Impregnation of Additive Manufactured Parts Using Absorbent Auxiliary Agent
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Solution Overview
Problem
Powder-based additively manufactured parts have porous surfaces that are prone to wear, dirt adhesion, and moisture absorption, making them aesthetically and structurally unsuitable, and conventional impregnation methods using volatile solvents are inefficient and harmful, leading to surface irregularities and health concerns.
Innovation Solution
A method involving a mixture of substances with a second plastic and a fluid, where an auxiliary agent absorbs or chemically binds the excess mixture, eliminating the need for drying and ensuring a consistent, spot-free surface, even with less volatile fluids like water, using aids such as silica gel to absorb and protect the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional impregnation methods using volatile solvents are used, then the porous surface can be sealed, but significant odor nuisance and health risks occur
Solution Approach 1:
The patent changes the key parameter of solvent volatility by replacing volatile organic solvents with water or less volatile fluids. This allows the impregnation process to continue effectively while eliminating the harmful odors and health risks associated with volatile solvents. The water-based mixture maintains the necessary penetration and sealing capabilities without the adverse effects of volatility.
Solution Approach 2:
The patent introduces disposable absorbent materials (paper towels, cloths, or disposable containers) to remove excess impregnation mixture. These single-use items eliminate the need for complex drying infrastructure and safely contain the impregnation fluid, preventing environmental contamination and health hazards while maintaining effective surface sealing.
2Productivity
If high proportions of volatile organic solvents are used to facilitate drying, then impregnation efficiency is improved, but health risks and odor nuisance increase
Solution Approach 1:
The patent changes the volatility parameter of the impregnation fluid by using water or less volatile solvents instead of highly volatile organic solvents. This maintains sufficient impregnation efficiency while dramatically reducing health risks and odor nuisance. The slower evaporation rate is compensated by using absorbent materials to remove excess fluid.
Solution Approach 2:
The patent introduces absorbent materials as intermediaries between the impregnation mixture and the environment. These materials (paper towels, cloths) absorb and retain the impregnation fluid, allowing controlled removal of excess mixture without direct exposure to harmful solvents. This mediator approach maintains productivity while protecting worker health.
3Manufacturing precision
If polishing is performed to eliminate pores, then surface smoothness is improved, but material is removed and geometry changes
Solution Approach 1:
Instead of removing material through polishing, the patent extracts the pore structure itself by impregnating it with a sealing mixture. The porous structure remains intact geometrically, but the pores are filled and sealed with the impregnation mixture, achieving smoothness without geometry change.
Solution Approach 2:
The patent changes the surface property parameter from porous to sealed by impregnation rather than mechanically altering the geometry. The impregnation mixture penetrates and fills the pores, transforming the surface characteristics through chemical/physical saturation rather than material removal, thus preserving the original geometry.
4Loss of substance
If conventional drying methods are used after impregnation, then excess mixture is removed, but surface irregularities and mottled appearance occur
Solution Approach 1:
The patent uses absorbent materials (paper towels, cloths) as intermediaries to remove excess impregnation mixture. These materials gently absorb excess fluid through capillary action without creating the mechanical stress or uneven evaporation patterns that cause mottled appearance. The intermediary approach ensures uniform surface finish while effectively removing excess substance.
Solution Approach 2:
The patent replaces mechanical drying systems (heaters, fans, ovens) with a simple absorbent material-based system. This substitution eliminates the thermal and airflow variations that cause uneven drying and surface irregularities. The absorbent materials provide gentle, uniform substance removal through absorption rather than evaporation, maintaining surface uniformity.
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 method achieves high surface quality with reduced volatile fluids, minimizing handling and packaging issues, and providing cost and environmental benefits by eliminating the need for drying and subsequent processing steps, while maintaining the surface's water-repellent properties.
Implementation Method 1
brought into contact with an auxiliary agent suitable for absorbing the mixture or components thereof
Implementation Method 2
penetrating pores or other cavities of the auxiliary material, being absorbed by the auxiliary material and/or being chemically bound by the auxiliary material
Implementation Method 3
a solvent/plastic mixture (substance mixture) exhibits particularly good capillary action, enabling the substance mixture to penetrate the pores of the porous surface of the molded parts
Data Source
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AI summary
The invention provides a method for treating a powder-based additively manufactured molded part made of a first plastic or a composite material. The method comprises the steps (a) contacting the molded part (1) with a mixture (2) for impregnating and/or coating the molded part; wherein the mixture contains at least a second plastic and at least one fluid; and (b) contacting the molded part treated according to step (a) with an auxiliary agent (3); wherein the auxiliary agent is suitable for receiving the mixture or components thereof.