Formula I Additives for Flame-Retardant 3D Printed Polymers
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Solution Overview
Problem
Existing 3D build materials often lack desirable mechanical properties and are unsuitable for high-temperature applications or those requiring flame resistance, limiting the application of 3D printing technology in certain fields.
Innovation Solution
The use of additives, specifically compounds of Formula I, which can be incorporated into polymerizable liquids to impart flame retardant properties and structural enhancements to 3D printed articles. These additives, along with an acrylate component, form polymerizable liquids that can be printed and cured to create articles with improved mechanical and flame-resistant properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If UV curable acrylate formulations are used to print parts with high resolution, then manufacturing precision is improved, but mechanical properties deteriorate and parts become prone to fracture
Solution Approach 1:
The patent uses composite materials by combining UV curable acrylate formulations with flame retardant additives and other functional components to create a multi-functional build material that simultaneously achieves high resolution printing and improved mechanical properties
Solution Approach 2:
The patent modifies the chemical composition parameters of the build material by incorporating specific additives and adjusting the formulation to change the mechanical properties while maintaining the resolution capabilities of UV curable acrylate systems
2Ease of manufacture
If conventional build materials are used, then ease of manufacture is maintained, but flame resistance and high-temperature suitability are lost
Solution Approach 1:
The patent introduces flame retardant additives as intermediary substances that mediate between the conventional UV curable acrylate formulation and the requirement for flame resistance, allowing the material to maintain its printing compatibility while gaining fire safety properties
Solution Approach 2:
The patent creates a universal build material formulation that performs multiple functions: it maintains the ease of manufacture characteristics of conventional UV curable materials while simultaneously providing flame resistance and high-temperature suitability through added functional components
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 incorporation of additives of Formula I into 3D build materials enhances the mechanical properties and flame resistance of printed articles, enabling their use in higher-temperature applications and fields requiring combustion resistance.
Implementation Method 1
curing of the polymerizable liquid may occur by irradiation of the liquid with light of the appropriate wavelength to initial free radical polymerization
Data Source
AI summary
Additives for three-dimensional build materials or inks are described herein which, in some embodiments, can impart flame retardant properties and/or structural enhancements to articles printed from the build materials. In some embodiments, such an additive comprises a compound of Formula I herein, wherein L and Z are ring substituents comprising at least one polymerizable point of unsaturation, and wherein R1 and R2 are independently selected from the group consisting of alkylene and alkenylene, and R3-R6 each represent one to four optional ring substituents, each one of the one to four ring substituents independently selected from the group consisting of alkyl, heteroalkyl, haloalkyl, halo, hydroxyl, alkoxy, amine, amide, and ether, and wherein n is an integer from 1 to 7.