Water-Soluble Polyester Resin Recovery from 3D Printing Effluent
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Solution Overview
Problem
The existing methods for removing support materials from 3D printed objects using fused deposition modeling, such as polyvinyl alcohol and methacrylic acid copolymers, face challenges like moisture absorption issues and the need for hazardous strong alkaline solutions, leading to environmental concerns and safety hazards.
Innovation Solution
A method involving the addition of metal salts like calcium, magnesium, sodium, or potassium salts to the effluent, followed by heat treatment, to precipitate and recover water-soluble polyester resin from the effluent, which is then separated and reused, reducing environmental impact and safety risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If polyvinyl alcohol is used as support material and dissolved in water, then the support material can be easily removed, but the material absorbs moisture from air causing foaming during printing
Solution Approach 1:
The invention changes the chemical composition parameters of the support material by using water-soluble polyester resin with specific molecular weight (5,000-50,000) and sulfonate group content (0.5-3.0 mmol/g), which modifies the material's moisture absorption characteristics while maintaining water solubility for easy removal
Solution Approach 2:
The support material is designed as a composite containing water-soluble polyester resin combined with other polymers (polyvinyl alcohol, carboxymethyl cellulose, starch, or proteins) in specific ratios, creating a material that balances moisture resistance with water solubility for support removal
2Reliability
If methacrylic acid copolymer is used as support material, then moisture absorption is reduced, but strong alkaline solutions are required for removal creating safety hazards
Solution Approach 1:
The invention changes the chemical composition by using water-soluble polyester resin with controlled sulfonate group content (0.5-3.0 mmol/g) and molecular weight, enabling the support material to be removed with mild aqueous solutions instead of strong alkaline solutions, thus eliminating safety hazards while maintaining moisture absorption resistance
Solution Approach 2:
The support material is designed as a disposable component that can be easily removed through dissolution in water or mild aqueous solutions, eliminating the need for hazardous chemicals and simplifying the removal process safety
3Object-affected harmful factors
If water-soluble polyester resin is used as support material, then safety is improved by eliminating strong alkaline solutions, but the resin dissolves in water creating environmental pollution
Solution Approach 1:
The invention implements a recovery system where the water-soluble polyester resin dissolved in the aqueous solution is recovered through precipitation using neutralizing agents (calcium hydroxide, magnesium hydroxide, sodium hydroxide, or potassium hydroxide in controlled amounts), converting the harmful dissolved resin back into solid form that can be separated and disposed of safely, thus eliminating environmental pollution while maintaining safety benefits
4Ease of operation
If water-soluble polyester resin is used with controlled sulfonate groups, then water solubility is maintained for easy removal, but moisture absorption resistance must be preserved
Solution Approach 1:
The invention precisely controls the sulfonate group content parameter within the range of 0.5-3.0 mmol/g and molecular weight within 5,000-50,000, which maintains sufficient water solubility for support material removal while limiting excessive moisture absorption from the environment
Solution Approach 2:
The support material is formulated as a composite where water-soluble polyester resin is combined with other polymers (polyvinyl alcohol, carboxymethyl cellulose, starch, or proteins) in specific ratios, creating a material system where the resin provides water solubility while the other polymers contribute moisture absorption resistance
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 method safely recovers water-soluble polyester resin from the effluent, minimizing environmental load and eliminating the need for hazardous chemicals, while maintaining moisture absorption resistance and improving handling safety.
Implementation Method 1
adding, to the effluent, at least one metal salt selected from the group consisting of a calcium salt, a magnesium salt, a sodium salt, a potassium salt, an aluminum salt, and an iron salt... to precipitate and recover water-soluble polyester resin from the effluent
Implementation Method 2
followed by heat treatment, to precipitate and recover water-soluble polyester resin from the effluent
Data Source
AI summary
The present invention is a three-dimensional-modeling soluble material to be used as a material of a support member for supporting a three-dimensional object when the three-dimensional object is produced with a 3D printer that employs a fused deposition modeling method. The three-dimensional-modeling soluble material contains a polyester resin comprising: an aromatic dicarboxylic acid monomer unit A having a sulfonic acid base; a dicarboxylic acid monomer unit B that does not have a sulfonic acid base; and a diol monomer unit, wherein the proportion of the aromatic dicarboxylic acid monomer unit A in the total of all dicarboxylic acid monomer units is 10 to 70 mol %. The present invention can provide a three-dimensional-modeling soluble material to be used for a support member, which material is suitable for production of a three-dimensional object by the FDM method, has moisture-absorption resistance, has a high rate of dissolution in neutral water, and can be quickly removed from a three-dimensional object precursor without using a strong alkali aqueous solution.