IT202100004769A1 - Optimized process for making a ceramic product and related system - Google Patents
Optimized process for making a ceramic product and related system Download PDFInfo
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- IT202100004769A1 IT202100004769A1 IT102021000004769A IT202100004769A IT202100004769A1 IT 202100004769 A1 IT202100004769 A1 IT 202100004769A1 IT 102021000004769 A IT102021000004769 A IT 102021000004769A IT 202100004769 A IT202100004769 A IT 202100004769A IT 202100004769 A1 IT202100004769 A1 IT 202100004769A1
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- 238000013386 optimize process Methods 0.000 title claims description 9
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- 239000011347 resin Substances 0.000 claims description 26
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- 238000007639 printing Methods 0.000 claims description 17
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
- B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
- B29C64/129—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/30—Auxiliary operations or equipment
- B29C64/307—Handling of material to be used in additive manufacturing
- B29C64/314—Preparation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
- B33Y40/10—Pre-treatment
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/62605—Treating the starting powders individually or as mixtures
- C04B35/62625—Wet mixtures
- C04B35/62635—Mixing details
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/62605—Treating the starting powders individually or as mixtures
- C04B35/6269—Curing of mixtures
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
- C04B35/632—Organic additives
- C04B35/634—Polymers
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
- C04B35/638—Removal thereof
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
- C04B2235/602—Making the green bodies or pre-forms by moulding
- C04B2235/6026—Computer aided shaping, e.g. rapid prototyping
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
- C04B2235/658—Atmosphere during thermal treatment
- C04B2235/6583—Oxygen containing atmosphere, e.g. with changing oxygen pressures
- C04B2235/6585—Oxygen containing atmosphere, e.g. with changing oxygen pressures at an oxygen percentage above that of air
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
- C04B2235/66—Specific sintering techniques, e.g. centrifugal sintering
- C04B2235/661—Multi-step sintering
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Ceramic Engineering (AREA)
- Structural Engineering (AREA)
- Inorganic Chemistry (AREA)
- Organic Chemistry (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Compositions Of Oxide Ceramics (AREA)
- Ceramic Products (AREA)
Description
Descrizione dell?Invenzione Industriale avente per titolo: Description of the Industrial Invention entitled:
?PROCEDIMENTO OTTIMIZZATO PER LA REALIZZAZIONE DI UN PRODOTTO CERAMICO E RELATIVO SISTEMA? ?OPTIMIZED PROCEDURE FOR THE CREATION OF A CERAMIC PRODUCT AND RELATED SYSTEM?
DESCRIZIONE DESCRIPTION
La presente invenzione si riferisce ad un procedimento di realizzazione di un prodotto ceramico, in particolare con tecnologie di stampa 3d. The present invention refers to a process for manufacturing a ceramic product, in particular with 3D printing technologies.
Altres? la presente invenzione si riferisce ad un sistema di attuazione del procedimento ottimizzato di realizzazione di un prodotto ceramico. Others? the present invention relates to a system for implementing the optimized process for manufacturing a ceramic product.
Sono noti metodi per la realizzazione di prodotti ceramici che comprendono molte fasi di sviluppo complicate e suscettibili di variazioni in funzione delle condizioni ambientali, in particolare ? nota la tecnica di creare un fango acquoso renderlo denso e sottoporlo poi a rullatura o ad altro tipo di formatura, successivamente il composto viene modellato per ottenere la forma geometrica desiderata e sottoposto poi ad essiccatura e cottura, che rendono la realizzazione di tali prodotti ceramici molto complessa con condizioni di processo e tecnologie richieste rigide ed efficienza di produzione scarsa, riducendo la possibilit? di realizzare tali prodotti ceramici a livello industriale. Are known methods for the production of ceramic products which include many complicated development phases and susceptible to variations according to the environmental conditions, in particular ? known is the technique of creating an aqueous mud, making it dense and then subjecting it to rolling or other type of forming, subsequently the compound is modeled to obtain the desired geometric shape and then subjected to drying and firing, which make the realization of these ceramic products very complex with rigid process conditions and required technologies and poor production efficiency, reducing the possibility? to make these ceramic products on an industrial level.
Sono noti i seguenti processi per la realizzazione di prodotti ceramici: The following processes for the production of ceramic products are known:
- Ceramic Injection Moulding (CIM) ? un processo di stampaggio mediante l?utilizzo di uno stampo metallico, pertanto ? necessario attendere i tempi di preparazione dello stampo, e non ? possibile effettuare rapidamente modifiche alla geometria del prodotto ceramico finale; - Ceramic Injection Molding (CIM) ? a molding process through the use of a metal mold, therefore ? necessary to wait for the preparation times of the mold, and not ? possible to quickly make changes to the geometry of the final ceramic product;
- Additive Manufacturing (AM) ? un processo di stampaggio a strati, dotato di una maggiore velocit? di esecuzione e di flessibilit? di processo rispetto al metodo precedente, ma pu? indurre problemi di sedimentazione nel prodotto ceramico finale inducendo una stratificazione ed una disomogeneit? che creano fragilit? strutturale nel prodotto ceramico finale o non offre un?elevata precisione dimensionale e una buona finitura superficiale del prodotto ceramico o non permette di utilizzare polveri ceramiche differenti. - Additive Manufacturing (AM) ? a layered molding process, featuring increased speed? of execution and flexibility? process compared to the previous method, but pu? induce sedimentation problems in the final ceramic product by inducing stratification and inhomogeneity? that create fragility? structure in the final ceramic product or does not offer high dimensional accuracy and a good surface finish of the ceramic product or does not allow the use of different ceramic powders.
E? noto che tali tecniche AM per la realizzazione di prodotti ceramici utilizzano principalmente tre tecnologie: AND? it is known that these AM techniques for the production of ceramic products mainly use three technologies:
- Binder Jetting (BJ): consiste nel depositare, alternandoli, uno strato di polvere ceramica e uno di legante polimerico, da eliminare in seguito a trattamento termico, ? un metodo molto veloce ma non offre un?elevata precisione dimensionale e una buona finitura superficiale del prodotto ceramico e non permette di utilizzare polveri ceramiche differenti; - Fused Deposition Modeling (FDM): consiste nel depositare un filamento polimerico drogato con particelle ceramiche e successivamente eliminare la parte polimerica attraverso un trattamento termico, tale metodo sebbene molto rapido, non consente un?elevata precisione dimensionale e una buona finitura superficiale dei manufatti realizzati. - Binder Jetting (BJ): consists of depositing, alternating them, a layer of ceramic powder and a layer of polymeric binder, to be eliminated following heat treatment, ? a very fast method but does not offer high dimensional accuracy and a good surface finish of the ceramic product and does not allow the use of different ceramic powders; - Fused Deposition Modeling (FDM): consists in depositing a polymeric filament doped with ceramic particles and subsequently eliminating the polymeric part through a heat treatment, this method although very rapid, does not allow high dimensional accuracy and a good surface finish of the manufactured articles .
- Stereolitografia (SLA): questo metodo consiste nella realizzazione di uno strato di particelle ceramiche in sospensione in una resina polimerica che impressionata da un fascio luminoso indurisce, e la successiva rimozione della parte polimerica in seguito a trattamento termico, tale metodo ? quello che consente la migliore finitura superficiale e precisione dimensionale dei prodotti ceramici ma pu? indurre problemi di sedimentazione nel prodotto ceramico finale inducendo una stratificazione ed una disomogeneit? che creano fragilit? strutturale nel prodotto ceramico finale. - Stereolithography (SLA): this method consists in the creation of a layer of ceramic particles suspended in a polymeric resin which hardens when impressed by a light beam, and the subsequent removal of the polymeric part following heat treatment, this method? what allows the best surface finish and dimensional accuracy of ceramic products but can? induce sedimentation problems in the final ceramic product by inducing stratification and inhomogeneity? that create fragility? structure in the final ceramic product.
E? evidente come i procedimenti noti non permettano l?implementazione e la realizzazione di prodotti ceramici, di elevate caratteristiche fisiche e dimensionali ad un costo contenuto, in tempi rapidi e con un?elevata resa in termini di resistenza, densit? e ripetibilit? del prodotto ceramico, permettendo di fornire la realizzazione di prodotti ceramici anche in scala industriale. AND? it is evident that the known processes do not allow the implementation and the realization of ceramic products, with high physical and dimensional characteristics, at a contained cost, in rapid times and with a high yield in terms of resistance, density? and repeatability? of the ceramic product, allowing to provide the realization of ceramic products also on an industrial scale.
Scopo della presente invenzione ? quello di risolvere i suddetti problemi della tecnica anteriore fornendo un procedimento ottimizzato di realizzazione di un prodotto ceramico di elevata precisione dimensionale. Purpose of the present invention? that of solving the aforesaid problems of the prior art by providing an optimized process for manufacturing a ceramic product with high dimensional accuracy.
Un altro scopo della presente invenzione ? quello di fornire un procedimento ottimizzato in grado di fornire un prodotto ceramico, denso, con bassa rugosit? e con elevate caratteristiche dimensionali e fisiche. Another object of the present invention ? to provide an optimized process capable of providing a ceramic product, dense, with low roughness? and with high dimensional and physical characteristics.
Un ultimo scopo ? quello di fornire un sistema di attuazione del procedimento ottimizzato di realizzazione del prodotto ceramico. One last goal? that of providing a system for implementing the optimized process for manufacturing the ceramic product.
I suddetti ed altri scopi e vantaggi dell?invenzione, quali risulteranno dal seguito della descrizione, vengono raggiunti con un procedimento ottimizzato di realizzazione di un prodotto ceramico come quello descritto nella rivendicazione 1. Altres? i suddetti ed altri scopi e vantaggi dell?invenzione, quali risulteranno dal seguito della descrizione, vengono raggiunti con un sistema di attuazione come descritto nella rivendicazione 3. Forme di realizzazione preferite e varianti non banali della presente invenzione formano l?oggetto delle rivendicazioni dipendenti. The aforesaid and other objects and advantages of the invention, as will appear from the following description, are achieved with an optimized process for manufacturing a ceramic product such as that described in claim 1. the above and other objects and advantages of the invention, as will appear from the following description, are achieved with an actuation system as described in claim 3. Preferred embodiments and non-trivial variants of the present invention form the object of the dependent claims.
Resta inteso che tutte le rivendicazioni allegate formano parte integrante della presente descrizione. It is understood that all the attached claims form an integral part of the present description.
Risulter? immediatamente ovvio che si potranno apportare a quanto descritto innumerevoli varianti e modifiche (per esempio relative a forma, dimensioni, disposizioni e parti con funzionalit? equivalenti) senza discostarsi dal campo di protezione dell'invenzione come appare dalle rivendicazioni allegate. will result? it is immediately obvious that innumerable variations and modifications may be made to what has been described (for example relating to shape, dimensions, arrangements and parts with equivalent functions) without departing from the scope of protection of the invention as appears from the attached claims.
La presente invenzione verr? meglio descritta da alcune forme preferite di realizzazione, fornite a titolo esemplificativo e non limitativo, con riferimento ai disegni allegati, nei quali: This invention will come better described by some preferred embodiments, provided by way of non-limiting example, with reference to the attached drawings, in which:
- la FIG. 1 mostra una vista in sezione di una realizzazione preferita di un primo componente del sistema secondo la presente invenzione; - FIG. 1 shows a sectional view of a preferred embodiment of a first component of the system according to the present invention;
- la FIG.2 mostra una vista in sezione di una realizzazione preferita di un secondo componente del sistema secondo la presente invenzione; e - FIG.2 shows a sectional view of a preferred embodiment of a second component of the system according to the present invention; And
- la FIG.3 mostra una vista tridimensionale di una seconda realizzazione del secondo componente del sistema secondo la presente invenzione. - FIG.3 shows a three-dimensional view of a second embodiment of the second component of the system according to the present invention.
Come noto l?utilizzo di tecniche di produzione additive di tipo SLA per la realizzazione dei componenti ceramici, permette sia la libert? della forma che una velocit? di processo dell?ordine di poche ore, ma presenta problemi di sedimentazione della componente ceramica, provocando nel prodotto ceramico finale una stratificazione ed una disomogeneit? che creano fragilit? strutturale nel prodotto ceramico finale, di conseguenza ? descritto, facendo riferimento alla FIGG. 1,2, un procedimento ottimizzato secondo la presente invenzione, progettato per la realizzazione di un prodotto ceramico di elevata precisione dimensionale, denso con bassa rugosit?, con elevate caratteristiche dimensionali e fisiche, anche a livello industriale, mediante un sistema di attuazione, vantaggiosamente dotato di: As known, the use of additive manufacturing techniques of the SLA type for the production of ceramic components allows both freedom of the form that a speed? of the order of a few hours, but presents problems of sedimentation of the ceramic component, causing stratification and inhomogeneity in the final ceramic product? that create fragility? structure in the final ceramic product, consequently ? described, with reference to FIGS. 1,2, an optimized process according to the present invention, designed for the production of a ceramic product of high dimensional precision, dense with low roughness, with high dimensional and physical characteristics, even at an industrial level, by means of an actuation system, advantageously with:
- almeno un dispositivo di miscelazione 1 progettato per la preparazione ottimale di una resina ceramica 3 mescolando un legante polimerico 13 con una pluralit? di polveri ceramiche 2; ed - almeno un dispositivo di stampa 10 stereolitografica progettato per ottenere, dalla resina ceramica 3 ottenuta mediante il dispositivo di miscelazione 1, un prodotto ceramico. - at least one mixing device 1 designed for optimal preparation of a ceramic resin 3 by mixing a polymeric binder 13 with a plurality of? of ceramic powders 2; and - at least one stereolithographic printing device 10 designed to obtain, from the ceramic resin 3 obtained by means of the mixing device 1, a ceramic product.
Vantaggiosamente, come mostrato in FIG.1 il dispositivo di miscelazione 1 ? dotato di: Advantageously, as shown in FIG.1, the mixing device 1 is with:
- un primo elemento setaccio 4, preferibilmente con una maglia retinica pari a 50?, progettato per favorire una filtrazione granulometrica della pluralit? di polveri ceramiche 2, disposto sulla superficie superiore del dispositivo di miscelazione 1 progettato per favorire una selezione della pluralit? di polveri ceramiche 2 e per permettere il passaggio per caduta libera in un elemento contenitore 6 della pluralit? di polveri ceramiche 2 avente dimensioni inferiori a quelle della maglia retinica del primo elemento setaccio 4; - a first sieve element 4, preferably with a retinal mesh equal to 50?, designed to favor granulometric filtration of the plurality? of ceramic powders 2, arranged on the upper surface of the mixing device 1 designed to favor a selection of the plurality? of ceramic powders 2 and to allow the passage by free fall into a container element 6 of the plurality of ceramic powders 2 having dimensions smaller than those of the retinal mesh of the first sieve element 4;
- un secondo elemento setaccio 5, preferibilmente con una maglia pari a 5?, progettato per favorire una filtrazione granulometrica della pluralit? di polveri ceramiche 2, disposto sulla superficie superiore del dispositivo di miscelazione 1 progettato per favorire una selezione della pluralit? di polveri ceramiche 2 e per permettere il passaggio per caduta libera nell?elemento contenitore 6 della pluralit? di polveri ceramiche 2 avente dimensioni inferiori a quelle della maglia retinica del secondo elemento setaccio 5; - a second sieve element 5, preferably with a mesh equal to 5?, designed to favor granulometric filtration of the plurality? of ceramic powders 2, arranged on the upper surface of the mixing device 1 designed to favor a selection of the plurality? of ceramic powders 2 and to allow the passage by free fall into the container element 6 of the plurality of ceramic powders 2 having dimensions smaller than those of the retinal mesh of the second sieve element 5;
- almeno un elemento miscelatore 7 quale, ad esempio una frusta miscelatrice, o altra analoga, posizionato all?interno dell?elemento contenitore 6 progettato per miscelare meccanicamente il legante polimerico 13 con la pluralit? di polveri ceramiche 2 filtrata dai due o pi? elementi setaccio 4 e 5; - almeno un elemento termico 8, disposto nell?elemento contenitore 6 progettato per fornire al dispositivo di miscelazione 1 energia termica con un valore di temperatura controllata costante, ad esempio 25?C, conferendo fluidit? alla resina ceramica 3 ottenuta evitandone il deterioramento per effetto della temperatura; ed infine - at least one mixing element 7 such as, for example a mixing whisk, or the like, positioned inside the container element 6 designed to mechanically mix the polymeric binder 13 with the plurality? of ceramic dust 2 filtered by the two or more? sieve elements 4 and 5; - at least one thermal element 8, arranged in the container element 6 designed to supply the mixing device 1 with thermal energy with a constant controlled temperature value, for example 25°C, thus conferring fluidity? to the ceramic resin 3 obtained by avoiding its deterioration due to the effect of the temperature; and finally
- l?elemento contenitore 6 quale, ad esempio un recipiente cilindrico, o altra analogo, dotato dell?elemento termico 8, dei due o pi? elementi di setaccio 4 e 5, dell?elemento miscelatore 7, progettato per ospitare al suo interno il legante polimerico 13 e la pluralit? di polveri ceramiche 2 filtrata dai due o pi? elementi setaccio 4 e 5. - the container element 6 which, for example a cylindrical container, or another similar one, equipped with the thermal element 8, of the two or more? sieve elements 4 and 5, of the mixing element 7, designed to house the polymeric binder 13 inside it and the plurality? of ceramic dust 2 filtered by the two or more? sieve elements 4 and 5.
In particolare il dispositivo di stampa 10 ? dotato di: In particular the printing device 10 ? with:
- almeno un elemento proiettore 14, ad esempio un laser o altro analogo, progettato per generare un fascio luminoso 11 in grado di irradiare dal basso la resina ceramica 3 disposta sulla superficie superiore di una piattaforma 9 per un intervallo di tempo predefinito, polimerizzando la resina ceramica 3 e di conseguenza indurendola; - at least one projector element 14, for example a laser or the like, designed to generate a light beam 11 capable of irradiating the ceramic resin 3 arranged on the upper surface of a platform 9 from below for a predefined time interval, polymerizing the resin ceramic 3 and consequently hardening it;
- la piattaforma 9, permeabile al fascio luminoso 11 prodotta dall?elemento proiettore 14 disposto inferiormente alla piattaforma 9, e progettata per favorire la disposizione della resina ceramica 3 ottenuta mediante il dispositivo di miscelazione 1; - almeno una piattaforma di stampa 12 mobile, progettata per muoversi verticalmente in entrambe le direzioni lungo un asse perpendicolare alla piattaforma 9, progettata per produrre una pluralit? di strati che daranno forma al prodotto ceramico finale; ed eventualmente - the platform 9, permeable to the light beam 11 produced by the projector element 14 arranged below the platform 9, and designed to facilitate the arrangement of the ceramic resin 3 obtained by means of the mixing device 1; - at least one movable printing platform 12, designed to move vertically in both directions along an axis perpendicular to the platform 9, designed to produce a plurality of of layers that will give shape to the final ceramic product; and eventually
- un elemento spatola 15, progettato per favorire un posizionamento corretto della resina ceramica 3 durante il procedimento di realizzazione del prodotto ceramico, favorendone la distensione e l?adesione tra la pluralit? di strati che daranno forma al prodotto ceramico. - a spatula element 15, designed to favor correct positioning of the ceramic resin 3 during the manufacturing process of the ceramic product, favoring its distension and adhesion between the plurality of? of layers that will give shape to the ceramic product.
Vantaggiosamente il procedimento ottimizzato per la realizzazione del prodotto ceramico comprende le fasi di: Advantageously, the optimized process for manufacturing the ceramic product comprises the steps of:
- predisposizione del sistema di attuazione del procedimento e inserimento del legante ceramico 13 all?interno dell?elemento contenitore 6; - preparation of the process actuation system and insertion of the ceramic binder 13 inside the container element 6;
- attivazione dell?elemento termico 8 ad un valore di temperatura tale da favorire la fluidificazione del legante ceramico 13 senza deteriorarlo; - activation of the thermal element 8 at a temperature value such as to favor the fluidification of the ceramic binder 13 without deteriorating it;
- attivazione del dispositivo di miscelazione 1, e selezione ed inserimento graduale della pluralit? di polveri ceramiche 2 all?interno dell?elemento contenitore 6; - activation of the mixing device 1, and selection and gradual insertion of the plurality? of ceramic powders 2 inside the container element 6;
- attivazione dell?elemento miscelatore 7, e miscelazione, con un valore di velocit? controllata, del legante polimerico 13 con la pluralit? di polveri ceramiche 2 all?interno dell?elemento contenitore 6; - ottenimento della resina ceramica 3 e posizionamento della resina ceramica 3 sulla superficie della piattaforma 9; - activation of the mixer element 7, and mixing, with a speed value? controlled, of the polymeric binder 13 with the plurality? of ceramic powders 2 inside the container element 6; - obtaining the ceramic resin 3 and placing the ceramic resin 3 on the surface of the platform 9;
- predisposizione del dispositivo di stampa 10, scelta di una pluralit? di supporti di stampa, e definizione di una pluralit? di parametri di stampa in particolare: lo spessore di ciascuno della pluralit? di strati che daranno forma al prodotto ceramico finale; il tempo di esposizione della resina ceramica 3 al fascio luminoso 11 dell?elemento proiettore 14; - preparation of the printing device 10, choice of a plurality? of print media, and definition of a plurality? of printing parameters in particular: the thickness of each of the plurality? of layers that will give shape to the final ceramic product; the exposure time of the ceramic resin 3 to the light beam 11 of the projector element 14;
- attivazione dell?elemento proiettore 14, ed esposizione della resina ceramica 3 al fascio luminoso 11 emesso dall?elemento proiettore 14; - activation of the projector element 14, and exposure of the ceramic resin 3 to the light beam 11 emitted by the projector element 14;
- attivazione della piattaforma di stampa 12 e formazione di un primo strato; - activation of the printing platform 12 and formation of a first layer;
- reiterazione della fase precedente, con la relativa formazione della pluralit? di strati reciprocamente adesi; e - recurrence of the previous phase, with the relative formation of the plurality? of mutually adherent layers; And
- formazione del prodotto ceramico finale. - formation of the final ceramic product.
Infine in seguito alla formazione del prodotto ceramico: Finally, following the formation of the ceramic product:
- estrazione manuale del prodotto ceramico dalla piattaforma di stampa 12; - manual extraction of the ceramic product from the printing platform 12;
- pulizia del prodotto dalla resina ceramica 3 eccedente: mediante l?utilizzo di aria compressa e di un solvente che non attacchi chimicamente il prodotto ceramico; - cleaning the product from the excess ceramic resin 3: by using compressed air and a solvent which does not chemically attack the ceramic product;
- eliminazione dei supporti di stampa mediante strumenti manuali a lama, o un micromotore elettrico, o un micromotore alimentato ad aria compressa, o altro analogo; - removal of the print media using manual blade tools, or an electric micromotor, or a micromotor powered by compressed air, or the like;
- rimozione del legante polimerico 13, mediante inserimento del prodotto ceramico in un forno ad ossigeno ad una temperatura di 400? per circa 14 ore; - removal of the polymeric binder 13, by placing the ceramic product in an oxygen oven at a temperature of 400? for about 14 hours;
- sinterizzazione del prodotto ceramico nel forno ad ossigeno a bassa temperatura (<800?C) per circa 2h e ad alta temperatura (<1400 ?C) per le successive 2h; e - sintering of the ceramic product in the oxygen furnace at low temperature (<800?C) for about 2h and at high temperature (<1400?C) for the following 2h; And
- raffreddamento ed estrazione dal forno del prodotto ceramico dopo circa 24 ore. - cooling and extraction of the ceramic product from the kiln after approximately 24 hours.
Di seguito ? descritto un esempio sperimentale di esecuzione del procedimento secondo la presente invenzione: Right away ? described an experimental example of execution of the process according to the present invention:
- il legante polimerico ? costituito da: - the polymeric binder ? consisting of:
50% di acrilato a bassa viscosit? ed eccellente reattivit? di reticolazione; 50% low viscosity acrylate and excellent responsiveness crosslinking;
24% di acrilato di uretano utilizzato come diluente reattivo; 24% urethane acrylate used as a reactive thinner;
23,4% di diluente reattivo iniziatore di polimerizzazione foto-inducibile, per ridurre l?indurimento della resina ceramica; 23.4% photo-inducible polymerization initiator reactive diluent, to reduce the hardening of the ceramic resin;
0,8% di catalizzatore; e 0.8% catalyst; And
1,8% di foto-iniziatore a base di ossido di monoacilfosfina, che assorbe la luce nell?ultravioletto (250-550 nm) generando radicali liberi che reagiscono con i monomeri favorendo la polimerizzazione. 1.8% photo-initiator based on monoacylphosphine oxide, which absorbs ultraviolet light (250-550 nm) generating free radicals which react with the monomers favoring polymerization.
- la pluralit? di polveri ceramiche: - the plurality? of ceramic powders:
30% wt di polvere a granulometria fine (> 5?); e 30% wt of fine particle size powder (> 5?); And
70% wt di polvere a granulometria grossolana (< 50?) Di conseguenza il fattore di riempimento del legante polimerico con le polveri ceramiche ? rispettivamente 50% vol.e 50% vol., permettendo un?accuratezza dimensionale del prodotto ceramico finale. 70% wt of coarse grained powder (< 50?) Consequently, the fill factor of the polymeric binder with ceramic powders? respectively 50% vol. and 50% vol., allowing a dimensional accuracy of the final ceramic product.
Il procedimento di realizzazione del prodotto ceramico prevede: The manufacturing process of the ceramic product includes:
- attivazione dell?elemento termico ad una temperatura di 25 ?C funzionale a fluidificare la resina polimerica senza deteriorarla per effetto della temperatura; - activation of the thermal element at a temperature of 25 ?C functional to fluidify the polymeric resin without deteriorating it due to the effect of the temperature;
- attivazione del dispositivo di miscelazione e dell?elemento miscelatore con un velocit? pari al 50% della velocit? massima durante la fase di inserimento della pluralit? di polveri e alla velocit? massima durante il completamente di tale fase per 30 minuti; successivamente la miscelazione prosegue ad una velocit? pari al 10% della velocit? massima per 10 minuti ogni ora che staziona nell?elemento contenitore, contribuendo ad ottenere un prodotto ceramico finale omogeneo e denso; - activation of the mixing device and the mixing element with one speed? equal to 50% of the speed? maximum during the phase of insertion of the plurality? of dust and at the speed? maximum during the completion of this phase for 30 minutes; then the mixing continues at a speed? equal to 10% of the speed? maximum for 10 minutes every hour that it stays in the container element, helping to obtain a homogeneous and dense final ceramic product;
- attivazione dell?elemento proiettore, ed esposizione della resina ceramica al fascio luminoso emesso dall?elemento proiettore con una lunghezza d?onda di 405 nm per un tempo di 5s per un numero di strati pari al 10% dell?altezza complessiva del prodotto ceramico finale, e di 3s per tutti i successivi strati, velocizzando il procedimento; - attivazione della piattaforma di stampa e formazione di un primo strato con uno spessore di 50 ?, permettendo di ottenere una bassa rugosit? del prodotto ceramico finale. Inoltre per evitare tempi di stampa troppo lunghi pur garantendo un ottimo prodotto ceramico finale ? stato impostato un tempo di riposo per la piattaforma di stampa tra la formazione di uno strato e il successivo pari a 4 s. - activation of the projector element, and exposure of the ceramic resin to the light beam emitted by the projector element with a wavelength of 405 nm for a time of 5s for a number of layers equal to 10% of the overall height of the ceramic product final, and 3s for all subsequent layers, speeding up the process; - activation of the printing platform and formation of a first layer with a thickness of 50?, allowing to obtain a low roughness? of the final ceramic product. Furthermore, to avoid excessively long printing times while guaranteeing an excellent final ceramic product? a rest time has been set for the printing platform between the formation of one layer and the next equal to 4 s.
La presente invenzione presenta i seguenti vantaggi: The present invention has the following advantages:
- incremento della velocit? di esecuzione, individuando un valore dello spessore dello strato ottenendo contemporaneamente una buona precisione dimensionale ed un tempo di esecuzione relativamente contenuto; - speed increase? of execution, identifying a value of the thickness of the layer obtaining at the same time a good dimensional precision and a relatively limited execution time;
- ripetibilit? del procedimento, individuando i parametri di processo che influenzavano le variazioni costruttive tra le versioni finali del medesimo prodotto ceramico, correggendoli per garantire la ripetibilit? del prodotto ceramico finale; - repeatability of the procedure, identifying the process parameters that influenced the constructive variations between the final versions of the same ceramic product, correcting them to ensure repeatability? of the final ceramic product;
- accuratezza dimensionale, individuando un fattore di restringimento del prodotto finale, dovuto alla perdita della parte polimerica durante il trattamento termico, assicurando una tolleranza dimensionale finale idonea; - dimensional accuracy, identifying a shrinkage factor of the final product, due to the loss of the polymeric part during the heat treatment, ensuring a suitable final dimensional tolerance;
- ottimizzazione della rugosit? della superficie interna del prodotto finale; - optimization of roughness? of the internal surface of the final product;
- versatilit? ed ottenimento di varie tipologie di prodotti ceramici con lo stesso sistema modificando solo la tipologia di polveri ceramiche utilizzate. - versatility and obtaining various types of ceramic products with the same system by changing only the type of ceramic powders used.
Si sono descritte alcune forme preferite di attuazione dell?invenzione, ma naturalmente esse sono suscettibili di ulteriori modifiche e varianti nell?ambito della medesima idea inventiva. In particolare, agli esperti nel ramo risulteranno immediatamente evidenti numerose varianti e modifiche, funzionalmente equivalenti alle precedenti, che ricadono nel campo di protezione dell'invenzione come evidenziato nelle rivendicazioni allegate. Some preferred embodiments of the invention have been described, but naturally they are susceptible to further modifications and variations within the scope of the same inventive idea. In particular, numerous variants and modifications, functionally equivalent to the previous ones, which fall within the scope of protection of the invention as highlighted in the attached claims, will be immediately evident to those skilled in the art.
Claims (5)
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|---|---|---|---|---|
| US20180057414A1 (en) * | 2016-08-30 | 2018-03-01 | General Electric Company | Light-curable ceramic slurries with hybrid binders |
| WO2019241731A1 (en) * | 2018-06-15 | 2019-12-19 | Base Se | Ceramic photoresin formulation |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| US20180057414A1 (en) * | 2016-08-30 | 2018-03-01 | General Electric Company | Light-curable ceramic slurries with hybrid binders |
| WO2019241731A1 (en) * | 2018-06-15 | 2019-12-19 | Base Se | Ceramic photoresin formulation |
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