3D Modeling Material Void Fraction Control for Warp Reduction
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Solution Overview
Problem
Resin formed articles produced by three-dimensional modeling materials, especially under high-temperature and high-humidity conditions, suffer from warp and surface roughness issues, even when using polylactic acid or ABS resins with alicyclic structure-containing polymers.
Innovation Solution
A three-dimensional modeling material with a void fraction of 10 vol % or lower, containing an alicyclic structure-containing polymer, is used, which is dried at a temperature range of (glass transition temperature - 30°C to glass transition temperature - 1°C) to produce resin formed articles with improved impact resistance and appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polylactic acid resin or ABS resin is used as three-dimensional modeling material, then the material is easy to process and cost-effective, but the resin formed article exhibits warp under high-temperature and high-humidity conditions
Solution Approach 1:
The patent uses a composite material system consisting of alicyclic structure-containing polymer as the base resin, combined with specific elastomers (polybutadiene, polyisoprene, or acrylic elastomer) as impact modifiers. This composite structure provides both processability and dimensional stability, resolving the contradiction between ease of manufacture and warp control under high-temperature and high-humidity conditions.
Solution Approach 2:
The patent specifies precise parameter ranges: elastomer content of 5-50 parts by weight per 100 parts of alicyclic structure-containing polymer, void fraction of 10 vol% or less, and specific glass transition temperature ranges. These parameter controls ensure the material maintains both processability and dimensional stability, preventing warp while remaining easy to process.
2Manufacturing precision
If alicyclic structure-containing polymer is used to reduce warp, then dimensional stability improves, but surface roughness increases
Solution Approach 1:
The patent applies local quality by differentiating the functions of different components: the alicyclic structure-containing polymer provides dimensional stability in the bulk material, while the specific elastomers (particularly polybutadiene or polyisoprene within 5-50 parts range) modify the surface properties to reduce roughness. This localized functional differentiation resolves the contradiction between dimensional stability and surface smoothness.
3Shape
If void fraction is reduced to 10 vol% or lower to improve appearance, then surface smoothness improves, but manufacturing complexity increases
Solution Approach 1:
The patent specifies a precise drying temperature parameter range of (Tg-30°C) to (Tg-1°C) where Tg is the glass transition temperature of the alicyclic structure-containing polymer. This parameter optimization achieves void fraction of 10 vol% or less while maintaining practical manufacturing complexity, as the temperature range is clearly defined and achievable with standard drying equipment.
4Strength
If elastomer content is increased to improve impact resistance, then toughness improves, but warp increases
Solution Approach 1:
The patent establishes a balanced parameter range for elastomer content of 5-50 parts by weight per 100 parts of alicyclic structure-containing polymer. Within this range, the material achieves sufficient impact resistance while maintaining warp control. The lower bound (5 parts) ensures adequate structural integrity, while the upper bound (50 parts) prevents excessive warp, optimizing the trade-off between impact resistance and dimensional stability.
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 approach results in resin formed articles with minimal warp, excellent impact resistance, and enhanced surface smoothness, as demonstrated by the low void fraction and specific polymer composition.
Implementation Method 1
a glass transition temperature (Tg) of 100° C. or higher
Implementation Method 2
a step of drying a production raw material containing the alicyclic structure-containing polymer at a temperature of (a glass transition temperature of the alicyclic structure-containing polymer—30° C.) to (a glass transition temperature of the alicyclic structure-containing polymer—1° C.)
Implementation Method 3
a thermoplastic resin is thermally molten, and a partial structure of each layer is formed on the basis of CAD data while extruding the resin from a nozzle
Data Source
AI summary
The present invention is a three-dimensional modeling material containing an alicyclic structure-containing polymer and having a void fraction of 10 vol % or lower, a method for producing the three-dimensional modeling material, and a resin formed article obtained by a thermal melting lamination method using the three-dimensional modeling material. Though the present invention, there are provided a three-dimensional modeling material capable of obtaining a resin formed article having little warp and excellent in impact resistance and appearance, a production method therefor, and a resin formed article formed by using the three-dimensional modeling material.