End-Capped Condensation Polymers for Faster 3D Printing
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Solution Overview
Problem
Condensation polymers used in 3D printing face challenges with low melt flow rates and rheological properties, limiting print speed and the ability to incorporate fillers due to uncontrolled molecular weight loss during melting and shearing, which is not addressed by traditional methods like injection molding or additive manufacturing.
Innovation Solution
A method involving heating condensation polymers with an end capping compound to form cleaved polymers, followed by reacting with the compound to create end-capped polymers, which enhances melt rheological properties and allows for higher molecular weight fractions, enabling improved layer fusion and filler incorporation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If standard thermoplastic polymers are used in 3D printing, then the process can be performed, but the melt flow rate is low which limits print speed and layer fusion quality
Solution Approach 1:
The patent applies parameter changes by modifying the molecular weight distribution of condensation polymers through controlled chain scission and end-capping processes. This creates polymers with optimized melt rheological properties that enable faster printing speeds while maintaining reliable layer fusion and preventing deformation, directly resolving the contradiction between productivity and melt flow rate.
2Ease of manufacture
If condensation polymers are melted and sheared in traditional processes, then processing can occur, but uncontrolled loss of molecular weight causes deformation during forming
Solution Approach 1:
The patent introduces end-capping compounds as intermediaries that react with the polymer chains during processing. These end-capping agents prevent uncontrolled molecular weight loss by stabilizing the polymer chain ends, thereby maintaining shape accuracy during forming while still allowing the necessary melting and shearing for processing.
Solution Approach 2:
The patent controls the molecular weight distribution parameter through controlled chain scission followed by end-capping. This creates a narrow molecular weight distribution that prevents deformation during forming while maintaining processing capability, resolving the contradiction between ease of manufacture and manufacturing precision.
3Strength
If thermoplastic polymers with low melt flow are used, then sufficient bonding within layers can be achieved, but the ability to load with inorganic filler to realize hardness and stiffness is limited
Solution Approach 1:
The patent changes the rheological parameters of the polymer by controlling molecular weight distribution through chain scission and end-capping. This creates optimal melt flow characteristics that enable high filler loadings (up to 60-70 wt%) while maintaining sufficient bonding strength within layers, resolving the contradiction between strength and quantity of substance.
4Stability of the object's composition
If condensation polymers undergo cleaving and reconstitution upon cooling, then molecular weight can be restored, but the desirable rheological properties during processing do not occur due to absence of significant shear
Solution Approach 1:
The patent performs preliminary chain scission and end-capping during the processing stage before the polymer is used in 3D printing. This preliminary action establishes the desired molecular weight distribution and rheological properties in advance, so that when the polymer is later processed in additive manufacturing, the optimal rheological behavior occurs even without significant shear, resolving the contradiction between stability and ease of manufacture.
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 process results in polymers with increased melt flow rates and polydispersity, allowing for faster 3D printing and higher filler loadings without deformation, thus improving the quality and speed of additive manufacturing processes.
Implementation Method 1
reacting at least a portion of the cleaved condensation polymer with the end capping compound to form the end capped condensation polymer
Implementation Method 2
heating a condensation polymer in the presence of an end capping compound to form cleaved condensation polymer
Data Source
AI summary
An end capped condensation polymer may be formed by heating a condensation polymer in the presence of an end capping compound to form cleaved condensation polymer reacting at least a portion of the cleaved condensation polymer with the end capping compound to form the end capped condensation polymer. The end capped condensation polymers may be used to form additive manufactured articles having high solids loading and improved processing due to improved rheological behavior.