Antioxidant Stabilizers for Orthodontic Resin Stability
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Solution Overview
Problem
Existing polymerizable resin compositions used in additive manufacturing for orthodontic appliances are prone to undesired polymerization and oxidation, leading to reduced processability and increased manufacturing costs.
Innovation Solution
Incorporating antioxidant stabilizers such as vitamin E and other phenolic compounds into the polymerizable resin compositions to prevent polymerization and oxidation, thereby stabilizing the resin during handling, storage, and transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If polymerizable resin compositions are used in additive manufacturing for orthodontic appliances, then high photopolymerization curing speed is achieved, but undesired polymerization and oxidation occur during handling, storage, and transportation
Solution Approach 1:
The patent applies preliminary action by incorporating antioxidant stabilizers (such as vitamin E, butylated hydroxytoluene, or gallate esters) into the polymerizable resin composition before the additive manufacturing process. These stabilizers are pre-added to prevent undesired polymerization and oxidation that would otherwise occur during handling, storage, and transportation. The stabilizers remain effective throughout the supply chain until the resin is actually cured during manufacturing, thus resolving the contradiction between maintaining high curing speed and ensuring compositional stability.
2Stability of the object's composition
If antioxidant stabilizers are added to prevent polymerization and oxidation, then resin stability is improved, but manufacturing costs increase
Solution Approach 1:
The patent applies parameter changes by carefully controlling the concentration of antioxidant stabilizers in the polymerizable resin composition. The stabilizers are present at specific low levels (typically 0.01-5 wt%, and in some embodiments 0.1-1 wt%) which are sufficient to prevent undesired polymerization and oxidation during storage and handling, yet low enough to minimize cost impact. This optimized concentration range resolves the contradiction between achieving adequate stability and controlling manufacturing costs.
3Duration of action of stationary object
If polymerizable resin compositions are stored for extended periods, then supply chain flexibility is improved, but undesired polymerization and oxidation increase
Solution Approach 1:
The patent applies the intermediary principle by introducing antioxidant stabilizers as mediating substances between the polymerizable resin components and environmental factors (oxygen, light, heat) that cause oxidation and undesired polymerization. These stabilizers act as intermediaries that sacrificially react with free radicals and oxygen, protecting the main resin components from degradation during extended storage. Common intermediaries include vitamin E (tocopherol), butylated hydroxytoluene (BHT), and gallate esters, which extend the shelf life of the resin without interfering with the intended photopolymerization process.
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 use of antioxidant stabilizers enhances the stability and processability of the polymerizable resin compositions, reducing manufacturing costs and maintaining the aesthetic quality of the 3D printed orthodontic appliances.
Implementation Method 1
The antioxidant stabilizers are employed to prevent undesired polymerization of polymerizable components, oxidation of reactive diluents, and depletion of photoinitiators
Implementation Method 2
Many additive manufacturing techniques involve successively adding layers of photopolymerizable materials and curing these layers by controlled light exposure. The photopolymerizable materials often include reactive components that are cured with light.
Data Source
AI summary
This disclosure provides stable polymerizable resin compositions comprising one or more antioxidant stabilizers to prevent undesired polymerization and/or oxidation of polymerizable components as well as undesired depletion of photoinitiators in the polymerizable resin composition. Such polymerizable resin compositions can be used to produce polymeric materials with properties suitable for use in various mechanical appliances, such as orthodontic appliances.