Multi-Valent Polymerizable Compositions for Tough, Low-Leachable 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) to create a continuous tough matrix, 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 functionality (divalent, trivalent, and tetravalent compounds) combined in specific ratios. This composite approach creates a multi-phase polymer network that simultaneously achieves superior mechanical properties (flexural modulus ≥175 MPa, tensile strength ≥30 MPa) and minimizes leachable components by ensuring complete reaction of all functional groups during curing.
2Strength
If highly crosslinked structures are formed to improve mechanical properties, then strength increases, but the material becomes more rigid and less resilient
Solution Approach 1:
The patent creates local quality variations within the polymer network by using polymerizable compounds with different functionality. The divalent compounds provide flexible linear segments, while the trivalent and tetravalent compounds create localized crosslinked regions. This spatial distribution of different network densities allows the material to achieve high flexural modulus (≥175 MPa) while maintaining resilience through the flexible segments between crosslinks.
3Object-generated harmful factors
If multiple reactive functional groups are used to reduce leachables, then the polymerization completeness increases, but the composition complexity increases
Solution Approach 1:
The patent utilizes parameter changes in the form of different functional group valencies (2, 3, and 4) to control the polymerization process. By carefully selecting the ratio of divalent, trivalent, and tetravalent compounds and matching them with appropriate photoinitiators and curing conditions, the system achieves complete polymerization (minimal leachables) while keeping the composition manageable through defined concentration ranges for each component type.
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 produce polymeric materials with improved mechanical properties, including high flexural modulus and reduced leachables, suitable for medical devices like dental appliances.
Implementation Method 1
at least one of the reactive functional groups coupled to the first terminal monomer or the second terminal monomer is an epoxide moiety or an alkene moiety
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.