Polymer Composite Powder Shell-Core Coating for Uniform Laser Absorption
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Solution Overview
Problem
Existing methods for preparing polymer composite materials for three-dimensional printing face challenges in achieving uniform laser energy absorption and mechanical strength due to non-uniform carbon powder distribution and high reflectivity, leading to complex processes and reduced mechanical properties.
Innovation Solution
A method involving dry mixing of polymer and carbon powders using a mixing mill with controlled temperature and rotation speed to embed carbon powder on the polymer surface, forming a shell-core structure without the need for additional dispersants or binders, ensuring uniform laser absorption and improved mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If carbon powder is added to polymer powder to increase laser absorption rate, then the polymer powder can be melted by semiconductor laser, but the carbon powder distribution becomes non-uniform and laser reflectivity varies significantly
Solution Approach 1:
The patent divides the carbon powder into different particle size ranges (first carbon powder: 0.1-10 μm, second carbon powder: 10-100 μm) to prevent agglomeration and achieve more uniform distribution on the polymer powder surface, thereby improving the uniformity of laser energy absorption while maintaining high absorption rate
Solution Approach 2:
The patent applies different carbon powder particle sizes to different aspects of the problem: finer carbon powder (0.1-10 μm) for base coverage and coarser carbon powder (10-100 μm) for surface distribution, creating a multi-level quality structure that optimizes both absorption rate and uniformity
2Manufacturing precision
If wet powdering method is used to coat carbon powder uniformly on polymer powder surface, then the carbon powder distribution becomes extremely uniform, but the manufacturing process becomes too complicated and time-consuming
Solution Approach 1:
The patent extracts and eliminates the complex wet powdering process steps (adding dispersants, binders, vacuum drying, heating) by using a simple dry mixing approach with controlled particle size distribution, achieving uniform carbon powder coating without the cumbersome wet processing steps
Solution Approach 2:
The patent allows the carbon powder and polymer powder to self-arrange into a uniform distribution through controlled dry mixing and shear force, without requiring external agents like dispersants or binders, thereby simplifying the manufacturing process while achieving the desired uniformity
3Ease of manufacture
If dry powdering method is used to mix carbon powder and polymer powder, then the manufacturing process is simple, but the carbon powder is not adhered on polymer powder surface and laser reflectivity remains high
Solution Approach 1:
The patent changes the physical parameters of the mixing process by controlling particle size distribution and applying shear force during mixing, which enables carbon powder to adhere to polymer powder surface through mechanical interlocking, thereby improving laser energy absorption while keeping the process simple
4Use of energy by moving object
If fine carbon powder (300 nm or lower) is used to increase laser absorption, then the absorption rate increases, but the powder easily agglomerates and requires complex dispersing processes
Solution Approach 1:
The patent segments the carbon powder into multiple particle size ranges instead of using only ultra-fine powder, which prevents agglomeration while maintaining high laser absorption rate through the combined effect of different size particles
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 method results in a polymer composite particle material with reduced laser reflectivity and enhanced mechanical properties, enabling cost-effective three-dimensional printing using semiconductor lasers.
Implementation Method 1
Heating is performed during the stirring, such that melting occurs at the surface of the polymer powder
Implementation Method 2
When a carbon powder is mixed with a polymer powder, a device with a shear force is used for stirring
Implementation Method 3
A mainstream laser forming method of a polymer bed fusion (PBF) is selective laser sintering (SLS)
Data Source
AI summary
The present invention provides a polymer composite particle material for three-dimensional printing. The polymer composite particle material is formed by embedding a carbon powder on a surface of a polymer powder. When the carbon powder is mixed with the polymer powder, a device with a shear force is used for stirring. Heating is performed during the stirring, such that melting occurs at the surface of the polymer powder. The carbon powder is embedded on the surface of the polymer powder to form a shell-core structure powder, and at the same time, the carbon powder is uniformly coated. The preparation method is simple and no additional dispersant and binder are needed. Besides the carbon powder will not easily separate from the polymer powder. At the same time, the agglomerated carbon powder can be dispersed by rubbing and evenly dispersed around the polymer powder to reduce a laser reflectivity.