Epoxy Silicone Binder for Low-Temperature Ceramic Casting
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Solution Overview
Problem
Previous formulations for ceramic casting cores fail to ensure complete polymerization and mechanical stabilization at low curing temperatures, resulting in reduced rigidity and elasticity, which is disadvantageous for complex geometries like multi-wall or multi-layer structures.
Innovation Solution
A slip is developed by mixing an inorganic component with a binder comprising epoxy resin and silicone copolymer, which allows for complete incorporation and curing at low temperatures without accelerators, ensuring suitable bending and breaking strengths, and can be used with wax templates for multi-layer designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional binder systems (anhydride-based epoxy resin and reactive solid silicone) are used for ceramic casting cores, then high-temperature resistance is achieved, but complete polymerization and mechanical stabilization cannot be guaranteed at low curing temperatures
Solution Approach 1:
The invention changes the chemical parameters of the binder system by replacing the conventional anhydride-based epoxy resin with a glycidyl-functionalized poly(phenylmethyl) silicone copolymer. This parameter change enables the binder to achieve complete polymerization at low curing temperatures (below 100°C) without requiring accelerators or elevated temperatures, thus resolving the contradiction between low curing temperature and complete polymerization reliability
Solution Approach 2:
The invention creates a composite binder system combining glycidyl-functionalized poly(phenylmethyl) silicone copolymer with sintered ceramic powder. This composite material achieves both low-temperature curability and high mechanical strength, eliminating the need for high-temperature curing while ensuring complete polymerization and mechanical stabilization of the green compact
2Strength
If conventional high-temperature binder systems are used, then high-temperature resistance is achieved, but reduced stiffness and low modulus of elasticity occur in the green compact
Solution Approach 1:
The invention changes the curing temperature parameter to below 100°C while using a specially designed glycidyl-functionalized poly(phenylmethyl) silicone copolymer binder. This parameter change achieves complete polymerization at low temperature, resulting in a green compact with high stiffness and modulus of elasticity, thus resolving the contradiction between strength and curing temperature
3Temperature
If accelerators are added to enable low-temperature curing, then curing temperature is reduced, but complete polymerization still cannot be guaranteed
Solution Approach 1:
The invention changes the chemical composition parameter of the binder from conventional epoxy resins to glycidyl-functionalized poly(phenylmethyl) silicone copolymer. This parameter change inherently enables low-temperature polymerization without requiring accelerators, achieving both low curing temperature and complete mechanical stabilization reliably
Solution Approach 2:
The invention extracts and eliminates the need for accelerator additives from the binder system. The glycidyl-functionalized poly(phenylmethyl) silicone copolymer is designed to self-polymerize at low temperatures without external accelerators, simplifying the formulation while ensuring complete polymerization and mechanical stabilization
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 provides a stable, low-temperature curing process that enables the production of mechanically robust ceramic casting cores with minimal reaction shrinkage and energy savings, suitable for complex geometries and multi-layer designs.
Implementation Method 1
the binder comprises a mixture of at least one epoxy resin and at least one curing agent for the at least one epoxy resin
Implementation Method 2
the filler powder fraction is sedimented and compacted according to the maximum packing density of the powder particle size distribution
Implementation Method 3
By applying vacuum and vibration, the solvent, which primarily serves to reduce viscosity, is removed
Implementation Method 4
Up to 300°C, the first binder component pyrolyzes and is largely driven off in the form of gaseous oxidation products
Data Source
Figure 1
AI summary
A process (S1, S1a, S1b, S1c) serves for production of a slip, wherein at least one inorganic constituent is mixed with at least one binder and the binder includes at least one epoxy resin and at least one silicone copolymer. A component has been produced by means of a slip, which slip has been produced by means of the process (S1, S1a, S1b, S1c). The invention is especially applicable to more economical production of complex metal blades in all kinds of gas and power turbines.