Carbonized or Graphitized 3D Objects with Staged Outgassing
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Solution Overview
Problem
Existing methods for producing carbonized or graphitized 3D objects suffer from microstructure defects such as cracks and gas inclusions due to volatile substance outgassing during high-temperature processing.
Innovation Solution
A method involving the preparation of a kneadable compound of carbonizable or graphitizable materials with a free-flowing organic adhesive, shaping into a 3D blank, followed by drying and outgassing at room temperature, stabilization and homogenization, and subsequent carbonization or graphitization under controlled conditions to prevent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the green molding is heated to high temperatures for carbonization or graphitization, then the desired carbonized or graphitized 3D object is produced, but violent outgassing of volatile substances occurs causing microstructure defects such as cracks or gas inclusions
Solution Approach 1:
The patent applies preliminary action by conducting a drying and outgassing process at room temperature or at a maximum of 100°C before the main carbonization/graphitization heating. This preliminary step removes volatile substances from the green molding in advance, preventing violent outgassing during subsequent high-temperature treatment and avoiding microstructure defects like cracks or gas inclusions.
Solution Approach 2:
The patent implements periodic action through a multi-stage heating process with distinct phases: first a drying and outgassing phase at low temperature (room temperature to 100°C), then a stabilization and homogenization phase at intermediate temperature (140°C to 450°C), and finally the carbonization/graphitization phase at high temperature. This staged approach allows controlled removal of volatiles and gradual transformation, preventing defects.
2Ease of manufacture
If a binder is used to form the green molding, then the compound becomes moldable and can be shaped into 3D objects, but the binder decomposes into volatile constituents during carbonization causing microstructure defects
Solution Approach 1:
The patent applies preliminary action by conducting a drying and outgassing process at room temperature or at a maximum of 100°C before the main carbonization/graphitization heating. This preliminary step removes volatile substances from the green molding in advance, preventing violent outgassing during subsequent high-temperature treatment and avoiding microstructure defects like cracks or gas inclusions.
Solution Approach 2:
The patent applies parameter changes by implementing a multi-stage temperature profile: first heating at low temperature (room temperature to 100°C) for drying and outgassing, then heating at intermediate temperature (140°C to 450°C) for stabilization and homogenization, and finally heating at high temperature for carbonization or graphitization. This controlled parameter change sequence allows the binder to decompose gradually and convert to stable carbon structure, minimizing volatile release and microstructure defects.
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
Enables the production of complex 3D objects without microstructure defects through a simple and effective process that stabilizes the structure and minimizes volatile substance outgassing.
Implementation Method 1
the binder decomposing into volatile constituents
Implementation Method 2
drying and outgassing process of the 3D blank at room temperature or at a maximum of 100° C.
Implementation Method 3
stabilization and homogenization process of the 3D molding at a temperature of 140° C. to a maximum of 450° C. in air
Implementation Method 4
subsequent carbonization or graphitization of the 3D molded part in a furnace under or protective gas atmosphere
Implementation Method 5
subsequent carbonization or graphitization of the 3D molded part in a furnace under or protective gas atmosphere
Data Source
AI summary
The invention relates to a method for producing carbonised or graphitised 3D objects which aims to realise such 3D objects particularly simply, and by means of which more complex 3D objects can also be produced without faults in the structure. This is achieved by mixing a carbonisable or graphitisable material with a free-flowing organic adhesive or a free-flowing thermoplastic organic substance to produce a kneadable, largely dimensionally stable compound and shaping the compound into a 3D blank, and by a subsequent drying and degassing process at an increased temperature over a predetermined period of time and subsequent carbonising or graphitising of the 3D blank in a furnace in a protective gas atmosphere to produce a 3D object, the temperature necessary for carbonising or graphitising being approached with a low heating gradient.