Elastomer Additive Manufacturing via Latex Micro-Drop Deposition
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The use of raw rubber in additive manufacturing is not precise due to its viscosity, and high temperatures can lead to premature vulcanization, making it difficult to produce flexible prototypes using conventional methods.
Innovation Solution
An additive manufacturing process using a liquid composition based on latex with a dispersion of polymers in an aqueous base, deposited as micro-drops under pressure, with simultaneous deposition of support materials and alternating drying steps to prevent premature vulcanization, and subsequent vulcanization of the elastomeric material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If raw rubber is used for additive manufacturing, then the material can be deposited, but the deposition precision is poor due to high viscosity
Solution Approach 1:
The patent changes the physical state and composition parameters of the rubber material by formulating it as a liquid latex-based composition with specific polymer concentration (30-70% by weight) and water content (at least 40% by weight). This parameter transformation reduces viscosity to a workable range (10-10,000 mPa·s) while maintaining elastomeric properties, enabling precise deposition through standard liquid dispensing equipment
Solution Approach 2:
The patent creates a composite liquid composition combining rubber polymers dispersed in an aqueous base, along with optional additives such as vulcanization agents, colorants, and processing aids. This composite formulation achieves optimal balance between flowability for precise deposition and elastomeric characteristics for final part performance
2Ease of manufacture
If high temperature is applied during deposition, then the liquid composition can be deposited, but premature vulcanization occurs
Solution Approach 1:
The patent performs deposition at low temperature (ambient or controlled low temperature) to place the liquid composition in the desired geometric configuration before any thermal processing occurs. The structure is established in the liquid state, then subsequent controlled heating initiates vulcanization only after proper placement, preventing premature curing during deposition
Solution Approach 2:
The patent implements a staged thermal process with distinct temperature phases: initial low-temperature deposition, followed by intermediate drying stages, and finally controlled high-temperature vulcanization. This periodic temperature application allows separation of deposition and curing functions, preventing premature vulcanization while ensuring complete polymerization
3Strength
If the polymer concentration is increased to improve material properties, then the elastomeric characteristics improve, but the viscosity increases making deposition difficult
Solution Approach 1:
The patent establishes an optimized parameter range with polymer concentration between 30-70% by weight and water content of at least 40% by weight. This specific parameter combination achieves the critical balance point where sufficient polymer content provides elastomeric strength while adequate water content maintains viscosity below 10,000 mPa·s for ease of deposition
Solution Approach 2:
The patent allows different regions or applications to use different compositions within the specified ranges. For example, parts requiring higher strength can use 50-70% polymer content, while applications prioritizing ease of deposition can use 30-50% polymer content with相应 higher water content, enabling localized optimization of the composition parameters
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 allows for precise and controlled deposition of elastomeric materials, preventing premature vulcanization and achieving high-quality, flexible prototypes with improved mechanical properties.
Implementation Method 1
the deposition is carried out by forming drops of liquid composition and ejecting said drops under pressure
Implementation Method 2
each drying step leading to at least partial evaporation of the aqueous base of one of said layers and to the formation of a solid surface on said layer
Implementation Method 3
the method then comprises a step of vulcanizing the at least one first elastomeric material
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a method for the additive manufacturing of an elastomer part (100), comprising: the creation of a model of spatial coordinates of the part; followed by the corresponding deposition of an elastomer material, said deposition being carried out in a plurality of substantially flat layers (66, 67, 68) which are vertically stacked. The elastomer material is deposited in the form of a latex-based liquid composition comprising a dispersion of polymers in an aqueous base, and the deposition is carried out by formation and pressurised ejection of drops (86) of a liquid composition.