Acrylate End-Capped Urethane Polymers for 2PP Resins
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Solution Overview
Problem
Current biodegradable resins for two-photon polymerization (2PP) applications lack biodegradability, accuracy, and shape fidelity, especially for complex structures, and require low writing speeds and high laser powers, which are not suitable for large-scale scaffold production and result in poor structure quality.
Innovation Solution
Development of acrylate end-capped urethane- or urea-based polymers with multiple photo-reactive end groups linked directly or via spacer groups, enabling fast crosslinking and processing at high writing speeds while maintaining biodegradability and shape fidelity, suitable for various technologies like 2PP, stereolithography, and electrospinning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If low molecular weight monomeric/oligomeric molecules are used for biodegradable 2PP resin, then biodegradability is achieved, but writing speed must be reduced and laser power increased, which is not favorable for large-scale production and increases burning risk
Solution Approach 1:
The patent changes the molecular weight parameter from low molecular weight (monomeric/oligomeric) to high molecular weight (macromolecular) compounds. This parameter change allows the resin to maintain biodegradability while enabling fast crosslinking at high writing speeds, thus resolving the contradiction between biodegradability and productivity
Solution Approach 2:
The patent uses composite macromolecular compounds with multiple photo-reactive end groups (acrylate, methacrylate, or vinyl groups) combined with biodegradable backbones (polyester, polyamide, polyether, polysaccharide, or polylactide). This composite structure provides both biodegradability and high crosslinking speed, resolving the contradiction
2Power
If high laser power is used to polymerize low molecular weight resins, then polymerization is achieved, but burning effect occurs and structure quality deteriorates
Solution Approach 1:
The patent changes the resin molecular weight parameter to high molecular weight macromolecular compounds with multiple photo-reactive end groups. This enables effective polymerization at lower laser powers and higher writing speeds, preventing burning effects and maintaining structure quality while still achieving complete polymerization
3Reliability
If current biodegradable resin formulations are used, then biodegradability is achieved, but CAD-CAM mimicry and shape fidelity are unsatisfactory
Solution Approach 1:
The patent employs composite macromolecular compounds with specific structural features: multiple photo-reactive end groups (acrylate, methacrylate, or vinyl) attached to biodegradable backbones. This composite structure provides both biodegradability and excellent CAD-CAM mimicry with high shape fidelity, resolving the contradiction between biodegradability and manufacturing precision
Solution Approach 2:
The patent introduces multiple photo-reactive end groups at the molecular level, creating local regions of high reactivity. This local quality enhancement enables fast and complete crosslinking, resulting in excellent CAD-CAM mimicry and shape fidelity while maintaining overall biodegradability of the polymer structure
4Productivity
If multiple photo-reactive end groups are introduced to enable fast crosslinking, then productivity is improved, but polymer structure complexity increases
Solution Approach 1:
The patent segments the polymer structure into distinct functional components: biodegradable backbone segments and photo-reactive end group segments. This segmentation allows independent optimization - the backbone provides biodegradability while the end groups provide fast crosslinking, achieving high productivity without excessive overall complexity
Solution Approach 2:
The patent creates multi-functional macromolecular compounds where the same molecule simultaneously provides biodegradability (through the backbone) and fast crosslinking (through multiple photo-reactive end groups). This multi-functionality resolves the contradiction by combining what would otherwise be separate functions into a single polymer structure
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 polymers provide biodegradability, fast and easy printing, excellent CAD-CAM mimicry, and tunable mechanical properties, enabling their use in multiple technologies and allowing for the creation of complex structures with high accuracy and stability.
Implementation Method 1
The photoreactive groups are linked to the backbone either directly or via means of (small) spacer groups, where the spacer groups enable flexibility of the chains and improve the reaction kinetics
Data Source
AI summary
The present invention in general relates to acrylate end-capped urethane-based polymers, which are in particular characterized by the presence of at least 3 acrylate end-groups, thereby making them particularly suitable for further processing using multiple kinds of technologies such as 2-photon polymerization, stereolithography (SLA printing), electrospinning, film casting, porogen leaching, extrusion based 3D-printing, spray drying, cryogenic treatment, coatings, cross-linkable micelles, spincoating, and electrospraying.