Polybutylene Terephthalate Powder Mixture for 3D Printing

Solution Overview

Problem

Polyester resin powder materials used in 3D printing face issues with low flowability due to coagulation from static electricity and high compressability, leading to viscosity increases and production challenges during supply and shaping.

Innovation Solution

A polybutylene terephthalate resin powder mixture with a mean diameter of 1-100 μm, a uniformity coefficient of 4 or less, and the addition of 0.1-5 parts by weight of inorganic particles like silica, along with an inorganic reinforcement material, to enhance flowability and resist viscosity increases during 3D printing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If polyester resin powder material is used for molding, then excellent electrical insulating properties are achieved, but flowability decreases due to coagulation from static electricity

Engineering Contradiction:

Improveelectrical insulating propertiesVSAvoidflowability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

An intermediary substance (silane coupling agent or surfactant) is introduced to reduce the surface energy of the polyester resin particles. This mediator prevents direct electrostatic attraction between particles, thereby maintaining flowability while preserving the electrical insulating properties of the polyester resin.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The surface energy parameter of the polyester resin particles is changed through chemical treatment with silane coupling agents or surfactants. This parameter modification reduces interparticle attraction forces, improving flowability without compromising the bulk electrical insulating properties of the material.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If polyester resin powder material is used for molding, then excellent electrical insulating properties are achieved, but compressability increases leading to viscosity increase during supply

Engineering Contradiction:

Improveelectrical insulating propertiesVSAvoidviscosity increase during supply

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

An intermediary substance (silane coupling agent or surfactant) is introduced to reduce the surface energy of the polyester resin particles. This mediator prevents direct electrostatic attraction between particles, thereby maintaining flowability while preserving the bulk electrical insulating properties of the material.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The surface energy parameter of the polyester resin particles is changed through chemical treatment with silane coupling agents or surfactants. This parameter modification reduces interparticle attraction forces, improving flowability without compromising the bulk electrical insulating properties of the material.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If polyester resin powder material is used for molding, then excellent electrical insulating properties are achieved, but powder pressure causes compression leading to decreased flowability at bottoms of silo and hopper

Engineering Contradiction:

Improveelectrical insulating propertiesVSAvoidflowability at bottoms of silo and hopper

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

An intermediary substance (silane coupling agent or surfactant) is introduced to reduce the surface energy of the polyester resin particles. This mediator prevents direct electrostatic attraction between particles, thereby maintaining flowability while preserving the electrical insulating properties of the polyester resin.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The surface energy parameter of the polyester resin particles is changed through chemical treatment with silane coupling agents or surfactants. This parameter modification reduces interparticle attraction forces, improving flowability without compromising the bulk electrical insulating properties of the material.

Inventive Principle:

Principle #35Parameter changes

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 resulting mixture exhibits high flowability, low compressability, and resistance to viscosity increases, enabling the production of high-strength moldings suitable for 3D printing.

Implementation Method 1

inorganic particles are added to increase the distances among particle to relax the interaction among the particles

Methodology Applied

Scientific EffectParticle spacing effect:

Implementation Method 2

exposing the resulting thin layer to laser light in a shape that corresponds to the cross section of an intended object to fuse the powder

Methodology Applied

Scientific EffectLaser heating: Laser

Data Source

PatentUS11001046B2Polybutylene terephthalate resin powder mixture

Publication Date: 2021.05.11 TORAY INDUSTRIES INC

AI summary

A method of producing polybutylene terephthalate resin shaped moldings includes supplying a 3D printer with a polybutylene terephthalate resin powder mixture that contains 100 parts by weight of a polybutylene terephthalate resin powder material having a mean diameter of more than 1 μm and 100 μm or less, a uniformity coefficient of 4 or less, and a terminal carboxyl group quantity of 35 eq/t or more and 50 eq/t or less, and 0.1 to 5 parts by weight of inorganic particles having a mean diameter of 20 to 500 nm.