Ionic Monomer Resin for 3D Support Removal
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Solution Overview
Problem
In three-dimensional optical molding, existing support materials are difficult to remove efficiently without damaging the molded product, often requiring finishing steps to address surface contamination and accuracy issues due to compatibility with the model material, and current methods can leave residues or require harsh chemicals.
Innovation Solution
An active energy ray-curable resin composition containing an ionic monomer is used, which allows for easy removal by immersion in a washing liquid, providing high molding accuracy and eliminating the need for finishing steps due to its water-soluble or water-dispersible properties, enhancing phase separation from the model material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a support material is used in three-dimensional optical molding, then the molded product can be supported during manufacturing, but the support material adheres to the molded product and is difficult to remove without causing breakage
Solution Approach 1:
The invention changes the chemical composition parameters of the support material by incorporating ionic monomers (anionic or cationic) that can be dissolved or dispersed in water or electrolyte solutions. This parameter change enables the support material to be easily removed from the molded product by immersion in water or electrolyte solution, eliminating the adhesion problem while maintaining the support function during manufacturing.
Solution Approach 2:
The invention introduces water or electrolyte solution as an intermediary medium that facilitates the separation between the support material and the molded product. The ionic monomer in the support material interacts with the water/electrolyte solution, allowing the support material to be dissolved or dispersed and easily removed without direct mechanical contact that could cause breakage.
2Reliability
If existing support materials are used, then the molded product can be supported, but the support material requires manual removal using spatulas or brushes which is time-consuming and burdensome
Solution Approach 1:
The invention replaces the mechanical removal system (manual scraping with spatulas or brushes) with a chemical dissolution system. The ionic monomer-containing support material dissolves or disperses in water or electrolyte solution, automatically separating from the molded product without requiring mechanical force, thereby dramatically improving removal efficiency and eliminating manual labor.
Solution Approach 2:
The support material performs self-removal by dissolving or dispersing in water or electrolyte solution. The ionic monomer structure enables the support material to automatically separate from the molded product through immersion, without requiring external mechanical intervention, thus achieving self-service removal that improves productivity.
3Ease of operation
If water-soluble or water-dispersible support materials are used, then the support material can be easily removed by immersion, but the support material may contaminate the surface of the molded product
Solution Approach 1:
The invention applies local quality by making only the support material water-soluble or water-dispersible through ionic monomer incorporation, while the molded product material remains unaffected. This localized property ensures that the support material dissolves or disperses in water/electrolyte solution for easy removal, while the molded product surface maintains its integrity and accuracy without contamination.
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 enables efficient and low-temperature removal of the support material, maintaining high molding accuracy and surface cleanliness of the three-dimensional product, with improved operational efficiency and reduced environmental impact.
Implementation Method 1
a cured product of an active energy ray-curable resin composition containing an ionic monomer as a support material... by immersing a roughly molded product supported by the support material in a washing liquid, the support material is dissolved or dispersed in the washing liquid
Implementation Method 2
active energy ray-curable resin composition... containing 0.1 to 5.0% by mass of a photopolymerization initiator (D)
Data Source
AI summary
An object of the present invention is to provide a shape supporting support material which can be efficiently removed after molding in addition manufacturing and an active energy ray-curable resin composition used for forming the support material. An active energy ray-curable resin composition containing the ionic monomer (A), the nonionic water-soluble monomer (B), the nonpolymerizable compound (C), and the photopolymerization initiator (D), and/or the polyfunctional monomer (E) is used. The support material can be thereby efficiently removed from the formed roughly modeled product. Furthermore, a three-dimensional modeled product having a non-contaminated surface and high molding accuracy can be obtained.