Alkaline Resol Binder Viscosity Control for 3D Printed Casting Molds
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Solution Overview
Problem
The viscosity of alkaline resol resin increases over time, leading to decreased printability and stability of bound casting molds, due to increased reactivity and shortened gel time.
Innovation Solution
The method involves using a binder comprising an alkaline resol resin produced from phenol and ortho- and/or para-substituted phenols, with a specific molar ratio, to maintain stable viscosity and reactivity, ensuring longer printability and mold stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If phenol is used as the monomer structural element for producing alkaline resol resin, then the binder can be applied selectively via printing head, but the viscosity of the resin increases strongly over time leading to decreased printability and failure of the printing head
Solution Approach 1:
The patent changes the chemical composition parameters of the resol resin by introducing ortho- and/or para-substituted phenols with specific molar ratios (1:1.5 to 1:15) to modify the resin's physical properties. This compositional parameter change reduces viscosity increase over time while maintaining printability, directly resolving the contradiction between ease of operation and stability of composition.
2Ease of operation
If phenol is used as the monomer structural element for producing alkaline resol resin, then the binder can be applied selectively via printing head, but the reactivity of the resin increases over time leading to shortened gel time and decreased stability of bound casting molds
Solution Approach 1:
The patent modifies the chemical composition by incorporating ortho- and/or para-substituted phenols in controlled molar ratios to alter the reactivity parameters of the resol resin. This changes the gel time and stability characteristics, ensuring reliable bound casting molds while preserving printability during the printing process.
3Extent of automation
If conventional resol resin is used for layered construction of bodies, then the process can be automated and controlled by CAD data, but the uniformity of the printing process deteriorates due to increasing viscosity and reactivity over time
Solution Approach 1:
The patent changes the chemical composition parameters of the binder resin to achieve stable viscosity and reactivity profiles during the automated printing process. This ensures uniform printing quality throughout the entire construction process, maintaining manufacturing precision while preserving full automation capability.
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 results in a more storage-stable resol resin with stable viscosity and reactivity, maintaining printability and mold stability over a longer period, thereby improving the uniformity and reliability of the printing process.
Implementation Method 1
The curing can take place in layers, because, e.g., the molding base material is provided with a corresponding curing agent, or once all of the layers, which are necessary for the production of the three-dimensional body, are completed.
Implementation Method 2
Resols or resol resins, respectively, are phenolic plastics and belong to the class of the phenolic formaldehyde resins. They are produced by means of condensation of a hydroxy aromatic and of an aldehyde, in particular formaldehyde, in the presence of alkaline catalysts.
Data Source
AI summary
The object of the invention is a method for the layered construction of bodies comprising refractory molding base material and resol resins as binders having, in addition to phenol, ortho- and/or para-substituted phenols as monomer structural elements and three-dimensional bodies produced according to this method, and a binder for 3-dimensionally constructing bodies, in particular molds and cores for the metal casting.