Phenolic Resin Binder Curing for Uniform 3D Powder Solidification
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Solution Overview
Problem
Existing methods for producing three-dimensional components using particulate materials and binders face issues such as binder toxicity, health concerns, and suboptimal process conditions, including temperature distribution, which affect the economic viability and quality of the components.
Innovation Solution
A method involving the layered construction of components with particulate material and a binder system, where the temperature in the construction space or material is adjusted to at least 70°C and maintained for at least 2 hours, using a water- or alcohol-based binder that is only slightly reactive at room temperature, allowing for uniform solidification and increased construction space efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a binder is used to bind particulate material in 3D printing, then the component can be formed and solidified, but the binder attacks the device and print head and creates health problems
Solution Approach 1:
The patent changes the chemical parameters of the binder system by using phenolic resins with controlled reactivity and water or alcohol as solvents instead of traditional toxic binders. This parameter change reduces the harmful effects on device and health while maintaining binding functionality.
Solution Approach 2:
The patent employs a binder system that is easier to clean and maintain, effectively treating the binder as a consumable that can be readily removed. The water- or alcohol-based binder allows for simple cleaning of the print head and device components, reducing maintenance complexity.
2Productivity
If the temperature is increased to accelerate binder reaction, then the solidification process is faster, but the temperature distribution becomes non-uniform and affects component quality
Solution Approach 1:
The patent changes the activation energy parameters of the binder system by selecting phenolic resins that react at lower temperatures (above 70°C) compared to traditional high-temperature binders. This allows for uniform temperature distribution across the construction space while maintaining adequate solidification speed.
Solution Approach 2:
The patent implements dynamic temperature control where the temperature is adjusted during the construction process to maintain optimal conditions for binder reaction. The temperature is kept above 70°C throughout the construction space to ensure uniform reaction conditions while preventing excessive heat concentration.
3Area of stationary object
If the construction space is increased to produce larger components, then the production capacity is improved, but the temperature distribution becomes non-uniform in large areas
Solution Approach 1:
The patent changes the thermal parameters of the process by using a binder system with lower activation energy that reacts effectively at temperatures above 70°C but below the temperature at which non-uniform distribution occurs. This allows for larger construction spaces to be maintained at relatively uniform temperatures.
Solution Approach 2:
The patent creates equipotential temperature conditions across the construction space by maintaining a uniform temperature above 70°C throughout the entire construction area. This ensures that all regions of the construction space experience similar thermal conditions, enabling large-area construction with uniform component properties.
4Loss of time
If the binder reactivity is increased to speed up solidification, then the production time is reduced, but the binder becomes more harmful to device and health
Solution Approach 1:
The patent optimizes the reactivity parameters of the binder by using phenolic resins with controlled reaction rates that are sufficient for practical solidification times but not so high as to create harmful effects. The water- or alcohol-based formulation further reduces toxicity while maintaining adequate reactivity.
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 homogeneous material properties, reduces costs, and enhances the economic viability by maintaining a large, uniform temperature area, resulting in components with high bending strength and low loss on ignition, while also simplifying machine maintenance and reducing binder reactivity risks.
Implementation Method 1
the temperature in the construction space or/and in the particulate material applied is adjusted to at least 70° C. and maintained for at least 2 hours, with the areas onto which the binder was selectively applied solidifying and forming the component
Data Source
AI summary
The invention relates to a method, a device, a binder system, and a material system for producing components using layering technology, wherein the temperature in the building space and/or in the applied material is set to at least 70° C. and maintained for at least 2 hours. Areas on which binder has been selectively applied, solidify and form the component.