Sol-Gel Ceramic Precursor for Stereolithography Homogeneity
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Solution Overview
Problem
The dispersion of ceramic powders in composite materials using stereolithography is often difficult, leading to non-homogeneous distribution, and previous methods such as core/shell particles face limitations in coating submicrometer or micrometer particles, especially those with chemical nature like stabilized or unstabilized zirconia.
Innovation Solution
Incorporating a ceramic precursor in the sol-gel state into the photopolymerizable resin mixture, allowing for easier dispersion and higher loading of ceramic materials, up to 50% by volume, with the precursor acting as a coating on the ceramic powder particles, resulting in a homogeneous distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ceramic powder is mixed with photopolymerizable resin for stereolithography, then the ceramic object can be manufactured by SLA technology, but the dispersion of ceramic powder is difficult and the distribution is not homogeneous
Solution Approach 1:
The patent changes the physical state of the ceramic material from solid powder to sol-gel liquid form. This parameter change enables the ceramic precursor to be uniformly dispersed in the photopolymerizable resin, solving the homogeneity issue while maintaining ease of manufacture through liquid-state mixing.
Solution Approach 2:
The sol-gel acts as an intermediary form between solid ceramic powder and final ceramic structure. It serves as a liquid precursor that can be easily mixed with resin, then transforms into ceramic through photopolymerization and subsequent heat treatment, bridging the gap between processability and final material properties.
2Manufacturing precision
If core/shell particles are used to coat ceramic materials, then composite ceramics can be manufactured, but it is not easy to coat submicrometer or micrometer particles and certain particles do not lend themselves to surface treatment
Solution Approach 1:
The patent eliminates the need for physical coating processes by changing the ceramic material to sol-gel liquid form. The liquid precursor naturally distributes throughout the resin matrix without requiring complex coating equipment or processes, and without being limited by particle size or chemical nature constraints.
Solution Approach 2:
The patent extracts the coating step from the manufacturing process entirely. Instead of coating solid particles with another material, the sol-gel ceramic precursor is directly incorporated into the resin mixture, eliminating the separate coating operation and its associated complexities.
3Quantity of substance
If heavy loading of ceramic material (70 to 90% by weight) is used in the resin, then dense ceramic pieces can be obtained, but the dispersion and distribution become more difficult
Solution Approach 1:
The patent changes the ceramic material from solid powder to sol-gel liquid form, which fundamentally alters the mixing and dispersion characteristics. This parameter change enables high ceramic loading (up to 50% by volume) while maintaining homogeneous distribution, because the liquid precursor can be uniformly mixed with the resin before polymerization.
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 enables the production of homogeneous composite ceramics with improved densification and properties, overcoming the challenges of dispersion and distribution in stereolithography, suitable for a wide range of resin types and applications including medical and microelectronic components.
Implementation Method 1
uses the principle of photopolymerization to manufacture models in acrylate or epoxy resin
Implementation Method 2
containing photoinitiators sensitive to UV
Implementation Method 3
at least an effective quantity of a sol or gel of at least one precursor of a ceramic
Data Source
Figure 1
AI summary
The present invention relates to the field of manufacturing ceramic parts, particularly composite ceramics, using a 3D technique, notably stereolithography, and more specifically aims to provide a new composite ceramic mixture useful for this manufacturing method. This composition comprises, in addition to a ceramic powder, referred to as the first ceramic material, a photopolymerizable resin, a photoinitiator, and a dispersant, at least an effective amount of a sol or gel of at least one ceramic precursor, referred to as the second material, preferably distinct from the first ceramic material.