Rosin Derivative Binder Resin for Low-Residue Ceramic Sintering
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Solution Overview
Problem
Existing methods for producing inorganic solid powder molded articles face issues with thermally decomposable binders and lubricants, such as poor kneading and residual impurities due to low decomposition temperatures, which affect the quality of sintered bodies and conductive layers.
Innovation Solution
A thermally decomposable binder resin is developed using a rosin derivative that undergoes distillation and disproportionation or hydrogenation treatments, ensuring a 99 wt % weight loss temperature of 500° C. or lower, improving compatibility with various polymers and preventing residual soil formation during thermal treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If stearic acid is used as lubricant, then the decomposition temperature is low which allows easy removal, but it decomposes during kneading with inorganic solid powder and thermoplastic binder resulting in poor kneading
Solution Approach 1:
The patent changes the chemical structure of the lubricant from stearic acid to behenic acid, altering the molecular chain length parameter. This structural modification increases the decomposition temperature while maintaining compatibility with the thermoplastic binder, thereby preventing decomposition during kneading and improving overall manufacturing quality.
2Temperature
If behenic acid is used as lubricant, then the decomposition temperature is increased to prevent decomposition during kneading, but its compatibility with thermoplastic binder becomes insufficient depending on the binder type
Solution Approach 1:
The patent employs a composite lubricant system combining behenic acid with specific thermoplastic binders (polyethylene, polypropylene, polyvinylidene fluoride, polyvinyl alcohol, or polyacrylic resin). This composite approach ensures compatibility between the high-decomposition-temperature lubricant and the binder, maintaining both thermal stability and processing suitability across different material systems.
3Use of energy by stationary object
If low-temperature calcination is used to form conductive layers, then energy consumption is reduced, but the rosin derivative does not thermally decompose sufficiently and remains as impurity in the sintered body
Solution Approach 1:
The patent modifies the molecular structure of the rosin derivative through hydrogenation treatment, reducing the number of aromatic rings and adjusting the molecular weight distribution. This structural change lowers the decomposition temperature of the rosin derivative, enabling complete decomposition at low calcination temperatures (300°C or lower) and preventing impurity formation in the sintered conductive layer.
4Temperature
If rosin derivative is used as binder, then thermal decomposability is improved, but residual soil may remain after thermal treatment
Solution Approach 1:
The patent optimizes the molecular weight distribution of the rosin derivative through controlled distillation and hydrogenation processes. By adjusting the average molecular weight and reducing high-molecular-weight components, the patent ensures complete thermal decomposition without residue formation, eliminating harmful residual soil while maintaining excellent thermal decomposability.
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 binder resin provides excellent thermal decomposability, suitable for injection molding and ceramic calcination, ensuring high-quality sintered bodies without residual impurities, and is compatible with various polymers, enhancing the production of inorganic solid powder molded articles and conductive patterns.
Implementation Method 1
a specific rosin derivative has excellent thermal decomposability and can be suitably used as a binder for an inorganic solid powder molded article... leaving no residual soil after being thermally treated at from 25° C. to 500° C.
Implementation Method 2
a rosin derivative (A) that is obtained by subjecting a rosin (a) to distillation and a disproportionation treatment and/or hydrogenation treatment
Data Source
AI summary
A thermally decomposable binder resin containing, as an active ingredient, a rosin derivative (A) that is obtained by subjecting a rosin (a) to distillation and a disproportionation treatment and/or hydrogenation treatment, wherein the rosin derivative (A) has a 99 wt % weight loss temperature of 500° C. or lower in thermogravimetric measurement, under an air atmosphere at a heating rate of 5° C./min, a binder resin composition containing the resin, and a use of the binder resin composition.