Photocurable PAES Formulations for High-Temperature 3D Printing

Solution Overview

Problem

Existing lithographic processes face challenges in producing 3D printed articles with high mechanical properties and thermal stability, particularly at temperatures above 150°C, due to the need for high performance polymers to remain thermally stable while avoiding thermal polymerization of photo-polymerizable functional groups.

Innovation Solution

A polymer formulation comprising poly(aryl ether sulfone) (PAES) with photo-polymerizable terminal groups and a polyfunctional cross-linker, which can be cured at or below the glass transition temperature of the polymer, resulting in high thermal properties and mechanical stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If high performance polymers are used to maintain thermal stability above 150°C, then thermal stability is improved, but the material becomes difficult to process in lithographic processes due to requiring heating above Tg or Tm

Engineering Contradiction:

Improvethermal stabilityVSAvoidprocessability in lithographic process

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent changes the physical state parameter of the polymer from solid to liquid by controlling the processing temperature to be below Tg, and introduces a photopolymerizable functional group that enables curing at this lower temperature, thus achieving both thermal stability and processability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces a photopolymerizable functional group as an intermediary that allows the high performance polymer to undergo crosslinking and curing at temperatures below Tg, mediating between the thermal stability requirement and the processing requirement

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If polymerizable formulations are heated above Tg or Tm to remain liquid for printing, then ease of operation is improved, but thermal stability deteriorates due to risk of thermal polymerization

Engineering Contradiction:

Improveliquid state for printingVSAvoidthermal stability

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The patent changes the processing temperature parameter to be below Tg, and introduces a photopolymerizable functional group that enables curing at this lower temperature, thus achieving both thermal stability and processability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces thermal energy (heating above Tg) with photonic energy (UV irradiation) as the curing mechanism, allowing the polymer to remain liquid at lower temperatures while still achieving crosslinking and curing

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If photo-polymerizable functional groups are added to high performance polymers, then lithographic processability is improved, but thermal stability deteriorates due to risk of thermal polymerization of these groups

Engineering Contradiction:

Improvelithographic processabilityVSAvoidthermal stability

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The patent introduces a photopolymerizable functional group as an intermediary that allows the high performance polymer to undergo crosslinking and curing at temperatures below Tg, mediating between the thermal stability requirement and the processing requirement

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces thermal energy (heating above Tg) with photonic energy (UV irradiation) as the curing mechanism, allowing the polymer to remain liquid at lower temperatures while still achieving crosslinking and curing

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 formulation enables the production of 3D printed articles with high mechanical properties and thermal stability, suitable for use in high-temperature environments.

Implementation Method 1

Lithographic processes involve the use of light, for example UV irradiation, to locally cure a polymerizable formulation at specific locations

Methodology Applied

Scientific EffectPhoto-polymerization: Photopolymerisation

Implementation Method 2

the use of a polyfunctional photo-crosslinker, which creates a high molecular weight network with polymer (P) after printing and curing

Methodology Applied

Scientific EffectCross-linking: Chemical Bonding

Data Source

PatentUS12473254B2Photocurable polymer compositions

Publication Date: 2025.11.18 VIRGINIA TECH INTELLECTUAL PROPERTIES INC

AI summary

The present invention relates to relates to a polymer formulation for three-dimensionally (3D) printing an article by stereolithography, the formulation comprising a functionalized polymer. The invention further relates to lithographic methods to form 3D objects that incorporate the aforementioned polymer formulation.