PIPS Acrylate Resins for 3D Printing Impact Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Standard UV curable resins lack adequate impact resistance and rheological stability, with existing additives like unreactive fillers and rubber particles failing to improve durability effectively, particularly in photopolymerized acrylate-based networks.
Innovation Solution
A polymerization-induced phase-separating (PIPS) composition comprising an acrylic block copolymer, a monofunctional acrylic monomer, and a multifunctional cross-linker, which forms a homogeneous liquid before curing and nano-structured domains after curing, enhancing impact resistance and rheological properties in 3D printing applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If unreactive fillers and rubber particles are incorporated into UV curable resins to improve impact resistance, then impact resistance is enhanced, but rheological stability deteriorates and brittleness increases
Solution Approach 1:
The invention changes the chemical reactivity parameter of the impact modifier by using polymerizable blocks instead of unreactive fillers. The blocks participate in the curing reaction (changing from unreactive to reactive), which maintains rheological stability during storage while providing impact resistance after curing through phase-separated domains.
Solution Approach 2:
The invention creates a composite system with multiple functional blocks within the impact modifier molecule itself (hydrophobic blocks for phase separation, hydrophilic blocks for interaction with resin, reactive blocks for curing participation). This multi-functional composite structure resolves the contradiction by combining rheological stability with impact resistance.
2Strength
If polymerization-induced phase-separation (PIPS) mechanism is applied to epoxy-based networks to develop cushioning domains, then toughness and impact resistance are improved, but the strategy is ineffective when applied to photopolymerized acrylate-based networks
Solution Approach 1:
The invention adapts the PIPS mechanism to acrylate systems by changing the chemical functionality parameters of the impact modifier blocks to be compatible with photopolymerization chemistry. The blocks contain acrylate or methacrylate functional groups that participate in UV-curing, enabling PIPS to work in acrylate-based networks as well as epoxy systems.
Solution Approach 2:
The invention creates a universal impact modifier that can function in both epoxy and acrylate photopolymerizable systems. The multi-functional blocks (hydrophobic, hydrophilic, and reactive) are designed to be adaptable to different resin chemistries, making the PIPS mechanism universally applicable across different polymerization systems.
3Strength
If additives are introduced to resin to create discrete phases that alleviate stresses, then durability and impact resistance are improved, but the resin may lose Newtonian flow profile
Solution Approach 1:
The invention changes the molecular architecture parameter of the additive from conventional single-phase structures to multi-block copolymer structures with specific hydrophobic/hydrophilic ratios. This architectural design allows the formation of discrete phases for durability while maintaining sufficient molecular flexibility to preserve Newtonian flow characteristics in the uncured state.
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 PIPS composition significantly enhances impact resistance and cohesive strength of 3D printed materials, maintaining a Newtonian flow profile and improving long-term durability, as demonstrated by increased tear strength and phase separation characteristics.
Implementation Method 1
polymerization-induced phase-separating (PIPS) mechanism to develop cushioning domains into epoxy-based networks
Implementation Method 2
photopolymerized acrylate-based networks
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Embodiments described herein are directed to polymerization-induced phase- separating (PIPS) compositions for enhancement of impact resistance and rheological properties in photocurable resinsfor 3D printing,such as for inks, coatings and adhesives. Embodiments described herein are advantageous with respect to properties such as impact resistance, shearadhesion and cohesive strength. The PIPS compositions may include components X, Y and Z, wherein X includesan acrylic based monomer; Y includes a copolymer of block A and block B; and Z includes a multifunctionalcross-linker. Methods of using the PIPS compositions are also described. Also described are methods of screening potential acrylic basedmonomeric or oligomeric additives that yield improved impact resistance.