Photocurable Resin Composition for Stereolithography
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Solution Overview
Problem
Current photocurable resin compositions for stereolithography struggle to achieve a balance between mechanical strength, flexibility, shock absorption, and water resistance, particularly in applications like mouthguards, occlusal splints, and denture base materials, with existing solutions either lacking in flexibility, water resistance, or mechanical strength.
Innovation Solution
A photocurable resin composition comprising a urethanized (meth)acrylic compound, a mono(meth)acrylic acid ester compound without a urethane bond, and a photopolymerization initiator, specifically formulated to provide low viscosity, superior flexibility, shock absorption, and water resistance, suitable for stereolithography applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-polarity monomers are used to develop mechanical strength, then mechanical strength is improved, but viscosity increases and curability decreases
Solution Approach 1:
The patent uses a composite resin system combining high-polarity monomers (for strength) with low-polarity monomers (for flexibility and processability). This composite approach allows the final cured product to achieve both high mechanical strength and appropriate viscosity for manufacturing, resolving the contradiction between strength and ease of manufacture.
Solution Approach 2:
The patent adjusts the molecular weight, functional group composition, and ratio of high-polarity to low-polarity monomers to optimize both viscosity and mechanical strength. By changing these parameters, the resin achieves low viscosity for easy fabrication while maintaining high mechanical strength after curing.
2Ease of operation
If low-polarity monomers are used to develop flexibility and water resistance, then flexibility and water resistance are improved, but curability decreases and mechanical strength is poor
Solution Approach 1:
The patent creates a composite resin system where low-polarity monomers provide flexibility and water resistance, while high-polarity monomers contribute mechanical strength. The synergistic combination allows the cured product to simultaneously achieve flexibility, water resistance, and high mechanical strength, resolving the contradiction between ease of operation and strength.
3Strength
If high-polarity monomers are used to improve mechanical strength, then mechanical strength is improved, but water resistance decreases
Solution Approach 1:
The patent combines high-polarity monomers (providing mechanical strength) with low-polarity monomers (providing water resistance). The low-polarity components create a more hydrophobic cured product that resists water absorption, while the high-polarity components ensure high mechanical strength. This composite approach resolves the contradiction between strength and water resistance.
4Reliability
If low-polarity monomers are used to improve water resistance, then water resistance is improved, but mechanical strength decreases
Solution Approach 1:
The patent uses a composite resin formulation where low-polarity monomers contribute to water resistance and flexibility, while high-polarity monomers provide mechanical strength. The synergistic interaction between these monomer types allows the cured product to simultaneously achieve high water resistance and high mechanical strength, resolving the contradiction between reliability and strength.
5Productivity
If stereolithography is used to reduce fabrication time, then productivity is improved, but the resin composition becomes difficult to optimize for multiple properties
Solution Approach 1:
The patent optimizes the resin composition parameters (monomer ratios, molecular weights, functional groups) specifically for stereolithography processing. By adjusting these parameters, the resin achieves appropriate viscosity for rapid stereolithographic fabrication while maintaining the ability to develop high mechanical strength, flexibility, and water resistance upon curing, thus resolving the contradiction between productivity and composition complexity.
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 exhibits excellent fabricability, flexibility, shock absorption, fracture resistance, and water resistance, making it ideal for mouthguards, occlusal splints, and denture base materials with improved dimensional accuracy and mechanical characteristics.
Implementation Method 1
a photopolymerization initiator (C)
Data Source
AI summary
The present invention provides a photocurable resin composition that has good fabricability, and that exhibits superior flexibility, fracture resistance, and water resistance in the form of a cured product. The present invention relates to a photocurable resin composition comprising:a urethanized (meth)acrylic compound (A);a mono(meth)acrylic acid ester compound (B) containing no urethane bond; anda photopolymerization initiator (C),the urethanized (meth)acrylic compound (A) being a (meth)acrylate comprising, per molecule, at least one kind of structure selected from the group consisting of a polyester, a polycarbonate, a polyurethane, a polyether, a poly-conjugated diene, and a hydrogenated poly-conjugated diene; and a urethane bond,the mono(meth)acrylic acid ester compound (B) containing no urethane bond comprising at least one selected from the group consisting of a mono(meth)acrylic acid ester compound (b-I) represented by general formula (I), and a mono(meth)acrylic acid ester compound (b-II) represented by general formula (II).