3D Printing Binder System Using Multifunctional Linkers
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Solution Overview
Problem
Existing three-dimensional printing techniques using liquid binders often fail to produce articles with sufficient strength and require excessive binder material, limiting their application in complex geometries and high-strength requirements.
Innovation Solution
A material system comprising a substantially dry particulate material with an insoluble filler, optionally a soluble filler and pigment, combined with a fluid binder material containing a multifunctional linker, which forms strong chemical bonds between particles using reactive sites or functional groups, reducing the need for excessive binder material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If liquid binder material is used in conventional three-dimensional printing techniques, then layering and bonding of particulate material is achieved, but the printed articles do not have sufficiently high strength
Solution Approach 1:
The patent changes the chemical parameters of the binder material by incorporating multifunctional linkers with specific functional groups (carboxyl, hydroxyl, amine, or isocyanate groups) that react with hydroxyl groups on silica particles to form strong covalent bonds. This chemical parameter change transforms the bonding mechanism from weak physical adhesion to strong chemical bonding, achieving the required strength and reliability.
Solution Approach 2:
The patent creates a composite binder material system combining multiple components: multifunctional linkers, silane-modified polysiloxane, and silane crosslinking agents. This composite formulation synergistically combines different bonding mechanisms (covalent bonding via linkers, crosslinking via polysiloxane) to achieve superior strength and reliability that neither component could provide alone.
2Quantity of substance
If conventional liquid binder materials are used, then bonding of particles is achieved, but relatively large amounts of binder material are required
Solution Approach 1:
The patent extracts and emphasizes the most effective bonding function from conventional binders by using multifunctional linkers that form strong covalent bonds with silica particles. This extraction of the essential bonding function allows for dramatically reduced binder quantity while maintaining or improving bond strength, as the remaining binder material is highly efficient at performing its bonding role.
Solution Approach 2:
The multifunctional linkers are designed with multiple reactive functional groups that can bond to multiple silica particles simultaneously, creating a universal bonding agent that performs multiple bonding functions with a single molecular structure. This multi-functionality reduces the total quantity of binder material needed compared to conventional monofunctional binders.
3Adaptability or versatility
If conventional liquid binder techniques are used, then layering process is simplified, but the number of liquid binder materials is limited
Solution Approach 1:
The patent develops a universal binder material formulation that can be adapted to different particulate materials and application requirements through the use of multifunctional linkers with various functional groups. This universal formulation maintains the simplicity of the layering process while providing versatility in material selection and performance tuning.
Solution Approach 2:
The patent enables versatility through parameter changes in the binder formulation, particularly adjusting the ratios of multifunctional linkers, silane-modified polysiloxane, and silane crosslinking agents. These parameter adjustments allow the same basic binder system to be optimized for different applications without requiring entirely different binder materials, thus maintaining process simplicity while increasing adaptability.
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 method achieves printed articles with superior mechanical properties, such as high flexural strength, while minimizing the use of binder material, allowing for complex geometries and tunable mechanical properties.
Implementation Method 1
The fluid binder material, in some cases, can comprise a multifunctional linker... the first and second functional groups can react with one another to form a covalent bond
Implementation Method 2
the soluble filler, when present, can also comprise a first functional group... the soluble filler is soluble in the fluid binder material
Data Source
AI summary
A method of printing a three dimensional article is provided wherein particles are bonded together with chemical bonds having a bond strength of at least 10 kJ/mol. In one aspect, kits for three dimensional printing are described herein. In some embodiments, a kit described herein comprises a substantially dry particulate material (20) comprising an insoluble filler having a first functional group on the surface of the insoluble filler; and a fluid binder material (26) comprising a multifunctional linker having a second functional group, wherein the insoluble filler is insoluble in the fluid binder material and wherein the first functional group and the second functional group can react with one another to form a covalent bond between the insoluble filler and the multi functional linker.