Plasma-Treated Polymer Sheets for Additive Manufacturing
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Solution Overview
Problem
Additive manufacturing processes often result in parts with lower intra-layer and inter-layer strength compared to traditional methods like injection molding, due to limited chain diffusion between material layers, leading to suboptimal attachment between sequentially formed layers.
Innovation Solution
The use of plasma-treated substrates with amine and epoxide functional groups, which form covalent bonds through dehydration reactions when heated, enhancing the inter-layer adhesion and overall strength of the parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional additive manufacturing processes are used to deposit successive layers of material, then the manufacturing process can be implemented, but the inter-layer strength and intra-layer strength are insufficient compared to traditional methods
Solution Approach 1:
The substrate surfaces are pre-treated with plasma to introduce reactive functional groups (amine and epoxide) before the layers are combined. This preliminary chemical modification enables strong covalent bonding when the layers are heated together, resolving the inter-layer strength issue without requiring complex post-processing steps.
Solution Approach 2:
The invention changes the chemical state of the substrate surfaces by introducing specific functional groups through plasma treatment. The amine-functionalized and epoxide-functionalized surfaces undergo dehydration reactions when heated, forming covalent bonds that dramatically improve inter-layer strength compared to conventional physical adhesion methods.
2Strength
If conventional additive manufacturing processes are used to deposit successive layers of material, then the manufacturing process can be implemented, but the intra-layer strength is insufficient compared to traditional methods like injection molding
Solution Approach 1:
The invention modifies the chemical parameters of the material layers by introducing reactive functional groups through plasma treatment. When layers are heated together, dehydration reactions form covalent bonds within layers, significantly enhancing intra-layer strength to match traditional manufacturing methods without requiring complex equipment modifications.
3Strength
If plasma treatment and covalent bonding are used to enhance inter-layer adhesion, then the strength of additively manufactured parts is improved, but the process complexity increases
Solution Approach 1:
Plasma treatment is performed in advance on substrate surfaces to introduce reactive functional groups before the layers are assembled and heated. This preliminary chemical modification simplifies the overall process by enabling self-bonding when layers are heated together, rather than requiring complex real-time bonding control systems.
Solution Approach 2:
The invention replaces mechanical/physical adhesion mechanisms with chemical bonding mechanisms. Instead of relying on mechanical interlocking or physical adhesion between layers, the plasma-treated surfaces undergo chemical dehydration reactions to form covalent bonds, providing superior adhesion with a relatively simple heating step.
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
This approach enables the creation of additively manufactured parts with strength comparable to those produced by injection molding, facilitating stronger inter-layer bonding and improved mechanical properties, while also enabling cost-effective production of high-strength parts.
Implementation Method 1
exposing a first substrate to a first plasma, such that an amine-functionalized substrate is formed. A second substrate is exposed to a second plasma, such that an epoxide-functionalized substrate is formed
Implementation Method 2
The heated workpiece is cooled to form a structure. Covalent bonds are formed by dehydration reactions occurring between amine chemical moieties of the amine-functionalized substrate and epoxide chemical moieties of the epoxide-functionalized substrate
Data Source
AI summary
Illustrative examples of forming and using suitably adapted material in an additive manufacturing process includes operations of: exposing a first polymer sheet to a first plasma, such that an amine-functionalized sheet surface is formed; exposing a second polymer sheet to a second plasma, such that an epoxide-functionalized sheet surface is formed; and combining the amine-functionalized sheet and the epoxide-functionalized sheet, such that the amine-functionalized sheet surface contacts the epoxide-functionalized sheet surface. The workpiece is subsequently heated to form a structure, where heating of the workpiece causes covalent chemical bonds to form between the plasma-treated first polymer sheet and the plasma-treaded second polymer sheet.