Composite Material Water-Soluble Resin Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing three-dimensional metal objects using composite materials face challenges such as high treatment costs, restricted use of organic solvents due to environmental concerns, and low moisture resistance leading to inaccurate shaping and residual organic matter.
Innovation Solution
A composite material comprising a resin with an aromatic dicarboxylic acid monomer unit having a hydrophilic group and a dicarboxylic acid monomer unit without a hydrophilic group, combined with metal compound particles, where the resin is removable with neutral water, facilitating high moisture resistance and reduced residual organic matter in the sintering process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If organic solvents are used to remove resin from composite material, then resin removal effectiveness is improved, but environmental safety and work environment deteriorate due to restricted use of organic solvents
Solution Approach 1:
The patent changes the chemical parameter of the removal medium from organic solvents to neutral water by selecting specific resin components (polyvinyl alcohol, carboxymethyl cellulose, starch) that are water-soluble or water-dispersible. This parameter change allows resin removal using environmentally safe water instead of restricted organic solvents, resolving the contradiction between removal effectiveness and environmental safety
Solution Approach 2:
The patent uses neutral water, which is inexpensive and environmentally benign, as a disposable removal medium. Water can be easily disposed of without environmental harm, unlike organic solvents that require special handling and disposal procedures. This approach maintains resin removal effectiveness while eliminating environmental safety concerns
2Ease of operation
If water-dispersible resin is used in composite material, then ease of resin removal with water is improved, but moisture resistance of composite material deteriorates leading to low shaping accuracy
Solution Approach 1:
The patent applies partial water dispersibility to the resin system. The resin contains water-soluble or water-dispersible components (polyvinyl alcohol, carboxymethyl cellulose, starch) that will be removed after molding, but during the molding process, only partial water interaction occurs, allowing the composite material to maintain sufficient shape stability. The resin removal is excessive in the sense that all binder material is eliminated, ensuring no residual organic matter remains
Solution Approach 2:
The patent performs preliminary molding with the water-dispersible resin in place, establishing the three-dimensional shape before resin removal. The composite material is molded under conditions where the resin provides sufficient binding and shape retention, then the resin is subsequently removed by water treatment. This preliminary action ensures shaping accuracy is achieved during molding before the resin becomes vulnerable to water removal
3Manufacturing precision
If resin is removed by heating decomposition, then resin removal is achieved, but treatment cost increases due to decomposed gas treatment requirements
Solution Approach 1:
The patent replaces expensive thermal decomposition processes with a cheap water-based removal method. Neutral water serves as a disposable, inexpensive medium that dissolves or disperses the resin without requiring expensive gas treatment systems. This eliminates the need for complex exhaust treatment infrastructure while achieving complete resin removal, significantly reducing treatment costs
Solution Approach 2:
The patent substitutes the thermal energy-based resin removal mechanism with a chemical dissolution mechanism using water. Instead of applying heat to decompose resin and treat the resulting gases, the process uses water's chemical properties to dissolve water-soluble resin components directly. This substitution eliminates the need for thermal energy input and associated gas treatment systems, reducing both energy loss and treatment costs
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 enables the production of three-dimensional metal objects with improved moisture resistance and reduced residual organic content, enhancing shaping accuracy and environmental sustainability by using neutral water for resin removal.
Implementation Method 1
a removing step of removing the resin α from the composite material molded body by bringing the composite material molded body into contact with neutral water
Implementation Method 2
A method for producing a metal-compound three-dimensional object according to the present invention sinters a three-dimensional object containing a metal compound
Data Source
AI summary
A composite material includes a resin α including an aromatic dicarboxylic acid monomer unit A having a hydrophilic group and a dicarboxylic acid monomer unit B having no hydrophilic group, a resin β that is a different from resin α, and metal compound particles γ. A content of the metal compound particles γ may be 50 to 500 parts by mass with respect to 100 parts by mass of the resin α and the resin β together. A weight average molecular weight of the resin α may be 5,000 to 50,000. A content of the resin β may be 1 to 500 parts by mass or less with respect to 100 parts by mass of the resin α.