Multi-Valent Polymerizable Compositions for Low-Leachable Orthodontic Resins
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Solution Overview
Problem
Existing curable compositions for polymeric materials used in additive manufacturing, particularly for medical devices, lack desirable mechanical properties and often contain leachable components.
Innovation Solution
Development of multi-valent polymerizable compounds with multiple reactive functional groups that form a pseudo-interpenetrating polymer network (IPN), reducing leachables and enhancing mechanical properties such as flexural modulus and resilience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional curable compositions are used for additive manufacturing, then the material can be processed, but the mechanical properties are insufficient and leachable components are present
Solution Approach 1:
The patent employs a composite material system consisting of multiple polymerizable compounds with different functionalities (monomers, oligomers, and crosslinkers) combined in specific ratios. This composite approach allows the formulation to achieve superior mechanical properties while the complete polymerization of all components eliminates leachable materials, resolving the contradiction between strength and harmful factors.
Solution Approach 2:
The patent modifies the chemical composition parameters by incorporating multi-valent polymerizable compounds with specific functional groups (epoxide, alkene, acrylate, methacrylate) and controlling the molecular weight and functionality distribution. These parameter changes enable the formation of highly crosslinked networks that provide both enhanced mechanical properties and complete reactivity to eliminate leachables.
2Strength
If highly crosslinked structures are formed to improve mechanical properties, then strength increases, but the material becomes more complex to synthesize
Solution Approach 1:
The patent segments the crosslinking function across multiple distinct compound types (monomers, oligomers, crosslinkers) rather than relying on a single complex molecule. This segmentation allows each component to perform its specific function (reactivity, viscosity control, crosslinking) while collectively achieving high flexural modulus, simplifying the overall synthesis approach through modular combination of commercially available materials.
Solution Approach 2:
The patent uses multi-valent polymerizable compounds that serve multiple functions simultaneously: they provide reactive functional groups for crosslinking, control viscosity through molecular weight selection, and contribute to the final mechanical properties. This multi-functionality reduces synthesis complexity by eliminating the need for separate additives for each property.
3Reliability
If multiple reactive functional groups are incorporated to reduce leachables, then completeness of polymerization improves, but the formulation becomes more complex
Solution Approach 1:
The patent controls formulation complexity by carefully selecting the functionality distribution and molecular weight parameters of the polymerizable compounds. By using compounds with functionality values of 2-6 and specific molecular weight ranges, the patent achieves complete polymerization of all components (eliminating leachables) while maintaining manageable formulation complexity through parameter optimization.
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 multi-valent polymerizable compounds provide polymeric materials with improved mechanical properties, including high flexural modulus and reduced leachables, suitable for medical and orthodontic devices.
Implementation Method 1
the reactive functional groups are capable of undergoing an intermolecular polymerization reaction... the intermolecular polymerization reaction is a radically or ionically induced photo-induced polymerization reaction
Data Source
AI summary
The present disclosure provides photo-polymerizable components, photo-curable resins comprising one or more of such monomers, as well as polymeric materials formed from the photo-curable resins. Further provided herein are methods of producing the compositions and using the same for the fabrication of medical devices, such as orthodontic appliances.