Sintered Molded Body Binder Composition for Rapid Degreasing
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Solution Overview
Problem
Existing techniques for producing sintered molded bodies using sinterable inorganic powders face challenges in suppressing cracking and swelling during the degreasing process, often requiring special facilities and extended heating times, and do not adequately address mold deposit and dimensional accuracy issues.
Innovation Solution
A composition comprising a sinterable inorganic powder and an organic binder, consisting of a polyacetal resin, a polyolefin resin, and an epoxy resin, with optimized total end amounts of polyoxymethylene units, enhances compatibility and reduces mold deposit and cracking by allowing for rapid degreasing without specialized equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the binder thermally decompose and gasify in a short period of time during degreasing, then the degreasing speed is improved, but cracks or swells occur in the molded bodies
Solution Approach 1:
The binder is segmented into multiple functional components: polyacetal resin (provides rigidity and shape retention), polyolefin resin (provides flexibility and crack suppression), and epoxy resin (provides adhesion and compatibility). This segmentation allows each component to perform its specific function during degreasing, enabling faster removal while preventing defects
Solution Approach 2:
The invention uses a composite binder system combining three different resin types with complementary properties. The polyacetal resin contributes rigidity, the polyolefin resin contributes flexibility and crack resistance, and the epoxy resin enhances adhesion and compatibility. This composite approach allows the binder to decompose more uniformly and completely, improving degreasing speed while preventing cracks and swells
2Stability of the object's composition
If a polyacetal resin and an epoxy resin are used together as a binder, then the compatibility of the binder resin components is improved and uniformity is promoted, but the total end amount with respect to all polyoxymethylene units must be controlled within a specific range to prevent mold deposit
Solution Approach 1:
The invention specifies precise parameter ranges for the polyacetal resin, particularly controlling the total end amount with respect to all polyoxymethylene units at 0.01 mol% or more and 5.0 mol% or less. This parameter control optimizes the resin's compatibility with other binder components while preventing excessive adhesion to the mold surface, thereby eliminating mold deposit issues
Solution Approach 2:
The invention applies different functional properties to different components of the binder system at specific concentrations. The polyacetal resin provides rigidity and shape retention, the polyolefin resin provides flexibility and crack suppression, and the epoxy resin provides adhesion. Each component's local quality is optimized to contribute to overall compatibility while minimizing harmful effects like mold deposit
3Manufacturing precision
If the green molded bodies are heated for a long time to prevent cracking and swelling, then the quality of sintered molded bodies is improved, but the production time is extended
Solution Approach 1:
The binder system is designed to undergo preliminary thermal decomposition in a controlled manner during the degreasing step. The polyacetal resin decomposes first to provide structural support, followed by the polyolefin and epoxy resins. This preliminary action allows complete binder removal without requiring extended heating times during subsequent sintering, reducing overall production time while maintaining quality
Solution Approach 2:
The binder components are formulated to decompose continuously and uniformly throughout the degreasing and sintering process. The polyacetal resin's rigidity maintains green body integrity during initial heating, while the polyolefin and epoxy resins continue to decompose and gasify, ensuring complete binder removal. This continuous useful action eliminates the need for prolonged heating cycles, reducing production time while preventing defects
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 enables rapid degreasing of sintered molded bodies without special facilities, prevents mold deposit, and suppresses cracking and swelling, resulting in improved dimensional accuracy and quality.
Implementation Method 1
the binder contained in the green molded bodies thermally decompose and gasify
Implementation Method 2
a technique using a composition for use in production of sintered molded bodies containing a sinterable inorganic powder
Data Source
AI summary
An object is to provide a composition for use in sintered molded bodies that enables an organic binder to be degreased in a short time without requiring a special facility or step, does not cause mold deposit during molding, and suppresses cracking and swelling during molding and after sintering. In order to achieve the above-mentioned object, the present disclosure is a composition for use in sintered molded bodies containing a sinterable inorganic powder and an organic binder, wherein the organic binder contains at least a polyacetal resin, a polyolefin resin and an epoxy resin, and a total end amount with respect to all polyoxymethylene units in the polyacetal resin is 0.1 mol % or more and 0.75 mol % or less.