Curable resin composition, cured object, and three-dimensional object

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Solution Overview

Problem

Existing photocurable resins used in three-dimensional optical modeling methods do not satisfy the demands for low viscosity and do not form cured products with excellent mechanical properties, such as elastic modulus and impact resistance.

Innovation Solution

A curable resin composition containing a specific urethane resin and a specific acrylate compound, which includes a polyester polyol, a polyisocyanate, and a compound with a hydroxyl group and a (meth)acryloyl group, is used to achieve low viscosity and excellent mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a radically polymerizable compound is used as photocurable resin, then curability is improved, but mechanical physical properties (elastic modulus, elongation, impact resistance) are insufficient

Engineering Contradiction:
ImprovecurabilityVSAvoidmechanical physical properties
Core Design Contradiction:
ReliabilityVSStrength

Solution Approach 1:

The patent uses a composite resin system combining radically polymerizable compounds (acrylates, vinyl ethers) with oxazoline compounds. This composite approach allows the radical polymerization to provide fast curing while the oxazoline segments contribute to enhanced mechanical properties including elastic modulus, elongation, and impact resistance through their unique molecular structure and intermolecular interactions.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent modifies the chemical structure parameters of the polymerizable monomers by incorporating specific functional groups (oxazoline rings, hydroxyl groups, ether linkages) into the monomer molecules. These structural parameter changes enable the cured resin to achieve both high curability and superior mechanical properties by balancing crosslinking density with molecular flexibility.

Inventive Principle:
Principle #35Parameter changes

2Strength

If resin composition is optimized for mechanical properties, then elastic modulus and impact resistance are improved, but viscosity increases

Engineering Contradiction:
Improveelastic modulus and impact resistanceVSAvoidviscosity
Core Design Contradiction:
StrengthVSQuantity of substance

Solution Approach 1:

The patent carefully selects monomers with specific molecular weight ranges and functional group configurations to maintain low viscosity. By using monomers with appropriate chain lengths and incorporating flexible linkages (ether groups, hydroxyl groups), the composition achieves low viscosity for easy handling while the crosslinking structure formed during curing provides high elastic modulus and impact resistance.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent employs specific photopolymerization initiators and catalysts as intermediaries that enable efficient polymerization at low monomer concentrations. These intermediaries facilitate the formation of a highly crosslinked network structure without requiring high monomer concentrations, thereby maintaining low viscosity in the uncured state while achieving excellent mechanical properties in the cured state.

Inventive Principle:
Principle #24Intermediary (Mediator)

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 curable resin composition forms a cured product with improved elastic modulus and impact resistance, making it suitable for three-dimensional optical modeling.

Implementation Method 1

a curable resin composition containing a urethane resin (A) and a (meth)acrylate compound (B)... irradiated from above with a computer-controlled spot ultraviolet laser to cure one layer... photopolymerization initiator

Methodology Applied
Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentEP4079777B1Curable resin composition, cured object, and three-dimensional object
Publication Date: 2026.01.28 DIC CORP
  • EP4079777B1 patent drawing

AI summary

The invention provides a curable resin composition that has low viscosity and forms a cured product having excellent mechanical physical properties, a cured product, and a three-dimensional object. The invention uses a curable resin composition containing a urethane resin (A) containing a (meth)acryloyl group, and a monofunctional (meth)acrylate compound (B1) and/or a bifunctional (meth)acrylate compound (B2), in which the urethane resin (A) is formed using, as essential reaction raw materials, a polyester polyol (a1), a polyisocyanate (a2), and a compound (a3) containing a hydroxyl group and a (meth)acryloyl group, and the polyester polyol (a1) is formed using, as essential reaction raw materials, a glycol (a1-1) containing a hydrocarbon group in a side chain, and a polycarboxylic acid (a1-2).