Ambient Cured Elastomeric Additive Manufacturing via Michael Addition
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Solution Overview
Problem
Current additive manufacturing methods for thermoplastic polymers are limited by the need for heating or irradiation, which restricts the materials that can be used and requires complex apparatus, making it difficult to produce parts with elastomeric properties or high temperature resistance without hazardous materials like isocyanates.
Innovation Solution
A method involving a mixture of a multifunctional Michael donor, a multifunctional Michael acceptor, and a catalyst, which reacts to form a Michael addition compound, allowing for the creation of thermoset elastomeric parts without heating or irradiation, using a combination of rheological modifiers to maintain shape and viscosity for layer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If heating or irradiation is used in additive manufacturing, then thermoplastic polymers can be processed, but the material selection is restricted and complex apparatus is required
Solution Approach 1:
The patent changes the fundamental chemical reaction parameters from thermal melting (FFF) or laser sintering (SLS) to ambient temperature Michael addition chemistry. This allows the use of diverse materials including elastomers and high-temperature resistant polymers without requiring heating apparatus, thereby expanding material selection while simplifying device complexity
Solution Approach 2:
The patent replaces thermal/mechanical processing systems (heating, melting, sintering) with chemical reaction systems (Michael addition). This substitution eliminates the need for complex temperature control apparatus and enables material processing at ambient conditions, resolving the contradiction between material versatility and apparatus complexity
2Adaptability or versatility
If support structures are extruded during additive manufacturing, then complex parts can be formed, but the support structures must survive elevated temperatures and be easily removed
Solution Approach 1:
By changing from thermal processing to ambient temperature chemical reaction, the patent eliminates the temperature survival requirement for support structures. This allows support structures to be made from the same Michael addition materials without requiring them to withstand elevated temperatures, making removal easier through chemical dissolution or degradation
3Temperature
If thermoset elastomeric parts are produced with high temperature resistance, then hazardous materials like isocyanates are typically required, but the invention avoids these hazardous materials
Solution Approach 1:
The patent replaces hazardous isocyanate chemistry with benign Michael addition chemistry between functionalized oligomers and monomers. This substitution maintains the ability to produce high-temperature resistant elastomeric parts while eliminating toxic materials, converting a harmful process into a safe one
Solution Approach 2:
The patent uses composite formulations combining functionalized oligomers with specific monomers and catalysts to achieve both high-temperature resistance and elastomeric properties without hazardous materials. The composite material system enables performance equivalent to isocyanate-based systems but with improved safety
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 thermoset elastomeric parts with high temperature resistance and elastomeric properties, such as noise mitigation, without the use of hazardous materials, and provides improved dimensional control and uniformity, achieving high decomposition temperatures and mechanical properties like elongation at break.
Implementation Method 1
providing a multi-functional Michael donor, a multi-functional Michael acceptor, and a catalyst; mixing the multi-functional Michael donor, the multi-functional Michael acceptor, and the catalyst to form a mixture
Data Source
AI summary
An additive elastomeric manufactured part is comprised of extrudates comprised of a reaction product of a multifunctional Michael donor and multifunctional Michael acceptor and a rheological modifier. The additive elastomeric manufactured part may have a high elongation and resistance to heat. Said part may be made by dispensing a mixture of the multifunctional Michael donor, multifunctional Michael acceptor, rheological modifier and a catalyst through a through a nozzle to form an extrudate deposited on a base. The base, nozzle or combination thereof is moved while dispensing the mixture so that there is horizontal displacement between the base and nozzle in a predetermined pattern to form an initial layer of the material on the base. Subsequent layers are then formed on the initial layer by repeating the dispensing and movement on top of the initial layer and layers that follow.