Inorganic 3D Forming with In-Process Heating and Degreasing
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Solution Overview
Problem
Existing stereolithography methods face challenges in producing high-quality inorganic material-formed bodies due to complex shapes leading to inadequate washing, residual organic material, dimensional inaccuracies, and thermal expansion defects, which compromise the quality and integrity of the final product.
Innovation Solution
A forming apparatus and method that includes a stage, supply units for inorganic and support materials, immobilization, heating, and control units to manage the supply and heating of compositions, enabling precise layer formation and degreasing to produce high-quality inorganic material-formed bodies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If stereolithography is used to produce complex three-dimensional shapes, then shaping capability is improved, but washing process becomes difficult and time-consuming
Solution Approach 1:
The patent extracts and removes the organic binder material from the formed body through degreasing processes. By eliminating the organic component that complicates washing, the method simplifies the post-processing step while maintaining the ability to produce complex three-dimensional shapes using inorganic particles.
Solution Approach 2:
The patent performs preliminary degreasing and drying actions during or immediately after the forming process, before the formed body is fully completed. This preliminary removal of organic material prevents subsequent washing difficulties and reduces the time required for post-processing washing steps.
2Object-generated harmful factors
If degreasing process is performed to remove organic material, then organic component removal is improved, but gaps are formed and dimensional accuracy deteriorates
Solution Approach 1:
The patent carefully controls the parameters of the degreasing and drying processes, including temperature, atmosphere composition, and processing time. By optimizing these parameters, the organic material is removed effectively while minimizing gap formation and dimensional changes in the formed body.
Solution Approach 2:
The patent employs controlled drying processes and atmospheric conditions during degreasing to prevent excessive gap formation. By preparing the formed body with appropriate moisture control and gradual organic material removal, dimensional accuracy is maintained while still achieving effective degreasing.
3Strength
If sintering process is performed at high temperature, then inorganic particle sintering is improved, but thermal expansion differences cause defects
Solution Approach 1:
The patent segments the sintering process into multiple stages with progressively increasing temperatures. This staged approach allows different portions of the formed body to reach their optimal sintering temperature sequentially, reducing thermal shock and minimizing defects caused by differential thermal expansion between various regions.
Solution Approach 2:
The patent performs preliminary drying and organic material removal before sintering to eliminate sources of thermal expansion differences. By removing organic binders and moisture beforehand, the subsequent sintering process experiences more uniform thermal behavior, reducing the likelihood of cracks and defects.
4Object-generated harmful factors
If washing process is extended to improve cleaning, then organic material removal is improved, but processing time increases
Solution Approach 1:
The patent replaces traditional mechanical washing processes with thermal and chemical methods including degreasing in organic solvent-free environments and controlled drying. This substitution achieves effective organic material removal without the time-consuming nature of extended washing, thereby reducing overall processing time while maintaining cleaning effectiveness.
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 apparatus and method ensure improved quality by effectively removing organic components, maintaining dimensional accuracy, and preventing defects, resulting in a reliable and precise three-dimensional inorganic material-formed body.
Implementation Method 1
a heating unit configured to apply heat to the first composition on the stage
Implementation Method 2
the inorganic particles in the formed body are sintered (sintering process), thereby obtaining an inorganic material formed body
Implementation Method 3
a light source that irradiates light for curing the photocurable composition from the upper side of the liquid tank
Data Source
AI summary
A forming apparatus capable of producing an inorganic material-containing formed body having improved quality, and a method of making the same is disclosed herein. In some embodiments, the forming apparatus includes a stage, a supply unit having a first supply unit and a second supply unit, where the first supply unit is configured to intermittently or continuously supply a first composition containing an inorganic material to a stage, where the second supply unit is configured to intermittently or continuously supply a second composition containing a support material configured to support the first composition to the stage, an immobilization unit configured to immobilize the second composition on the stage, a heating unit configured to apply heat to the first composition on the stage, and a control unit configured to control the first supply unit and the heating unit to repeat supply and heating of the first composition.