Fluoropolymer Filament Printing for Buckling-Free Elastomer Layers
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Solution Overview
Problem
Existing additive manufacturing methods face challenges in processing soft elastomers, particularly fluorine-containing elastomers, due to high viscosity and the need to prevent premature curing, which leads to issues like buckling and weak inter-layer adhesion, making it difficult to form complex geometries efficiently and cost-effectively.
Innovation Solution
A method involving the use of a curable fluoropolymer filament that is heated below the curing temperature, extruded through a support tube and nozzle, and printed layer-by-layer in an additive manufacturing process, allowing for controlled deposition and subsequent curing to enhance inter-layer adhesion and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fluorine-containing elastomer compositions are processed using conventional additive manufacturing methods, then the material can be deposited, but the high viscosity causes buckling and weak inter-layer adhesion
Solution Approach 1:
The patent applies parameter changes by controlling the temperature of the elastomer composition throughout the printing process. The composition is heated to a specific temperature range (above its glass transition temperature but below decomposition temperature) to reduce viscosity and prevent buckling, while maintaining controlled inter-layer adhesion. This temperature parameter control resolves the contradiction between preventing buckling and ensuring proper layer bonding.
Solution Approach 2:
The patent implements preliminary action by pre-heating the build platform and the elastomer composition before deposition begins. This preliminary heating ensures that the material is at the optimal temperature for deposition, preventing viscosity-related buckling issues from the start of the printing process and ensuring proper adhesion from the first layer.
2Ease of operation
If the elastomer composition is heated to reduce viscosity for printing, then flowability improves, but premature curing occurs
Solution Approach 1:
The patent applies preliminary action by pre-heating the build platform and material to the optimal temperature range before printing begins. This ensures immediate flowability upon deposition without requiring additional heating during the process that could trigger premature curing. The preliminary heating action establishes the correct thermal state for the entire printing operation.
Solution Approach 2:
The patent implements dynamics by continuously monitoring and adjusting the temperature of both the build platform and the elastomer composition during the printing process. This dynamic temperature control allows the material to maintain optimal flowability throughout deposition while preventing temperature excursions that would cause premature curing, adapting to the changing thermal conditions as layers are built.
3Stability of the object's composition
If conventional thermoset elastomers are used, then material properties are maintained, but processing difficulty increases due to high viscosity
Solution Approach 1:
The patent applies parameter changes by controlling the temperature of the elastomer composition above its glass transition temperature during printing. This temperature parameter change temporarily modifies the rheological properties to reduce viscosity and improve processability, while the material retains its fundamental compositional stability and intended material properties. After printing, controlled curing restores the final material properties.
Solution Approach 2:
The patent utilizes phase transitions by heating the elastomer composition above its glass transition temperature to transform it from a rigid, high-viscosity state to a more flexible, lower-viscosity state that is suitable for printing. This temporary phase change enables processing while the underlying chemical composition remains stable, and subsequent curing establishes the final material properties.
4Ease of manufacture
If additive manufacturing is used for fluorine-containing elastomers, then manufacturing cost and waste are reduced, but inter-layer adhesion remains weak
Solution Approach 1:
The patent applies preliminary action by pre-heating the build platform to the optimal temperature range before printing begins. This ensures that the first layer and subsequent layers are deposited on a pre-heated surface, promoting proper adhesion from the start. This preliminary heating action prevents the common problem of weak inter-layer adhesion that plagues conventional additive manufacturing of thermoset elastomers.
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 approach enables the formation of fluorine-containing elastomer articles with improved inter-layer adhesion and mechanical properties, reducing manufacturing costs and waste, while allowing for complex geometries and high-performance applications.
Implementation Method 1
heated below the curing temperature
Implementation Method 2
subsequent curing to enhance inter-layer adhesion
Data Source
AI summary
An apparatus suitable for extruding curable polymers for forming elastomer articles using additive manufacturing, and curable fluorine-containing polymer compositions suitable for use in such an apparatus are disclosed along with an additive manufacturing method for forming a fluorine-containing elastomer article including providing a filament formed of a curable fluoropolymer composition; providing an additive manufacturing printer having a drive mechanism and a printer nozzle; feeding the filament into an additive manufacturing printer through the drive mechanism and through a longitudinal passage defined by an interior wall of a support tube, wherein the support tube extends from a first end to a second end, and wherein the second end of the support tube is positioned near an inlet to a printer nozzle; applying heat to the filament; and printing successive layers of the heated filament exiting an outlet of the nozzle onto a substrate using the additive manufacturing printer to form the fluorine-containing elastomer article.