Additive Manufacturing Curing Agent Prevents Sintering Inhibition
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Solution Overview
Problem
Conventional three-dimensional object producing methods face challenges such as clogging in nozzle heads, restrictions on adhesive materials, high costs, inefficiencies, and issues with resin residues causing sintering inhibition and decreased strength, especially when dealing with complex and fine objects.
Innovation Solution
A method involving a powder material layer formed with a base material and a resin containing reactive functional groups, where a curing liquid with an aliphatic compound having two or more isocyanate groups is applied to form a covalent bond, preventing sintering inhibition and maintaining shape even when immersed in solutions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional adhesive materials are used in powder adhesion method, then three-dimensional objects can be formed, but resin residues cause sintering inhibition and decreased strength
Solution Approach 1:
The invention changes the chemical parameters of the adhesive material by specifying functional groups (carboxyl, hydroxyl, or amine groups) that enable complete reaction and elimination of residues. This parameter change ensures that the adhesive fully cures without leaving harmful residues that would inhibit sintering or weaken the final object.
Solution Approach 2:
The invention converts the potential harm of resin residues into a benefit by selecting adhesive materials that completely react and leave no residues. The functional groups are chosen specifically because they undergo complete chemical reactions, transforming what would be a harmful residual component into a fully integrated part of the cured structure.
2Shape
If conventional adhesive materials are used, then three-dimensional objects can be formed, but the shape is not maintained when immersed in solution
Solution Approach 1:
The invention changes the chemical resistance parameters by selecting adhesive materials with specific functional groups that form chemically stable bonds. These groups (carboxyl, hydroxyl, amine) create crosslinked structures that are resistant to dissolution or degradation in liquid environments, thereby maintaining shape stability.
Solution Approach 2:
The invention creates a composite structure where the adhesive material with specific functional groups forms a chemically resistant network within the powder matrix. This composite approach combines the structural properties of the powder with the chemical stability of the cured adhesive, resulting in shape maintenance in solution environments.
3Productivity
If powder adhesion method is used to produce complex and fine three-dimensional objects, then low-lot production needs are met, but clogging in nozzle heads and restrictions on adhesive materials occur
Solution Approach 1:
The invention changes the physical parameters of the adhesive material by selecting compounds with appropriate viscosity and reactivity characteristics. The specified functional groups enable the adhesive to be delivered through nozzles without clogging while maintaining effectiveness in binding particles, thus facilitating smooth operation in low-lot production.
4Ease of manufacture
If conventional adhesive materials are used, then three-dimensional objects can be formed, but high costs and inefficiencies occur
Solution Approach 1:
The invention changes the chemical composition parameters to use readily available functional groups (carboxyl, hydroxyl, amine) that are common in industrial chemistry. This selection reduces material costs while improving manufacturing efficiency through complete reactions that eliminate waste and rework.
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 method effectively prevents sintering inhibition and maintains the shape of three-dimensional objects, ensuring storage stability and improved strength, especially for complex and fine objects, by using a curing agent that forms covalent bonds with reactive functional groups in the resin.
Implementation Method 1
the curing liquid contains a curing agent capable of forming a covalent bond with the reactive functional group
Implementation Method 2
The curing agent includes an aliphatic compound having two or more isocyanate groups at a molecular terminal thereof
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 2C~2D
AI summary
A three-dimensional object producing method including: forming a powder material layer with a powder material for three-dimensional object formation, where the powder material includes a base material and a resin including a reactive functional group; and applying a curing liquid to the powder material layer to form a cured product, where the curing liquid contains a curing agent capable of forming a covalent bond with the reactive functional group, wherein the curing agent includes an aliphatic compound having two or more isocyanate groups at a molecular terminal thereof.