reaction having a moisture absorbing function and generates a catalytic effect to a coating material mixed with or coated with an acid as a catalyst which activates and hardens an organic binder for binding the granular material.