Porous Plastic Component Infiltration for Strength
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Solution Overview
Problem
Porous plastic components produced by generative 3D processes often exhibit poor strength values and unfavorable surface properties due to their porosity, which limits their application, especially when infiltration methods require high temperatures or labor-intensive processes.
Innovation Solution
The method involves using a medium that partially dissolves the generatively produced matrix to create a homogeneous connection with the infiltrate, accelerating the hardening of the surface layer through chemical or physical means, such as polymerization initiators and high-energy radiation, to enhance strength and prevent geometric distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If porous plastic components are produced by generative 3D processes, then manufacturing complexity is reduced and production time is shortened, but strength values and surface properties deteriorate
Solution Approach 1:
The patent creates a composite structure by infiltrating the porous plastic component with a liquid medium that penetrates the pores and solidifies within the matrix. This forms an integrated composite material where the original plastic matrix and the infiltrated medium work together, significantly enhancing strength values while preserving the rapid production advantages of generative 3D processes.
Solution Approach 2:
The invention utilizes the porous structure created during generative 3D printing as a beneficial feature rather than a defect. The controlled porosity allows the liquid medium to penetrate and distribute uniformly throughout the component, transforming the weakness of porosity into an advantage for achieving homogeneous reinforcement without requiring dense manufacturing.
2Temperature
If infiltration materials with low melting point are used, then processing temperature is reduced, but strength values deteriorate
Solution Approach 1:
The patent changes the key parameter of the infiltrated medium from low melting point (as in traditional wax infiltration) to high molecular weight polymer or resin that solidifies through polymerization rather than freezing. This parameter change allows the use of materials with superior mechanical properties and strength characteristics while avoiding the need for high temperature processing, thus resolving the contradiction between temperature and strength.
3Strength
If two-component polymerizing mixtures are used for infiltration, then strength values are improved, but processing time and automation capability deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-coating the porous plastic component with a catalyst or initiator before infiltration. When the liquid medium is introduced, the pre-applied catalyst immediately activates polymerization throughout the component. This eliminates the need for separate mixing operations and allows direct immersion processing, enabling automation while achieving high strength values through complete polymerization.
Solution Approach 2:
The invention segments the infiltration process into two independent stages: (1) application of catalyst/initiator to the porous component surface, and (2) introduction of the liquid monomer medium. This segmentation allows each stage to be optimized independently and enables automated processing where the component can be sequentially treated in different baths or stations, dramatically reducing processing time compared to manual mixing and application.
4Stability of the object's composition
If uniform infiltration is achieved throughout the component, then homogeneity is improved, but surface layer softening and geometric distortion occur
Solution Approach 1:
The patent applies local quality by creating different properties in different regions of the component. The surface layer receives enhanced catalyst concentration or different treatment to achieve rapid polymerization and form a hardened, stable shell. The interior maintains uniform infiltration for homogeneity. This spatial differentiation of properties allows the surface to resist distortion while the interior achieves complete infiltration and strength enhancement.
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 approach results in higher strength values and improved surface smoothness of the components, with the surface layer hardening faster than the rest of the component, ensuring dimensional stability and reducing labor-intensive processing bottlenecks.
Implementation Method 1
a medium (5) is introduced into a plastic component (10) which is generatively produced. The medium (5) has the property that it at least partially detaches the plastic component (10) and forms a homogeneous connection with it
Implementation Method 2
Especially preferred, the edge layer (8) is accelerated hardened in comparison to the rest of the plastic component (10) by chemical and/or physical measures. The hardening of the surface layer could take place, for example, through the additional application of accelerators and the use of polymerisation media with radiation initiation
Implementation Method 3
The hardening of the surface layer could take place, for example, through the additional application of accelerators and the use of polymerisation media with radiation initiation
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
The present invention relates to a method for changing properties of a plastic component (10), wherein a medium (5) is introduced into a porous plastic component, and wherein by dissolving (7) the plastic component at least partially the medium forms a homogeneous compound therewith.