3D Ceramic Object Shaping via Solvent-Controlled Layer Stability
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Solution Overview
Problem
Existing methods for producing three-dimensional shaped objects face challenges in achieving excellent shape accuracy while preventing deformation and bleeding during the shaping process, particularly when forming flat plates.
Innovation Solution
A method involving the formation of layers from secondary particles containing a binder resin and primary ceramic particles, with a solvent that dissolves the binder resin, where the solvent has a boiling point between 100°C and 210°C and a relative energy difference of 1.0 or less with the binder resin, and secondary particles have a loose bulk density between 25% and 55%, ensuring stable solubility and dryness balance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional shaping materials are used to form three-dimensional shaped objects, then the shaping process can be completed, but deformation and bleeding occur during shaping leading to poor shape accuracy
Solution Approach 1:
The invention changes the parameter of solvent boiling point to a specific range (100-210°C) to optimize the balance between solubility and dryness. This parameter change prevents deformation and bleeding during shaping while maintaining excellent shape accuracy, resolving the contradiction between manufacturing precision and composition stability.
Solution Approach 2:
The invention adjusts the loose bulk density of secondary particles to a specific range (25-55%) to control the packing and stability of the shaped object during the shaping process. This parameter change prevents deformation and bleeding while maintaining shape accuracy.
2Quantity of substance
If the solvent has high solubility for the binder resin, then the binder dissolves well, but the liquid bleeds outside the shaping portion
Solution Approach 1:
The invention changes the boiling point parameter of the solvent to a specific range (100-210°C) that provides optimal solubility for the binder resin while controlling evaporation rate. This prevents the liquid from bleeding outside the shaping portion during the shaping process, resolving the contradiction between solubility and bleeding control.
Solution Approach 2:
The invention uses the relative energy difference (RED) as a feedback parameter to select solvents that match the binder resin properties. By controlling RED ≤ 1.0, the invention achieves optimal solubility while preventing excessive liquid flow and bleeding, resolving the contradiction between quantity of substance dissolved and harmful bleeding effects.
3Speed
If the solvent evaporates too quickly, then drying is fast, but deformation occurs during the shaping process
Solution Approach 1:
The invention changes the boiling point parameter of the solvent to a controlled range (100-210°C) that provides moderate evaporation rate. This allows sufficient time for the binder resin to dissolve and for the shaping process to complete without deformation, while still achieving reasonable drying speed. This resolves the contradiction between drying speed and shape 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
This approach effectively stabilizes each layer, preventing deformation and bleeding, thereby improving the shape accuracy and integrity of three-dimensional shaped objects, especially in large structural members.
Implementation Method 1
applying a liquid that dissolves the binder resin on the formed layer. The liquid contains a solvent.
Implementation Method 2
The solvent has a boiling point of 100°C or higher and 210°C or lower
Data Source
Figure 1~3
Figure 4A~4C
Figure 4D~4F
AI summary
A three-dimensional shaped object producing method is provided that includes: forming a layer from secondary particles (51) including a binder resin and primary particles containing at least a ceramic material; and applying a liquid that dissolves the binder resin on the formed layer. The liquid contains a solvent having a boiling point of 100°C or higher and 210°C or lower, a relative energy difference (RED) between the binder resin and the solvent is 1.0 or less, and the secondary particles (51) have a loose bulk density of 25% or higher and 55% or lower.