Inhibitor-Functionalized Resin Particles for Stable 3D Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current additive manufacturing technologies face issues with premature and spontaneous polymerization of ethylenically unsaturated polymeric precursors, such as acrylates, during handling, storage, transport, and elevated temperatures, leading to increased viscosity and reduced processability, which affects the efficiency and cost of 3D printing processes.
Innovation Solution
Incorporation of surface-functionalized polymerization inhibitor particles into curable resin compositions, which are removable before use, to inhibit premature polymerization and extend the shelf life and reusability of the resins, allowing for the use of more effective inhibitors like TEMPO without contaminating the final 3D printed objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polymerization inhibitors are added to curable resin compositions to prevent premature polymerization, then shelf life and processability are improved, but the inhibitors may contaminate the final 3D printed objects
Solution Approach 1:
The patent extracts the polymerization inhibitor from the final product by using removable particles. The inhibitor is carried on the surface of particles that are removed from the resin composition before the 3D printing process, thus preventing contamination of the final printed object while maintaining inhibition effectiveness during storage and handling.
Solution Approach 2:
The patent introduces particles as an intermediary carrier that delivers the polymerization inhibitor to the resin composition temporarily. These particles serve as a mediator that provides inhibition functionality during storage and transport, then are removed before the actual printing process, separating the inhibitor from the final product.
2Ease of manufacture
If conventional polymerization inhibitors are used to prevent premature polymerization, then processability is improved, but manufacturing costs increase due to waste and inefficiency
Solution Approach 1:
The patent implements a system where the particle carrier with embedded inhibitor is discarded (removed) after delivering its protective function during storage and transport. This allows the resin composition to be used efficiently without waste, as the inhibitor is not needed during the actual printing process and can be completely removed.
3Reliability
If effective polymerization inhibitors like TEMPO are used, then inhibition effectiveness is improved, but contamination of 3D printed objects occurs
Solution Approach 1:
The patent extracts the effective inhibitor TEMPO from the final product by loading it onto removable particles. The particles are removed before 3D printing, ensuring that highly effective inhibitors like TEMPO do not contaminate the final printed object while still providing strong inhibition during storage and transport.
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 use of polymerization inhibitor-functionalized particles stabilizes the curable compositions, prolongs shelf life, reduces manufacturing costs, and enhances the processability of 3D printing by preventing unwanted polymerization, thereby improving the efficiency and reducing waste.
Implementation Method 1
a plurality of polymerization inhibitor moieties covalently bonded to the surface of the particle
Implementation Method 2
Acrylate-based resins, which undergo free-radical polymerization, are the most commonly used photosensitive resins for additive manufacturing technologies
Implementation Method 3
Many additive manufacturing techniques involve successively adding layers of photopolymerizable materials and curing these layers by controlled light exposure
Data Source
AI summary
The present disclosure provides curable compositions comprising polymerization inhibitor-functionalized particles to prevent undesired polymerization of the polymerizable compounds in the curable compositions during their transportation, handling or storage, or during 3D printing processes. Such curable compositions can be used to produce polymeric materials with properties suitable for use in various 3D printed objects, such as orthodontic appliances.