3D Printing Binder Chemistry for Strong Interlayer Particle Bonding

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Solution Overview

Problem

Current three-dimensional printing technologies face challenges in effectively bonding solid particles across layers, leading to incomplete or weak interlayer adhesion, which affects the structural integrity and stability of printed articles.

Innovation Solution

The use of a liquid binder comprising a 1,1-di-activated vinyl compound or its multifunctional form, which infiltrates between solid particles and reacts to solidify, forming a cross-linked binder that bonds both individual layers and stacks of layers together, enhancing interlayer adhesion and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional liquid binders are used in three-dimensional printing, then the printing process can be completed, but the interlayer adhesion is weak and structural integrity is compromised

Engineering Contradiction:

Improveinterlayer adhesionVSAvoidstructural integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent changes the chemical parameters of the binder by using 1,1-di-activated vinyl compounds instead of conventional binders. This chemical parameter change enables strong covalent bonding between layers, directly resolving the contradiction between weak interlayer adhesion and compromised structural integrity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite material system where the 1,1-di-activated vinyl compound binder combines with solid particles to form layers. The binder itself forms a cross-linked composite network that provides both strong adhesion and structural integrity, resolving the contradiction between these two properties.

Inventive Principle:

Principle #40Composite materials

2Strength

If conventional binders are used, then layer bonding can be achieved, but the bonding is incomplete and mechanical properties are reduced

Engineering Contradiction:

Improvebonding strengthVSAvoidbonding completeness

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent changes the reactivity parameters of the binder through the use of 1,1-di-activated vinyl compounds. The di-activated vinyl group provides high reactivity that ensures complete bonding across layers, resolving the contradiction between incomplete bonding and reduced mechanical properties.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces mechanical or physical bonding mechanisms with chemical bonding mechanisms. The 1,1-di-activated vinyl compound forms covalent bonds that are chemically stronger and more complete than conventional physical adhesion, resolving the contradiction between bonding strength and bonding completeness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If simple binders are used, then the printing process is simple, but complex geometries require additional support structures

Engineering Contradiction:

Improvesupport structure requirementVSAvoidgeometry complexity

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The patent uses the 1,1-di-activated vinyl compound to create a binder that forms a self-supporting composite structure. This composite material system provides inherent structural support that eliminates the need for additional support structures, resolving the contradiction between device complexity and geometry complexity.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The binder system provides self-support capabilities through its strong bonding and structural properties. The printed structure supports itself during and after printing without requiring external support structures, resolving the contradiction between simple printing processes and complex geometry capabilities.

Inventive Principle:

Principle #25Self-service

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 produces monolithic and integral three-dimensional articles with improved bonding between layers, resulting in enhanced mechanical properties, such as strength and stability, and allows for the creation of complex geometries without additional support structures.

Implementation Method 1

The 1,1-di-activated vinyl compound, or multifunctional form thereof, or combination thereof, is reacted to solidify the liquid binder and bind the solid particles in the first cross-sectional layer of the article

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Data Source

PatentUS20230211551A1Three-Dimensional Printing Processes Using 1,1-Di-Activated Vinyl Compounds

Publication Date: 2023.07.06 PPG INDUSTRIES OHIO INC

AI summary

A process for producing an article by three-dimensional printing includes applying a 1,1-di-activated vinyl compound-containing liquid binder over a predetermined area of a layer of solid particles. The liquid binder infiltrates gaps between the solid particles to form a first cross-sectional layer of an article, and the 1,1-di-activated vinyl compound reacts to solidify the liquid binder and bind the solid particles in the first cross-sectional layer of the article. Also provided is an article produced by the three-dimensional printing process, set forth herein.