KR20170108305A - Fabrication method of ceramic mold or core using 3d printer and and slurry composition for 3d printer - Google Patents
Fabrication method of ceramic mold or core using 3d printer and and slurry composition for 3d printer Download PDFInfo
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- KR20170108305A KR20170108305A KR1020160031996A KR20160031996A KR20170108305A KR 20170108305 A KR20170108305 A KR 20170108305A KR 1020160031996 A KR1020160031996 A KR 1020160031996A KR 20160031996 A KR20160031996 A KR 20160031996A KR 20170108305 A KR20170108305 A KR 20170108305A
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- polymer
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- inorganic binder
- molded body
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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
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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
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
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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
- B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
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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
- B29C64/40—Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
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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
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Producing Shaped Articles From Materials (AREA)
Abstract
Description
The present invention relates to a ceramic slurry composition for a 3D printer using heterogeneous polymers, and to the development of a ceramic mold and a core process having an effective strength for producing a ceramic mold and a core using a 3D printing technique.
Presently, molds for precision casting used in the manufacture of various mechanical parts such as impellers, blades, and vanes are produced by a series of injection molding processes. However, these molding methods require a large amount of time and cost for manufacturing a mold, And it is difficult to produce patterns of complicated shapes when the pattern is implemented, and the lifetime of the molds is also limited by consumables.
Recently, due to the development of 3D printing technology, it is possible to manufacture precise and complicated parts with low cost and time easily without a separate mold manufacturing step. Accordingly, many researches and developments have been made on the 3D printer technology, and in particular, attempts have been made to improve the slurry composition so as to produce a high-quality molded product (Korean Patent No. 10-1551255). However, the materials used or developed in previous 3D printers have problems in that they can not manifest the molding and plastic strength of precision cast ceramic mold and core.
In order to solve the problems of the prior art, the present invention has developed a new binder and a manufacturing process for manufacturing a precision casting ceramic mold and a core using a 3D printing technique. Specifically, the binder to be used is first coated on the ceramic starting powder with one of the different kinds of binders having different molecular weights (physical properties) and / or dissolution characteristics (molecular and structural properties) After forming a formed body, one binder is removed to effectively coat an inorganic binder with the molded body to produce a ceramic mold and a core body having a high burning strength. In particular, the binder developed in the present invention is based on a polymer compound, and hereinafter, the binder is referred to as a polymer.
According to an aspect of the present invention, there is provided a method of manufacturing a semiconductor device, comprising: preparing a starting powder coated with a first polymer by coating a starting polymer powder or ceramic powder with a first polymer; Mixing the starting polymer coated with the first polymer and the second polymer to form a starting powder-first polymer-second polymer composite; Molding the composite into a 3D printer to form a formed body; Removing the first polymer from the molded body; Immersing the molded body from which the first polymer has been removed in an inorganic binder to coat an inorganic binder in the ceramic in the molded body; And thermally treating the molded article coated with the inorganic binder to vitrify the coated inorganic binder and removing the second polymer. The present invention also provides a method for manufacturing a ceramic mold or a core.
Another aspect of the present invention provides a ceramic mold or a ceramic body manufactured by a method of manufacturing a ceramic mold or a core according to an aspect of the present invention, wherein the inorganic binder is coated with ceramic.
According to another aspect of the present invention, there is provided a method for preparing a ceramic powder, comprising: preparing a starting powder coated with a first polymer by coating a ceramic powder with a first polymer; Mixing the starting polymer coated with the first polymer and the second polymer to form a starting powder-first polymer-second polymer composite; Molding the composite into a 3D printer to form a formed body; Removing the first polymer from the molded body; Immersing the molded body from which the first polymer has been removed in an inorganic binder to coat an inorganic binder in the ceramic in the molded body; And a step of heat treating the formed body coated with the inorganic binder to remove the second polymer.
Another aspect of the present invention provides a slurry composition for a 3D printer, which is produced by a method for producing a slurry composition for a 3D printer according to one aspect of the present invention, and comprises a ceramic coated with an inorganic binder.
It is possible to facilitate the production of the ceramic mold and the core using the 3D printer by using the binder of the heterogeneous polymer having different molecular weight and / or dissolution characteristics, and to improve the bonding force and strength of the ceramic mold and the core by effectively coating the inorganic binder . The present invention not only improves the molding strength by developing a new starting powder and a binder, but also improves the plasticity strength by efficiently introducing the inorganic binder into the produced molded article.
FIG. 1 schematically illustrates the production of a ceramic slurry composition according to an embodiment of the present invention and a process for manufacturing a ceramic mold and a core.
FIG. 2 is a schematic view showing the production of a ceramic slurry composition according to an embodiment of the present invention and a process for producing a ceramic mold and a core.
Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings, which will be readily apparent to those skilled in the art.
It should be understood, however, that the present invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. In order to clearly illustrate the present invention, parts not related to the description are omitted, and similar parts are denoted by like reference characters throughout the specification.
According to one aspect of the present invention, there is provided a method of manufacturing a semiconductor device, comprising: preparing a starting powder coated with a first polymer by coating a starting polymer powder or ceramic powder with a first polymer; Mixing the starting polymer coated with the first polymer and the second polymer to form a starting powder-first polymer-second polymer composite; Molding the composite into a 3D printer to form a formed body; Removing the first polymer from the molded body; Immersing the molded body from which the first polymer has been removed in an inorganic binder to coat an inorganic binder in the ceramic in the molded body; And thermally treating the molded article coated with the inorganic binder to vitrify the coated inorganic binder and removing the second polymer. The present invention also provides a method for manufacturing a ceramic mold or a core.
According to another aspect of the present invention, there is provided a method of manufacturing a semiconductor device, comprising: preparing a starting powder coated with a first polymer by coating a ceramic starting powder with a first polymer; Mixing the starting polymer coated with the first polymer and the second polymer to form a starting powder-first polymer-second polymer composite; Molding the composite into a 3D printer to form a formed body; Removing the first polymer from the molded body; Immersing the molded body from which the first polymer has been removed in an inorganic binder to coat an inorganic binder in the ceramic in the molded body; And thermally treating the molded article coated with the inorganic binder to vitrify the coated inorganic binder and removing the second polymer. The present invention also provides a method for producing a slurry composition for a 3D printer.
In one embodiment of the present invention, the step of removing the first polymer from the molded body may be performed by heating at a temperature higher than the boiling point of the first polymer. Alternatively, the step of removing the first polymer from the molded body may be performed by eluting the first polymer from the molded body in an aqueous solution, a nonaqueous solution, or a solvent.
In one embodiment of the present invention, the first polymer and the second polymer use different kinds of polymers having different molecular structural characteristics such as physical properties such as molecular weight and / or dissolution characteristics. For example, the first polymer may be a low molecular weight polymer and the second polymer may be a high molecular weight polymer, or the first polymer may be a water-soluble polymer and the second polymer may be a liposoluble polymer. Or the first polymer may be a lipid soluble polymer and the second polymer may be a water soluble polymer. The first polymer and the second polymer may each independently be selected from the group consisting of polyvinyl alcohol, polyethylene, polyglycol, polyolefin, polystyrene, polyester, polycarbonate, polyamide and combinations thereof can do.
In one embodiment of the present invention, in the starting powder-first polymer-second polymer composite, the surface of the starting powder may be coated with the starting powder-first polymer-second polymer in this order, have. For example, the first polymer may be formed by coating a second polymer on the surface and the interface of the starting powder coated with the first polymer.
In one embodiment of the invention, the inorganic binder includes a metal alkoxide, a silicate-based material, and combinations thereof. The metal alkoxide is represented by a general formula MOR, M is an alkali metal, R is hydrogen or an alkyl group, and specifically, one of methyl, ethyl, propyl, butyl, isopropyl, hexyl, 40 to 60% by weight is used.
The inorganic binder is impregnated with the inorganic binder by impregnation and coated on the starting powder after the removal of the first polymer in the molded body manufactured by the 3D printer so that the glassy material is uniformly distributed among the powders to increase the bonding force between the particles And thus the durability of the molded article can be improved.
In one embodiment of the invention, the starting powder is a metal selected from alumina, zirconia, silica, mullite, silicon carbide, titanium carbide, titanium oxide, titanium diboride, yttria, silicon nitride, titanium nitride, tungsten carbide and boron carbide Carbides, oxides, nitrides, sulfides, or mixtures thereof.
Hereinafter, a new binder using the 3D printer will be described with reference to FIGS. 1 and 2, and a new process for manufacturing a ceramic mold and a core will be described in detail.
FIG. 1 illustrates a process using a low molecular weight polymer as a first polymer and a high molecular weight polymer as a second polymer, and the first polymer is removed using the difference in boiling point of the polymer.
As a first polymer, a low molecular weight polymer is first coated on a starting powder to prepare a starting powder coated with a low molecular weight polymer. The starting powder coated with the low molecular weight polymer is then mixed with the high molecular weight polymer to form a complex. A molded article is prepared with a 3D printer using a starting powder / high molecular weight polymer composite coated with a low molecular weight polymer. Therefore, the molding strength of the starting powder is expressed by a high molecular weight polymer chain. The molded body is heated to a temperature above the boiling point of the low molecular weight polymer to remove the low molecular weight polymer and the molded body from which the low molecular weight polymer has been removed is immersed in an inorganic binder so that the inorganic binder is coated on the surface of the ceramic starting powder. After the heat treatment, the coated inorganic binder is vitrified and the high molecular weight polymer is removed to prepare a ceramic powder coated with an inorganic binder. Unlike the conventional 3D printing technique, the use of a different kind of polymer is intended to improve the plasticity strength by inserting an inorganic binder at the position of the polymer removed during the process so that the glass quality by the inorganic binder is effectively formed between the powders.
FIG. 2 is a view showing a process using a polymer (oil-soluble polymer and water-soluble polymer) having different solubility characteristics as a first polymer and a second polymer, and the first polymer is removed using difference in dissolution characteristics of the polymers. 2 shows the case where the first polymer is a water-soluble polymer and the case where the first polymer is a oil-soluble polymer. In the left part of the drawing, the first polymer is a water-soluble polymer, and the right part is a case where the first polymer is a liposoluble polymer.
First, the case where the first polymer is a water-soluble polymer will be described first. As a first polymer, a water-soluble polymer is first coated on a starting powder to prepare a starting powder coated with a water-soluble polymer. The starting powder coated with the water soluble polymer is then mixed with the liposoluble polymer to form a complex. A molded body is manufactured with a 3D printer using a starting powder / liposoluble polymer composite coated with a water-soluble polymer. Therefore, the molding strength of the starting powder is expressed by a fat-soluble polymer chain. The formed body is dissolved in an aqueous solution capable of dissolving the water-soluble polymer to remove the water-soluble polymer, and the formed body from which the water-soluble polymer is removed is immersed in an inorganic binder to coat the surface of the ceramic starting powder with an inorganic binder. After the heat treatment, the coated inorganic binder is vitrified, and the oil-soluble polymer is removed to prepare an inorganic binder-coated powder. Unlike the conventional 3D printing technique, the use of a different kind of polymer is intended to improve the plasticity strength by inserting an inorganic binder at the position of the polymer removed during the process so that the glass quality by the inorganic binder is effectively formed between the powders.
The first polymer is a liposoluble polymer. As a first polymer, a liposoluble polymer is first coated on a starting powder to prepare a starting powder coated with a liposoluble polymer. The starting powder coated with the oil-soluble polymer is then mixed with the water-soluble polymer to form a complex. A molded article is prepared with a 3D printer using a starting powder / water-soluble polymer composite coated with a liposoluble polymer. Therefore, the molding strength of the starting powder is expressed by the water-soluble polymer chain. Dissolving the oil-soluble polymer in a solvent capable of dissolving the oil-soluble polymer to remove the oil-soluble polymer, and immersing the molded body in which the oil-soluble polymer has been removed in an inorganic binder to coat the inorganic binder on the surface of the ceramic starting powder. Thereafter, the coated inorganic binder is vitrified by heat treatment, and the water-soluble polymer is removed to prepare an inorganic binder-coated powder. Unlike the conventional 3D printing technique, the use of a different kind of polymer is intended to improve the plasticity strength by inserting an inorganic binder at the position of the polymer removed during the process so that the glass quality by the inorganic binder is effectively formed between the powders.
Another aspect of the present invention provides a ceramic mold or a ceramic body manufactured by a method of manufacturing a ceramic mold or a core according to an aspect of the present invention, wherein the inorganic binder is coated with ceramic.
The ceramic mold or core has improved molding strength and plasticity strength as an inorganic binder is efficiently introduced into the formed body.
Another aspect of the present invention provides a slurry composition for a 3D printer, which is produced by a method for producing a slurry composition for a 3D printer according to one aspect of the present invention, and comprises a ceramic coated with an inorganic binder.
The scope of the present invention is defined by the appended claims rather than the detailed description, and all changes or modifications derived from the meaning and scope of the claims and their equivalents should be interpreted as being included in the scope of the present invention .
Claims (20)
Mixing the starting polymer coated with the first polymer and the second polymer to form a starting powder-first polymer-second polymer composite;
Molding the composite into a 3D printer to form a formed body;
Removing the first polymer from the molded body;
Immersing the molded body from which the first polymer has been removed in an inorganic binder to coat an inorganic binder in the ceramic in the molded body; And
Heat-treating the molded article coated with the inorganic binder to vitrify the coated inorganic binder and removing the second polymer;
Of the ceramic mold or core.
Wherein the step of removing the first polymer from the molded body is performed by heating at a temperature equal to or higher than the boiling point of the first polymer.
Wherein the step of removing the first polymer from the molded body is performed by eluting the first polymer from the molded body in an aqueous solution, a nonaqueous solution, or a solvent.
Wherein the first polymer and the second polymer are heterogeneous polymers having different physical and / or molecular structural characteristics from each other.
Wherein the starting powder surface is coated with a starting powder, a first polymer, and a second polymer in this order.
Wherein the first polymer and the second polymer each independently comprise a polymer selected from the group consisting of polyvinyl alcohol, polyethylene, polyglycol, polyolefin, polystyrene, polyester, polycarbonate, polyamide and combinations thereof , A method for producing a ceramic mold or core.
Wherein the inorganic binder is selected from the group consisting of metal alkoxides and silicate-based materials.
Wherein the inorganic binder is impregnated at a position where the first polymer is coated.
Wherein the starting powder of the core of the ceramic mold is selected from the group consisting of carbides of metals selected from alumina, zirconia, silica, mullite, silicon carbide, titanium carbide, titanium oxide, titanium diboride, yttria, silicon nitride, titanium nitride, tungsten carbide and boron carbide, Oxide, nitride, sulfide, or a mixture thereof.
Mixing the starting polymer coated with the first polymer and the second polymer to form a starting powder-first polymer-second polymer composite;
Molding the composite into a 3D printer to form a formed body;
Removing the first polymer from the molded body;
Immersing the molded body from which the first polymer has been removed in an inorganic binder to coat an inorganic binder in the ceramic in the molded body; And
Heat-treating the molded article coated with the inorganic binder to vitrify the coated inorganic binder and removing the second polymer;
≪ / RTI >
Wherein the step of removing the first polymer from the molded body is performed by heating at a temperature higher than the boiling point of the first polymer.
Wherein the step of removing the first polymer from the molded body is performed by eluting the first polymer from the molded body in an aqueous solution, a nonaqueous solution, or a solvent.
Wherein the first polymer and the second polymer are heterogeneous polymers having different physical and / or molecular structural characteristics from each other.
Wherein the surface of the starting powder is coated with a starting powder, a first polymer, and a second polymer in this order.
Wherein the first polymer and the second polymer each independently comprise a polymer selected from the group consisting of polyvinyl alcohol, polyethylene, polyglycol, polyolefin, polystyrene, polyester, polycarbonate, polyamide and combinations thereof , A method for producing a slurry composition for a 3D printer.
Wherein the inorganic binder is selected from the group consisting of a metal alkoxide and a silicate-based material.
Wherein the inorganic binder is impregnated in a position where the first polymer is coated.
Wherein the starting powder of the core of the ceramic mold is selected from the group consisting of carbides of metals selected from alumina, zirconia, silica, mullite, silicon carbide, titanium carbide, titanium oxide, titanium diboride, yttria, silicon nitride, titanium nitride, tungsten carbide and boron carbide, Oxide, nitride, sulfide, or a mixture thereof.
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| KR1020160031996A KR101806802B1 (en) | 2016-03-17 | 2016-03-17 | Fabrication method of ceramic mold or core using 3d printer and and slurry composition for 3d printer |
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| KR1020160031996A KR101806802B1 (en) | 2016-03-17 | 2016-03-17 | Fabrication method of ceramic mold or core using 3d printer and and slurry composition for 3d printer |
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| KR101806802B1 KR101806802B1 (en) | 2017-12-08 |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR101969335B1 (en) * | 2018-01-29 | 2019-08-13 | 주식회사 엠오피(M.O.P Co., Ltd.) | Method for manufacturing structure for mobile device by using 3d printing |
| KR20210080473A (en) * | 2018-11-29 | 2021-06-30 | 프라운호퍼-게젤샤프트 추르 푀르데룽 데어 안제반텐 포르슝 에 파우 | Thermally crosslinkable composition for use as a binder in a binder spraying process |
| US20220073432A1 (en) * | 2020-09-09 | 2022-03-10 | Lawrence Livermore National Security, Llc | Three-dimensional printing of ceramic materials |
| FR3125446A1 (en) | 2021-07-21 | 2023-01-27 | Safran | Process for producing a refractory preparation for the manufacture of a ceramic mould, preparation obtained by this process, process for manufacturing a ceramic mold and mold for a turbomachine blade obtained by this process |
Family Cites Families (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP3433219B2 (en) * | 1998-11-17 | 2003-08-04 | 独立行政法人産業技術総合研究所 | Manufacturing method of metal or ceramic products |
| JP6191076B2 (en) * | 2014-03-12 | 2017-09-06 | 三菱重工業株式会社 | MANUFACTURING METHOD FOR CORE, AND TURBINE MEMBER MANUFACTURING METHOD FOR OBTAINING CORE WITH MANUFACTURING METHOD |
-
2016
- 2016-03-17 KR KR1020160031996A patent/KR101806802B1/en active IP Right Grant
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR101969335B1 (en) * | 2018-01-29 | 2019-08-13 | 주식회사 엠오피(M.O.P Co., Ltd.) | Method for manufacturing structure for mobile device by using 3d printing |
| KR20210080473A (en) * | 2018-11-29 | 2021-06-30 | 프라운호퍼-게젤샤프트 추르 푀르데룽 데어 안제반텐 포르슝 에 파우 | Thermally crosslinkable composition for use as a binder in a binder spraying process |
| US20220073432A1 (en) * | 2020-09-09 | 2022-03-10 | Lawrence Livermore National Security, Llc | Three-dimensional printing of ceramic materials |
| US11858858B2 (en) * | 2020-09-09 | 2024-01-02 | Lawrence Livermore National Security, Llc | Three-dimensional printing of ceramic materials |
| FR3125446A1 (en) | 2021-07-21 | 2023-01-27 | Safran | Process for producing a refractory preparation for the manufacture of a ceramic mould, preparation obtained by this process, process for manufacturing a ceramic mold and mold for a turbomachine blade obtained by this process |
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|---|---|
| KR101806802B1 (en) | 2017-12-08 |
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