Halogen-Free Resin Composition for 3D Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current 3D-printing materials for lithography-based additive manufacturing lack sufficient flame retardancy, especially at small wall thicknesses, and existing flame-retardant solutions often contain halogenated compounds that raise environmental concerns.
Innovation Solution
A resin composition combining light-curable components with a nitrogen donor and polyphosphate or polyphosphonate, along with inorganic phosphinate salts, to achieve halogen-free flame retardancy while maintaining high (thermo)mechanical performance, using a weight ratio of 1/9 to 9/1 for the nitrogen donor and polyphosphate/polyphosphonate to inorganic phosphinate salts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogenated flame retardants are used in resin compositions for lithography-based 3D-printing, then flame retardancy is improved, but environmental harm and health concerns worsen
Solution Approach 1:
The patent changes the chemical composition parameters by replacing halogenated flame retardants with a specific combination of inorganic phosphinate salts and nitrogen donors/polyphosphates. This substitution maintains flame retardant effectiveness while eliminating the harmful environmental effects associated with halogenated compounds, particularly the formation of dioxins and furans during combustion.
Solution Approach 2:
The patent employs a composite flame retardant system combining inorganic phosphinate salts with nitrogen donors and/or polyphosphates. This composite approach creates a synergistic effect where the interaction between different chemical components enhances flame retardancy performance while avoiding the use of harmful halogenated substances, thus resolving the contradiction between effectiveness and environmental safety.
2Reliability
If flame retardant additives are added to resin compositions, then flame retardancy is improved, but (thermo)mechanical properties worsen
Solution Approach 1:
The patent optimizes the concentration parameters of flame retardant components, specifically using inorganic phosphinate salts in amounts of 0.1-10 wt% and nitrogen donors/polyphosphates in amounts of 0.1-20 wt%. These controlled concentrations ensure sufficient flame retardancy while minimizing the negative impact on (thermo)mechanical properties. The patent also specifies a weight ratio between 1/9 and 9/1 for optimal balance.
Solution Approach 2:
The patent uses a composite system of inorganic phosphinate salts combined with nitrogen donors and/or polyphosphates, which creates a synergistic flame retardant effect. This composite approach allows for reduced overall additive content while maintaining effective flame protection, thereby preserving the (thermo)mechanical integrity of the resin composition better than single-component systems would allow.
3Reliability
If high content of flame retardant is used, then flame retardancy is improved, but manufacturing complexity and cost worsen
Solution Approach 1:
The patent establishes specific concentration ranges for flame retardant components (inorganic phosphinate salts: 0.1-10 wt%, nitrogen donors/polyphosphates: 0.1-20 wt%) that achieve effective flame retardancy without requiring excessive amounts. This parameter optimization reduces manufacturing complexity by avoiding the need for handling and processing large quantities of additives, while still meeting flame safety requirements.
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 resin composition provides effective flame retardancy down to <4 mm wall thickness with improved (thermo)mechanical properties, including high glass transition temperature and elongation at break, while being environmentally friendly and reducing the need for halogenated compounds.
Implementation Method 1
the photoinitiator is activated via light irradiation and generates a reactive site (e.g., a radical, cation or anion) that can then react with the respective reactive components to form a cured material
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A resin composition for the 3D-printing of objects, comprising a light-curable component A functioning as 3D-structurable matrix, a component B functioning as a synergistic combination of flame retardants, and at least one photoinitiator suitable for polymerization upon light excitation, wherein, based on the total combined weight of components A and B, the amount of the curable component A ranges from 60 wt% to 95 wt%, preferably from 65 wt% to 90 wt%, more preferably from 70 wt% to 85 wt%, the amount of the flame-retardant component B, based on the total weight of components A and B, ranges from 5 wt% to 40 wt%, preferably from 10 wt% to 35 wt%, more preferably from 15 wt% to 30 wt%, and, based on the weight of component A alone, the amount of the photoinitiator ranges from 0.01 wt% to 10 wt%.