Photocurable Polysiloxane Composition for 3D Printing
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Solution Overview
Problem
Current photocurable polysiloxane compositions are unsuitable for three-dimensional fabrication due to insufficient shear-thinning properties, transparency issues, slow curing times, and difficulties in controlling dimensions and processing, making them inadequate for efficient 3D printing techniques.
Innovation Solution
A photocurable composition comprising a first polysiloxane with acrylate or methacrylate groups, a second polysiloxane with Si—H groups, a third polysiloxane with reactive aliphatic ethylene groups, a free radical photoinitiator, and a hydrosilylation catalyst, which can be cured using UV radiation and optionally further treated with heat to form a three-dimensional body with improved properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional photocurable polysiloxane compositions are used, then curing can be achieved, but the compositions exhibit high viscosity, slow curing times, and insufficient shear-thinning properties making them unsuitable for 3D printing
Solution Approach 1:
The patent changes the chemical composition parameters by incorporating specific polysiloxane structures with acrylate/methacrylate groups and controlling molecular weight and functionality to achieve the desired balance of low viscosity, fast curing, and appropriate shear-thinning behavior for 3D printing
Solution Approach 2:
The patent creates a composite photocurable composition combining multiple polysiloxane components with different functions (crosslinking, viscosity control, reactivity) along with photoinitiators and catalysts to achieve properties that individual components cannot provide alone
2Reliability
If conventional photocurable polysiloxane compositions are used, then curing can be achieved, but transparency of the cured product is insufficient
Solution Approach 1:
The patent optimizes compositional parameters including polysiloxane purity, molecular weight distribution, and crosslinking density to minimize light scattering and achieve high transparency in the cured product while maintaining controllable curing characteristics
3Loss of time
If conventional photocurable polysiloxane compositions are used, then curing can be achieved, but curing time is inconveniently slow
Solution Approach 1:
The patent modifies the photoinitiator system and polysiloxane reactivity parameters to accelerate the photocuring reaction rate, reducing curing time while maintaining precise dimensional control through optimized formulation that prevents excessive shrinkage and distortion
Solution Approach 2:
The patent enables continuous or near-continuous curing action through highly reactive composition formulation that cures rapidly and uniformly under UV irradiation, minimizing the time the material remains in a vulnerable uncured state
4Manufacturing precision
If conventional photocurable polysiloxane compositions are used, then curing can be achieved, but dimensions of cured material are difficult to control
Solution Approach 1:
The patent optimizes the polysiloxane composition parameters including crosslinking density, molecular weight, and functional group concentration to achieve minimal and uniform shrinkage during curing, enabling precise dimensional control of printed features
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 achieves low viscosity, high UV sensitivity, and oxygen polymerization inhibition, enabling faster and more precise 3D printing with improved fabrication rates and resolution, allowing for the creation of three-dimensional polymeric bodies with desirable mechanical properties.
Implementation Method 1
a free radical photoinitiator in an amount of about 0.01 to about 10 weight % based on the total weight of (meth)acrylate-containing polysiloxane in the composition
Implementation Method 2
a hydrosilylation catalyst in an amount of about 0.001 to about 10 weight % based on the total weight of hydride-containing polysiloxane and vinyl-containing polysiloxane in the composition
Data Source
AI summary
The present disclosure relates generally to photocurable compositions and methods for continuously forming a three-dimensional body from these compositions. More particularly, the present disclosure relates to photocurable compositions comprising a mixture of polysiloxanes capable of being dually cured, i.e., first by UV radiation followed by thermal treatment, or being cured by UV radiation. In one aspect, the disclosure provides a photocurable composition, including: a first polysiloxane comprising at least two acrylate or methacrylate groups per molecule; a second polysiloxane containing at least one (e.g., at least two) Si—H group per molecule; a third polysiloxane containing at least one (e.g., at least two) reactive aliphatic ethylene group per molecule; a free radical photoinitiator in an amount of about 0.01 to about 10 weight % based on the total weight of (meth)acrylate-containing polysiloxane in the composition; and a hydrosilylation catalyst in an amount of about 0.001 to about 10 weight % hydride-containing polysiloxane and vinyl-containing polysiloxane in the composition.