Diallyl Phthalate Patterning Material for Stereolithography
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Three-dimensional stereolithography faces challenges in improving curing speed and suppressing shrinkage of shaped articles, particularly with the surface exposure technique, which struggles to control light dosage and optical path length, leading to reduced reproducibility and dimensional accuracy due to warping.
Innovation Solution
A patterning material comprising a diallyl phthalate prepolymer, photocurable monomer, and photopolymerization initiator, which is liquid at room temperature, is used in a method involving light exposure to form and laminate patterns, enhancing curing speed and minimizing shrinkage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If surface exposure technique is used to reduce material usage, then material consumption is reduced, but curing speed is insufficient and dimensional accuracy deteriorates due to uncontrollable light dosage and optical path length
Solution Approach 1:
The patent changes the chemical composition parameters of the photocurable material by incorporating a cyclic carbonate compound with specific molecular structure and ratio (5-50 mass%), which fundamentally alters the curing characteristics to achieve both high curing speed and dimensional stability under surface exposure conditions
Solution Approach 2:
The patent creates a composite photocurable material system combining cyclic carbonate compound, polymerizable compound, and photopolymerization initiator, where the synergistic interaction between components enables simultaneous achievement of fast curing and minimal shrinkage that cannot be achieved with single components
2Productivity
If conventional photocurable materials are used to improve curing speed, then productivity increases, but shrinkage of shaped article occurs leading to reduced manufacturing precision
Solution Approach 1:
The patent modifies the chemical parameters of the curing system by using cyclic carbonate compound instead of conventional acrylic/methacrylic monomers, which changes the polymerization mechanism to produce minimal volumetric shrinkage while maintaining rapid curing kinetics
Solution Approach 2:
The patent converts the typically harmful shrinkage effect into a beneficial controlled process by using cyclic carbonate polymerization, which exhibits inherent low shrinkage characteristics, thereby achieving high curing speed without the usual penalty of dimensional inaccuracy
3Productivity
If high light intensity is applied to increase curing speed, then productivity improves, but optical path control becomes more difficult leading to warping and reduced manufacturing precision
Solution Approach 1:
The patent changes the photopolymerization kinetics parameters by selecting specific photopolymerization initiators and cyclic carbonate compounds that enable efficient curing at controlled light intensities, avoiding the need for excessively high intensity that would cause optical path control issues
Solution Approach 2:
The patent enables dynamic control of the curing process by adjusting light intensity and exposure time parameters within an optimized range, allowing flexible process control that maintains both high curing speed and shape reproducibility through the unique properties of the cyclic carbonate-based material system
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 solution significantly improves curing speed and reduces shrinkage of the shaped article, maintaining high reproducibility and dimensional accuracy, making it suitable for surface exposure techniques in stereolithography.
Implementation Method 1
a photopolymerization initiator, wherein the patterning material is liquid at room temperature
Data Source
Figure 1(a)~1(f)
AI summary
Provided is a patterning material for three-dimensional stereolithography, with which it is possible to improve the curing speed and suppress a shrinkage of the three-dimensionally shaped article. The patterning material for three-dimensional stereolithography contains a diallyl phthalate prepolymer, a photocurable monomer and a photopolymerization initiator, and is liquid at room temperature. The patterning material is suitable for use in patterning performed by surface exposure. The proportion of the diallyl phthalate prepolymer is, for example, 5 to 40 mass% in the total amount of the diallyl phthalate prepolymer and the photocurable monomer.