Cyanate Ester Inkjet Formulation for Thermal Stability
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Solution Overview
Problem
Current 3D inkjet printing technologies face limitations in using thermally-curable cyanate esters due to high viscosity at printing temperatures, instability, and slow curing kinetics, which restrict their compatibility with PolyJet™ methodology.
Innovation Solution
A formulation system comprising a thermally-curable cyanate ester and an activating agent that promotes polymerization upon thermal curing, designed to meet the viscosity, surface tension, and reactivity requirements of 3D inkjet printing, while providing objects with high thermal stability and improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermally-curable cyanate esters are used as building material, then thermal stability of the printed object is improved, but viscosity at printing temperature increases making jetting difficult
Solution Approach 1:
The curing process is segmented into two distinct stages: UV curing during printing and thermal curing after printing. This segmentation allows the material to be jetted in uncured state and then cured progressively, resolving the contradiction between maintaining low viscosity for jetting and achieving high thermal stability through complete curing.
Solution Approach 2:
UV curing is applied preliminarily during the printing process to provide initial stabilization and green strength, enabling the uncured cyanate ester to be jetted successfully. This preliminary action allows subsequent thermal curing to achieve full thermal stability without compromising printability.
2Temperature
If thermally-curable cyanate esters are used, then thermal stability is improved, but curing kinetics become slow reducing productivity
Solution Approach 1:
Two curing mechanisms (UV and thermal) are merged into a dual-cure system. UV curing provides rapid initial setting during printing, while thermal curing completes the polymerization afterward. This combination achieves both high thermal stability and maintains productivity by not relying solely on slow thermal curing kinetics.
Solution Approach 2:
The curing action continues in two phases: UV curing acts continuously during the printing process, and thermal curing continues after printing. This continuous useful action ensures complete curing and maximum thermal stability without interrupting the printing workflow, maintaining productivity.
3Temperature
If thermally-curable cyanate esters are used, then thermal stability is improved, but formulation stability during storage and jetting deteriorates
Solution Approach 1:
The curing reaction is segmented and delayed: UV initiators and thermal curing agents are kept separate or in dormant states during storage and jetting, preventing premature curing. The actual curing is activated only when needed - UV during printing and thermal afterward - thus maintaining formulation stability while achieving thermal stability.
Solution Approach 2:
UV curing acts as an intermediary step that stabilizes the uncured cyanate ester formulation during printing without triggering full thermal curing. This intermediary UV curing allows the material to remain jettable while providing enough initial structure to prevent formulation instability, with complete thermal stability achieved in the subsequent thermal curing stage.
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 formulation system enables successful 3D inkjet printing by maintaining stability during jetting, undergoing partial curing upon dispensing, and achieving full curing post-printing, resulting in objects with high thermal stability and enhanced mechanical properties.
Implementation Method 1
a first curable material being a thermally-curable cyanate ester and a second modeling material formulation which comprises an activating agent for promoting polymerization of the cyanate ester
Implementation Method 2
exhibiting a suitable viscosity during jetting (thus being non-curable under jetting conditions) and rapid curing or solidification (e.g., within milliseconds or seconds), typically upon exposure to a stimulus (a curing condition) on the receiving medium
Data Source
AI summary
A formulation system usable in additive manufacturing of a three-dimensional object that comprises, in at least a portion thereof, a cyanate ester-containing polymeric network, and additive manufacturing processes employing the formulation system are provided. Also provided are objects obtainable by the additive manufacturing and kits containing the formulation system. The formulation system includes a first modeling material formulation which includes a first curable material which is a thermally-curable cyanate ester and a second modeling material formulation which comprises an activating agent for promoting polymerization of the cyanate ester and is devoid of the first curable material, and further includes a second curable material which is different from the first curable material, and optionally an agent for promoting hardening of the second curable material.