Binder Resin for Low-Temperature Degreasing and Carbon Reduction
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Solution Overview
Problem
Existing binder resins for inorganic fine particle-dispersed paste compositions either require high temperatures for decomposition, leading to residual carbon issues or result in insufficient viscosity, making them unsuitable for low-melting-point materials and high-energy processes.
Innovation Solution
A binder resin composed of segments derived from methyl methacrylate, isobutyl methacrylate, and polyoxyalkylene ether monomethacrylate, optimized within specific weight ratios, which enhances thermal decomposition properties and reduces residual carbon, allowing for low-temperature degreasing and improved viscosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ethylcellulose is used as a binder resin, then the paste composition can be processed into desired shapes, but high firing temperatures are required which increase energy consumption and time
Solution Approach 1:
The invention changes the chemical composition parameters of the binder resin from conventional ethylcellulose to a copolymer containing polyoxyalkylene ether monomethacrylate segments. This parameter change enables the binder to decompose at lower temperatures (below 400°C) while still maintaining adequate shape retention during the firing process, thus resolving the contradiction between shape retention and energy consumption.
Solution Approach 2:
The invention uses a composite polymer structure combining polyoxyalkylene ether monomethacrylate with other methacrylate monomers (from 5 to 55 mass%). This composite material approach allows the binder resin to have both low decomposition temperature and sufficient binding strength for shape retention, eliminating the need for high firing temperatures while maintaining structural integrity.
2Temperature
If polyether-based resin is used as a binder resin, then low temperature decomposition is achieved, but residual carbon remains on the surface of inorganic fine particles
Solution Approach 1:
The invention introduces polyoxyalkylene ether monomethacrylate segments at specific locations within the polymer chain (5 to 20 mass%). These segments act as localized low-temperature decomposition sites that break down first during heating, creating pathways for complete combustion and preventing carbon residue formation on the inorganic particle surfaces, while the rest of the polymer matrix provides structural support.
Solution Approach 2:
The polyoxyalkylene ether monomethacrylate segments promote accelerated oxidation during the decomposition process. The ether linkages in these segments facilitate more complete combustion reactions, converting carbon-containing decomposition products into gaseous CO and CO2 rather than leaving residual carbon on the particle surfaces, thus eliminating the harmful carbon residue effect.
3Stability of the object's composition
If polyether-based resin or acrylic resin with polyether side chain is used, then sufficient viscosity can be achieved, but a large amount of resin is required which increases the composition ratio
Solution Approach 1:
The invention optimizes the molecular weight and composition parameters of the copolymer binder resin. By carefully selecting the ratio of polyoxyalkylene ether monomethacrylate (5-20 mass%) to other methacrylate monomers (55-95 mass%) and controlling the weight average molecular weight, the resin achieves high viscosity and binding strength at lower overall resin content, eliminating the need to use large amounts of resin while maintaining paste stability.
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 binder resin enables efficient low-temperature degreasing with reduced residual carbon and maintains sufficient viscosity, making it suitable for a wide range of inorganic fine particle applications, including low-melting-point materials, while minimizing energy consumption.
Implementation Method 1
heated and fired for thermal decomposition of the binder resin
Data Source
AI summary
It is an object of the present invention to provide a binder resin which, when used in an inorganic fine particle-dispersed paste composition, leaves little amount of residual carbon after sintering and can be degreased even under low temperature conditions. It is also an object of the present invention to provide a vehicle composition and an inorganic fine particle-dispersed paste composition, which are obtained by using the binder resin.The binder resin of the present invention is for use in an inorganic fine particle-dispersed paste composition containing inorganic fine particles. The binder resin contains from 5 to 55% by weight of a segment derived from methyl methacrylate, from 30 to 80% by weight of a segment derived from isobutyl methacrylate, and from 5 to 20% by weight of a segment derived from polyoxyalkylene ether monomethacrylate.