Self-Curing Resin for Additive Manufacturing Mold Casting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing self-curing furan resins and sodium silicate binders used in additive manufacturing exhibit poor resistance to high temperatures, low tensile strength at normal temperatures, and poor collapsibility, limiting their application in large-scale cast-iron and steel castings.
Innovation Solution
A self-curing organic synthetic resin composition comprising 30-75% linear thermoplastic phenolic resin and 25-70% phenol modified furan resin, formulated with specific raw materials and additives, which enhances high-temperature resistance and tensile strength while improving collapsibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If self-curing furan resin is used for additive manufacturing, then rapid curing at normal temperature is achieved, but resistance to high temperature deteriorates with tensile strength of only 0.15 MPa at 1000°C
Solution Approach 1:
The patent combines furan resin and phenolic resin in a composite binder system where furan resin provides rapid curing at normal temperature and phenolic resin provides high-temperature resistance. This composite approach allows the binder to exhibit both fast setting properties and maintained strength at elevated temperatures, resolving the contradiction between curing speed and heat resistance.
2Temperature
If self-curing basic phenolic resin is used for additive manufacturing, then resistance to high temperature is improved, but tensile strength at normal temperature deteriorates with strength of only about 1.2 MPa
Solution Approach 1:
The patent creates a composite binder combining phenolic resin and furan resin where phenolic resin contributes high-temperature resistance and furan resin contributes rapid curing and adequate normal-temperature strength. The synergistic effect of the composite system overcomes the limitation of phenolic resin's low normal-temperature tensile strength.
3Ease of manufacture
If self-curing sodium silicate binder is used for additive manufacturing, then eco-friendliness and low cost are achieved, but tensile strength at normal temperature deteriorates with strength of about 1.2 MPa and collapsibility becomes poor
Solution Approach 1:
The patent develops an organic composite binder using furan and phenolic resins that achieves superior mechanical properties including tensile strength above 2.0 MPa at normal temperature and maintained strength at 1000°C. This organic composite system provides both the required performance and reasonable cost-effectiveness for industrial casting applications.
4Stress or pressure
If inorganic binder with small-molecule structure is used for additive manufacturing, then compressive strength is achieved at about 4.5 MPa, but toughness deteriorates resulting in poor collapsibility and difficult sand cleaning
Solution Approach 1:
The patent modifies the binder's molecular structure by using polymer-based organic resins with appropriate chain lengths and cross-linking densities. This structural parameter adjustment provides both sufficient compressive strength and adequate toughness for collapsibility, enabling easy sand cleaning while maintaining required mechanical properties.
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 composition achieves high tensile strength at normal and elevated temperatures, rapid curing with acidic solutions, and easy sand cleaning, making it suitable for additive manufacturing in mold casting.
Implementation Method 1
The linear thermoplastic phenolic resin is prepared from raw materials A through addition polymerization reaction
Implementation Method 2
The phenol modified furan resin is prepared from raw materials B through addition polymerization reaction
Implementation Method 3
the self-curing organic synthetic resin composition has high activity, since it reacts quickly with an aqueous or alcoholic sulfonic acid solution
Data Source
AI summary
The present invention relates to organic polymer synthetic materials, and discloses a self-curing organic synthetic resin composition for additive manufacturing. The self-curing organic synthetic resin composition includes 30-75% by weight of a linear thermoplastic phenolic resin and 25-70% by weight of a phenol modified furan resin. The self-curing organic synthetic resin composition is prepared through three stages. The linear thermoplastic phenolic resin prepared in stage (1) and the phenol modified furan resin prepared in stage (2) are mixed in a certain weight ratio in stage (3) to obtain the self-curing organic synthetic resin composition for additive manufacturing, which has the advantages of high strength at normal temperature, excellent resistance to high temperature, high activity and excellent collapsibility. Thus, the self-curing organic synthetic resin composition provided in the invention is suitable for additive manufacturing, and particularly for 3D printing in mold casting.