Ionic Polymeric Materials for Mold-Free 3D Printing

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Solution Overview

Problem

Current polymeric materials are not dimensionally stable enough to enable the creation of water-soluble objects on a voxel-by-voxel basis without a mold, and they lack controllable solubility in aqueous environments, which hinders the manufacturing of advanced utility items.

Innovation Solution

A method involving the creation of polymers derived from the condensation reaction of polyols and ionic monomers, with calculated charge densities between 0.01 to 0.7 mEq/g, allowing for the fabrication of three-dimensional objects using additive manufacturing techniques like FDM, where the polymers are both dimensionally stable and water-soluble.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If water soluble polymers are used to enable solubility in aqueous environments, then solubility is improved, but dimensional stability deteriorates making voxel-by-voxel manufacturing impossible without molds

Engineering Contradiction:

Improvewater solubilityVSAvoiddimensional stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The patent modifies the chemical parameters of polyethylene glycol by introducing ionic groups through reaction with epoxides or carbonyl compounds, creating charged polymeric materials with controlled charge densities (0.01 to 0.7 mEq/g). This parameter change enables the material to achieve both water solubility and dimensional stability, resolving the contradiction between solubility and structural integrity for additive manufacturing

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates composite polymeric materials by combining modified polyethylene glycol chains with ionic groups, forming a composite structure that exhibits both hydrophilic properties (for solubility) and cross-linking capability (for dimensional stability). These composite materials enable voxel-by-voxel manufacturing without molds while maintaining controllable water solubility

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If high charge density polymers are used to improve water solubility, then solubility is improved, but manufacturing precision deteriorates due to insufficient dimensional stability

Engineering Contradiction:

Improvewater solubilityVSAvoidvoxel-by-voxel fabrication accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent systematically varies the charge density parameter of the polymeric material (controlling it between 0.01 to 0.7 mEq/g) to find the optimal balance point where sufficient water solubility is achieved while maintaining enough dimensional stability for precise voxel-by-voxel manufacturing without molds, thereby resolving the contradiction between solubility and manufacturing precision

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If low charge density polymers are used to improve dimensional stability, then dimensional stability is improved, but solubility deteriorates making water soluble articles impossible

Engineering Contradiction:

Improvedimensional stabilityVSAvoidwater solubility

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The invention creates composite polymeric structures combining polyethylene glycol backbones with ionic groups, where the composite nature allows simultaneous achievement of dimensional stability (from the polymer network) and water solubility (from the hydrophilic ionic groups), resolving the contradiction between these two opposing properties

Inventive Principle:

Principle #40Composite materials

4Adaptability or versatility

If high temperatures are used to dissolve polymers, then solubility is improved, but efficacy of incorporated active agents deteriorates

Engineering Contradiction:

Improvewater solubilityVSAvoidefficacy of active agents

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent modifies the chemical structure of the polymer to achieve solubility through ionic group introduction rather than thermal dissolution, enabling the material to dissolve in water at lower temperatures that preserve the efficacy of incorporated active agents, thus resolving the contradiction between solubility and active agent efficacy

Inventive Principle:

Principle #35Parameter changes

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

Enables the production of three-dimensional objects with controlled water solubility, preserving the efficacy of incorporated active agents and allowing for the creation of complex structures with enhanced utility.

Implementation Method 1

a polymer derived from: polyol and an ionic monomer

Methodology Applied

Scientific EffectCondensation reaction:

Data Source

PatentUS11529760B2Polymeric materials and articles manufactured there from

Publication Date: 2022.12.20 PROCTER & GAMBLE CO

AI summary

A method for manufacturing a three dimensional object includes steps of: providing a digital description of the object as a set of voxels; sequentially creating an actual set of voxels corresponding to the digital set of voxels. At least one voxel comprises a polymer derived from: polyol and an ionic monomer. The calculated charge density of the resulting polymer is 0.01 to 0.7 mEq/g. A three-dimensional object having at least one voxel. The at least one voxel including a polymer derived from: a polyol and an ionic monomer, and the calculated charge density of the resulting polymer is 0.01 to 0.7 mEq/g.