Polycaprolactone Light-Curable Resin for Additive Manufacturing
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Solution Overview
Problem
Current light-curable compositions for generative manufacturing lack sufficient mechanical properties, such as impact resistance and stretchability, due to limitations in crosslinking density and molecular weight, which are hindered by high viscosity issues in existing photopolymerizable materials.
Innovation Solution
A light-curable composition with a viscosity of at least 20 Pa·s at 20°C, comprising a photopolymerizable matrix material, a thermoplastic polymer, and a photoinitiator, where polycaprolactone or its derivative is used as the dissolved thermoplastic polymer, improving mechanical properties by increasing molecular weight and reducing crosslinking density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the crosslinking density is reduced and molecular weight is increased to improve mechanical properties, then impact resistance and elongation are improved, but viscosity and melting point increase making the resin unprocessable
Solution Approach 1:
The patent changes the chemical composition parameters of the resin system by introducing specific monomers (caprolactone, glycolide, lactide) with controlled ratios. By adjusting the molecular weight and functional group content of these monomers, the patent achieves optimal balance between mechanical properties and processability, resolving the contradiction between strength improvement and viscosity increase.
Solution Approach 2:
The patent creates a composite resin system combining multiple monomer types (caprolactone, glycolide, lactide) with different molecular weights and functionalities. This composite approach allows the resin to exhibit both improved mechanical properties from higher molecular weight components and maintained processability from lower viscosity components, effectively resolving the technical contradiction.
2Stability of the object's composition
If the crosslinking density is reduced and molecular weight is increased to improve mechanical properties, then elongation is improved, but viscosity and melting point increase making the resin unprocessable
Solution Approach 1:
The patent adjusts the molecular weight parameters of the polyol components and the ratio of polyfunctional monomers to achieve optimal elongation properties. By controlling these parameters within specific ranges, the patent improves elongation while preventing excessive viscosity increase that would compromise manufacturability.
3Ease of manufacture
If conventional resins are used for generative manufacturing, then low viscosity enables easy processing, but mechanical properties such as impact resistance and stretchability are insufficient
Solution Approach 1:
The patent develops a composite resin formulation that integrates multiple monomer components with complementary properties. The combination includes low-viscosity monomers for processability and high-molecular-weight monomers for mechanical strength, creating a synergistic effect that simultaneously achieves both easy processing and superior impact resistance.
Solution Approach 2:
The patent optimizes the molecular weight and functional group content parameters of the resin components to achieve the desired balance. By carefully selecting and adjusting these parameters, the patent produces a resin that maintains low enough viscosity for generative manufacturing while achieving high impact resistance and stretchability.
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 use of polycaprolactone significantly enhances the mechanical properties of cured products, including impact resistance and water resistance, while maintaining a high viscosity suitable for generative manufacturing processes.
Implementation Method 1
Radical (e.g., for acrylates) and cationic (e.g., for expoxy) polymerization are often used for this purpose. Special photoinitiators are added to the resin; they will change their state after having been exposed to light and thus trigger the polymerization of the reactive components.
Implementation Method 2
They will change their state after having been exposed to light
Data Source
AI summary
A light-curable composition is provided which may be used as a photopolymerizable material in an additive manufacturing process. The additive manufacturing process involves heating the light-curable composition which has a viscosity at 20° C. of at least 20 Pa·s. The light-curable composition includes a photopolymerizable matrix material, at least one thermoplastic polymer dissolved therein, and at least one photoinitiator. Polycaprolactone or a derivative thereof is used as the dissolved thermoplastic polymer.