3D Printed Carbon Articles via Binder Jetting and Pitch Infiltration

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Solution Overview

Problem

Conventional subtractive manufacturing methods for carbon articles result in significant material waste and limited geometries, while binder jetting techniques face challenges in forming high-quality carbon articles due to the difficulty of working with carbon materials like graphite or coke.

Innovation Solution

A three-dimensional printing process using carbon powder and a binder, followed by curing, carbonization, and graphitization, which allows for the creation of densified carbon articles with minimal material loss and virtually limitless geometric configurations, reducing waste and improving efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If subtractive manufacturing methods are used to make carbon articles, then the manufacturing process is simple and reliable, but significant material loss occurs and geometric flexibility is limited

Engineering Contradiction:

Improvematerial lossVSAvoidmanufacturing simplicity

Core Design Contradiction:

Loss of substanceVSEase of manufacture

Solution Approach 1:

The patent inverts the conventional subtractive manufacturing approach by using additive manufacturing (binder jetting) to build carbon articles layer by layer from powder, eliminating material removal and achieving near-net-shape production with minimal waste

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the physical state and binding parameters of carbon powder through controlled binder application, curing, and sintering processes, transforming loose powder into dense, structurally sound carbon articles with precise geometric control

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If binder jetting technique is used with carbon materials, then geometric flexibility is improved, but the difficulty of working with carbon materials increases

Engineering Contradiction:

Improvegeometric flexibilityVSAvoidease of working with carbon materials

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent introduces a binder as an intermediary substance that facilitates the binding of carbon powder particles during binder jetting, enabling geometric flexibility while managing the challenges of working with carbon materials through controlled binder application and curing processes

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates a composite structure combining carbon powder with binder material, where the binder serves as a temporary matrix that holds carbon particles in the desired geometric configuration during manufacturing, which is later removed or carbonized to leave pure carbon structures

Inventive Principle:

Principle #40Composite materials

3Loss of substance

If binder jetting is used to form carbon articles, then material waste is reduced, but the density and quality of the carbon article deteriorates

Engineering Contradiction:

Improvematerial wasteVSAvoidarticle density

Core Design Contradiction:

Loss of substanceVSManufacturing precision

Solution Approach 1:

The patent applies preliminary binder application and curing steps that prepare the carbon powder structure for subsequent densification, establishing a controlled framework that enables later sintering to achieve high density while maintaining near-net-shape geometry

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent utilizes phase transitions during sintering where carbon particles undergo densification and bonding transformations, converting the porous green body from binder jetting into a dense, high-quality carbon article with minimal material waste

Inventive Principle:

Principle #36Phase transitions

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 process produces near-net shape carbon articles with reduced material waste and expanded geometric possibilities, achieving densities suitable for various applications with minimal distortion, thus overcoming the limitations of traditional machining methods.

Implementation Method 1

The printed layers are injected with a furan binder solution

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

The printed article is cured at 80°C

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Implementation Method 3

carbonised at 520°C

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Implementation Method 4

the printed article is infiltrated with liquid Si at 1450°C

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentEP3227109B1Process for making densified carbon articles by three dimensional printing

Publication Date: 2020.08.19 THE EX ONE

AI summary

Methods for making densified carbon printed articles from carbon powder are described. Three-dimensional binder jet printing is used to make a printed article from the carbon powder. The printed articles are infiltrated with pitch and may be heated to graphitize at least a portion of the pitch to provide a near net shape densified carbon printed article.