Binder Viscosity Control for Sand Mold Additive Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing binder technologies in additive manufacturing face issues with viscosity, leading to poor bonding and nozzle clogging, and have limitations in hardening speed and storage life, particularly when used with fine sand materials.
Innovation Solution
A method involving the formulation of a binder comprising furfuryl alcohol, an acid catalyst, phenolic compounds, and polyoxymethylene, with a coupling agent, to create a phenolic resin binder that can be adjusted for viscosity and surface tension, allowing for effective spraying and rapid hardening, even with fine sand materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the binder has a low viscosity, then the binder can be sprayed easily, but the bonding effect between the binder and powder material is poor, causing drying and molding to be slowed down
Solution Approach 1:
The patent applies parameter changes by adjusting the viscosity of the binder through chemical modification. Specifically, it uses a binder with controlled viscosity that allows easy spraying while maintaining good bonding effect, resolving the contradiction between sprayability and bonding strength.
Solution Approach 2:
The patent employs composite materials by combining the binder with specific additives and controlling its chemical composition to achieve both low viscosity for easy spraying and sufficient bonding strength. The binder is formulated as a composite system that balances these opposing requirements.
2Strength
If the binder has a proper viscosity, then the bonding effect between the binder and powder material is good, but the binder is not easy to be sprayed out through the nozzle, causing nozzle clogging
Solution Approach 1:
The patent uses parameter changes to optimize the binder viscosity specifically for nozzle spraying. By controlling the viscosity within a specific range, the binder flows easily through the nozzle without clogging while still providing good bonding effect when applied to the powder material.
3Strength
If the binder has a high viscosity, then the bonding effect between the binder and powder material is good, but the binder cannot be sprayed out through the nozzle, requiring regular cleaning or maintenance
Solution Approach 1:
The patent applies parameter changes by setting the binder viscosity within an optimal range that prevents nozzle clogging. This eliminates the need for frequent cleaning or maintenance while maintaining good bonding effect, reducing device complexity and operational burden.
4Quantity of substance
If the binder is sprayed too much through the nozzle, then the bonding effect is poor, but if the binder viscosity is reduced to spray more, then drying and molding are slowed down
Solution Approach 1:
The patent uses parameter changes to control the binder spray amount precisely. By optimizing the viscosity and spray parameters, it achieves the right amount of binder deposition that provides good bonding effect without excessive spraying that would slow down drying and molding.
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 solution provides improved mechanical strength, extended storage life, and adjustable viscosity, preventing nozzle clogging while ensuring rapid curing and suitable for various sand sizes and materials, including fine sands.
Implementation Method 1
reacting the binder sprayed through the nozzle with the surface of the sand material evenly coated with the hardener to harden a sand mold
Implementation Method 2
heating at a high temperature of 100-110° C. for mixing, and drying
Data Source
AI summary
A method for additive manufacturing is provided, including: mixing a hardener with a sand material, so that the hardener is evenly coated on a surface of the sand material, and then spraying a binder through a nozzle, reacting the binder sprayed through the nozzle with the surface of the sand material evenly coated with the hardener to harden a sand mold. Therefore, the problem of nozzle clogging may be overcome, and a solid with a particle size of less than 0.6 μm may be obtained by the additive manufacturing. In addition, the hardening speed can be adjusted according to the size of the sand mold. Compared with a general sand mold product, the hardening speed may be increased and the storage life of the binder may be prolonged when the sand mold has a large size.