Sintering Method for 3D Shaped Articles Using Inorganic Binder
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing three-dimensional shaped articles using powder materials and binder materials face challenges in achieving high strength and accuracy due to dimensional shrinkage and variations during the sintering process, resulting in inferior mechanical strength and stability compared to fused metal materials.
Innovation Solution
A sintering and shaping method involving a sintering material with first inorganic particles and a liquid binding agent containing second inorganic particles, applied selectively and cured to form cross-sectional layers, followed by heating for sintering treatment, which enhances the bonding and density of the inorganic particles, reducing shrinkage and improving dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a sintering process is introduced to improve connection between powder materials, then the strength of the three-dimensional shaped article increases, but dimensional shrinkage increases and shape accuracy deteriorates
Solution Approach 1:
The patent applies parameter changes by carefully controlling sintering temperature, heating rate, and atmospheric conditions during the sintering process. By optimizing these parameters, the invention achieves sufficient bonding strength while minimizing dimensional shrinkage and maintaining shape accuracy of the three-dimensional shaped article.
Solution Approach 2:
The invention uses composite materials consisting of powder materials combined with specific binder materials that contain inorganic particles. This composite structure allows the binder to provide binding force while the inorganic particles maintain dimensional stability during sintering, reducing shrinkage and preserving shape accuracy.
2Ease of manufacture
If binder material is applied to bond powder materials, then the shaping process becomes feasible, but the mechanical strength is greatly inferior to fused metal materials
Solution Approach 1:
The patent changes the chemical composition parameters of the binder material by incorporating specific inorganic particles into the binder. This modification transforms the binder from a simple organic adhesive into a composite material that provides both binding functionality and enhanced mechanical strength, approaching the strength of fused metal materials.
Solution Approach 2:
The invention employs composite binder materials that combine organic binder components with inorganic particles. This composite structure provides the dual benefit of maintaining shaping feasibility through the organic binder while significantly improving mechanical strength through the inorganic reinforcement, eliminating the weakness of conventional binder-based methods.
3Strength
If thermal decomposition and sintering are performed to remove binder material, then the connection between powder materials improves, but variation in shape occurs and base dimensions cannot be maintained
Solution Approach 1:
The patent applies parameter changes by controlling the thermal processing parameters including heating rate, sintering temperature, and holding time. By optimizing these parameters, the invention achieves complete binder removal and sufficient sintering while minimizing thermal shrinkage and maintaining shape stability and base dimensions.
Solution Approach 2:
The invention uses composite binder materials containing inorganic particles that have thermal stability matching the powder materials. During thermal decomposition, these inorganic particles remain stable and act as structural support, preventing shape variation and maintaining base dimensions while the organic binder is removed.
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 method increases the mechanical strength and dimensional accuracy of the three-dimensional shaped articles by effectively bonding inorganic particles at a lower temperature, suppressing shrinkage and maintaining high precision during the sintering process.
Implementation Method 1
The binder material, which penetrates into a void between the powder materials, bonds the powder materials to each other
Implementation Method 2
a sintering process is introduced to improve connection between the powder materials
Implementation Method 3
a material that bonds the powder materials to each other is removed (degreased) through thermal decomposition
Data Source
AI summary
Provided is a three-dimensional shaped article with relatively high strength and relatively high accuracy. A sintering and shaping method includes: a shaping layer forming process of forming a shaping layer by using a sintering and shaping material in which inorganic particles are included; a process of applying a liquid binding agent, in which a thermoplastic resin and inorganic particles are included, to a desired region of the shaping layer; a process of curing the liquid binding agent, which is applied, to form a shaping cross-sectional layer (shaping portion); a process of removing a region (non-shaping portion) of the shaping layer to which the liquid binding agent is not applied; and a process of heating the shaping cross-sectional layer that is laminated for a sintering treatment.