Additive Manufacturing Polymer with Alignment Additive
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Solution Overview
Problem
The limited flowability of high molecular-weight thermoplastic polymers in additive manufacturing due to randomly oriented and entangled polymer chains, which requires high temperatures and pressures, increasing manufacturing costs and potentially degrading material properties.
Innovation Solution
Incorporating an alignment additive, such as liquid-crystal compounds or hyperbranched macromolecules, into the polymer matrix to align polymeric chains in the flow direction, improving flowability and reducing viscosity, thereby facilitating the additive manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high molecular-weight thermoplastic polymers are used to achieve desirable mechanical properties and thermal stability, then the material strength and thermal resistance are improved, but the flowability deteriorates due to randomly oriented and entangled polymer chains
Solution Approach 1:
The patent applies preliminary action by incorporating an alignment additive into the polymer matrix before the additive manufacturing process. This alignment additive pre-aligns the polymer chains in the flow direction, so that when the material is extruded through the nozzle, the chains remain oriented rather than becoming randomly entangled. This preliminary alignment improves flowability during printing while maintaining the mechanical properties provided by high molecular-weight polymers.
2Ease of manufacture
If high temperatures and pressures are applied to improve the flowability of high molecular-weight polymers, then the manufacturing process becomes feasible, but the material properties may be degraded and manufacturing costs increase
Solution Approach 1:
The patent applies parameter changes by modifying the molecular structure of the polymer through the incorporation of alignment additives. This changes the physical parameters of the material, specifically the orientation and arrangement of polymer chains, which fundamentally alters the flow characteristics. Instead of relying on extreme temperature and pressure parameters to achieve flowability, the aligned chain structure enables processing at more moderate conditions while preserving material properties.
3Productivity
If high temperatures and pressures are used to process high molecular-weight polymers, then the material can be extruded, but the manufacturing cost increases
Solution Approach 1:
The alignment additive fundamentally changes the rheological parameters of the polymer material. By pre-aligning the polymer chains, the material exhibits improved flow characteristics that reduce the energy required for extrusion. This parameter change in molecular orientation allows the material to be processed at lower temperatures and pressures, directly reducing energy consumption and manufacturing costs while maintaining extrusion capability.
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 alignment additive enhances the flowability of thermoplastic polymers, allowing for lower processing temperatures and pressures, maintaining desirable material properties while improving the manufacturing efficiency and range of usable polymers.
Implementation Method 1
Incorporating an alignment additive, such as liquid-crystal compounds or hyperbranched macromolecules, into the polymer matrix to align polymeric chains in the flow direction
Data Source
Figure 1
Figure 2A~2B
Figure 3A
AI summary
A material, an additively manufactured article, and a process for additive manufacture of an article comprises conveying a material through a heated nozzle to form a flowing mass of the material. The material comprises a polymer matrix including a plurality of polymeric chains and an alignment additive dispersible within the polymer matrix. The alignment additive is configured to align the plurality of polymeric chains in a flow direction of the flowing mass of the material. The process further comprises aligning at least a portion of the polymeric chains, via the alignment additive, along a direction of flow through the heated nozzle, releasing the flowing mass of the material from the heated nozzle, and allowing the material to solidify.