Photocurable Resin With Polyethylene Particles for Tough 3D Parts
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Solution Overview
Problem
Existing curable resin compositions struggle to simultaneously achieve high toughness and sliding properties, especially when used in stereolithography for shaping actual products, and often include thermosetting resins that limit their application.
Innovation Solution
A photo-curable resin composition comprising a polyfunctional radical polymerizable compound, a monofunctional radical polymerizable compound, polyethylene particles, and a curing agent, with specific ethylenically unsaturated group equivalents and content ratios to enhance toughness and sliding properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyethylene particles are added to improve sliding properties, then wear resistance and low friction are achieved, but toughness decreases
Solution Approach 1:
The patent uses a composite resin system combining thermoplastic polyethylene particles (for sliding properties) with thermosetting resin matrix (for toughness). The thermosetting resin compensates for the low toughness of polyethylene while maintaining its low friction coefficient, achieving a balance between sliding properties and mechanical strength through material composition
Solution Approach 2:
The patent optimizes the particle size distribution of polyethylene particles (mixing different size ranges: 10-50μm, 50-100μm, 100-200μm) and their content (10-40 parts by mass per 100 parts resin) to simultaneously achieve low friction, high wear resistance, and adequate toughness. The particle size parameters are carefully controlled to prevent aggregation while ensuring proper distribution
2Strength
If thermosetting resin is used to maintain mechanical strength, then rigidity and toughness are improved, but sliding properties deteriorate
Solution Approach 1:
The patent creates a composite system where thermosetting resin (epoxy, polyester, or vinyl ester resin) provides the mechanical strength and rigidity, while dispersed polyethylene particles provide the sliding properties. The combination allows the material to exhibit both high mechanical strength from the thermosetting matrix and low friction from the polyethylene particles
Solution Approach 2:
The patent creates local quality differentiation within the resin composition: the thermosetting resin matrix provides rigidity and strength in the continuous phase, while polyethylene particles distributed throughout provide low friction and wear resistance at contact surfaces, allowing different regions to fulfill different functional requirements
3Reliability
If polyethylene content is increased to improve sliding properties, then wear resistance increases, but manufacturing precision decreases
Solution Approach 1:
The patent carefully controls the polyethylene particle size distribution (using specific ranges: 10-50μm, 50-100μm, 100-200μm) and content (10-40 parts by mass per 100 parts resin) to prevent particle aggregation that would cause defects. The optimized particle size ensures good flowability during shaping while maintaining wear resistance, achieving both manufacturing precision and sliding properties
Solution Approach 2:
The patent uses different particle size ranges for different functions: smaller particles (10-50μm) for filling and surface quality, medium particles (50-100μm) for balance, and larger particles (100-200μm) for bulk wear resistance. This local quality differentiation within the particle size distribution optimizes both shaping accuracy and sliding properties
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 composition produces shaped articles with excellent toughness and sliding properties, suitable for stereolithography, addressing the limitations of existing technologies.
Implementation Method 1
a curing agent (D), wherein the polyfunctional radical polymerizable compound (A) is a single polyfunctional radical polymerizable compound having an ethylenically unsaturated group equivalent of 700 g/eq or more and 8,000 g/eq or less
Data Source
AI summary
A photo-curable resin composition for three-dimensional shaping includes a polyfunctional radical polymerizable compound (A), a monofunctional radical polymerizable compound (B), polyethylene particles (C), and a curing agent (D). The polyfunctional radical polymerizable compound (A) is a single polyfunctional radical polymerizable compound having an ethylenically unsaturated group equivalent of 700 g/eq or more and 8,000 g/eq or less or a mixture including a plurality of types of polyfunctional radical polymerizable compounds and having an ethylenically unsaturated group equivalent of 700 g/eq or more and 8,000 g/eq or less, the ethylenically unsaturated group equivalent being a weighted average of ethylenically unsaturated group equivalents of the polyfunctional radical polymerizable compounds in terms of weight ratio. A content of the polyethylene particles (C) is 5 parts by mass or more and 50 parts by mass or less relative to 100 parts by mass of a total of the polyfunctional radical polymerizable compound (A) and the monofunctional radical polymerizable compound (B).