3D Green Body Binder Composition for Stronger Metal Particle Adhesion
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Solution Overview
Problem
Existing 3D printing methods face challenges in effectively binding particulate build materials to form robust green body objects, particularly when using metal particles, due to inadequate adhesion and structural integrity during the formation process.
Innovation Solution
A binding agent comprising 0.3 wt% to 3 wt% adhesion promoter with an aromatic maleic anhydride-containing copolymer, 2 wt% to 20 wt% (meth)acrylic latex binder, 10 wt% to 40 wt% solvent package, and 40 wt% to 88 wt% water is used to bind particulate build materials, enhancing structural integrity through heat-driven solidification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional binders are used to bind metal particles, then the binding process is simple, but the structural integrity and adhesion of the green body object are insufficient
Solution Approach 1:
The patent uses a composite binder system combining (meth)acrylic latex binder with adhesion promoters (silane-modified polymers, carboxylic acids, or phosphonic acids). This composite approach creates synergistic effects where the latex provides base binding and the adhesion promoters enhance metal particle attachment, resolving the contradiction between simple application and strong adhesion.
Solution Approach 2:
The patent optimizes specific parameters including latex particle size (0.1-1.0 micrometers), binder concentration (1-20% by weight), and adhesion promoter ratios to achieve maximum green strength. These parameter adjustments transform a simple binder into a high-performance binding system that delivers robust structural integrity.
2Strength
If binder concentration is increased to improve adhesion, then binding strength improves, but handling and processing becomes more difficult
Solution Approach 1:
The patent identifies an optimal binder concentration range of 1-20% by weight, with preferred ranges of 5-15%. This parameter optimization achieves strong adhesion while maintaining manageable viscosity and handling characteristics, avoiding the difficulties associated with overly concentrated binders.
Solution Approach 2:
The adhesion promoters are specifically targeted at the metal particle-binder interface, providing localized enhancement of adhesion strength without uniformly increasing overall binder concentration. This localized quality improvement maintains handling ease while achieving superior bonding at critical interfaces.
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 binding agent significantly improves the structural integrity of green body objects, allowing for robust handling and subsequent sintering into 3D printed metal objects, as demonstrated by increased strength in bend testing.
Implementation Method 1
0.3 wt % to 3 wt % adhesion promoter including an aromatic maleic anhydride-containing copolymer
Implementation Method 2
heating the individually patterned layers of the 3D green body object to drive off water and further solidify the 3D green body object
Implementation Method 3
2 wt % to 20 wt % a (meth)acrylic latex binder
Data Source
AI summary
The present disclosure relates to a binding agent for printing a 3D green body object. The binding agent includes from about 0.3 wt % to about 3 wt % adhesion promoter including an aromatic maleic anhydride-containing copolymer, from about 2 wt % to about 20 wt % a (meth)acrylic latex binder, from about 10 wt % to about 40 wt % solvent package including from about 3 wt % to about 40 wt % of a coalescing solvent, and from about 40 wt % to about 88 wt % 10 water. The weight percentage ranges are based on total content of the binding agent.