Polymer Coating Adhesion on 3D Printed Objects
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Solution Overview
Problem
The challenge lies in achieving a polymer coating that adheres well to a polymer shaped object produced through 3D printing, as existing methods often result in the coating being stripped off due to uneven surfaces and thermal deformation issues.
Innovation Solution
A method involving the use of a curable composition with an organic compound having a functional group that reacts with energy rays, where the polymer shaped object is cured in a partially cured state and then irradiated with energy rays to form a stable polymer coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a polymer coating is formed on a polymer shaped object produced by 3D printing, then the surface characteristics are improved, but the polymer coating is stripped off from the polymer shaped object
Solution Approach 1:
The polymer shaped object is prepared in a partially cured state before coating application, allowing the coating to be applied to a more receptive surface. This preliminary state enables better coating penetration and bonding, preventing subsequent stripping while achieving desired surface characteristics.
Solution Approach 2:
The curing degree of the polymer shaped object is changed from fully cured to partially cured state. This parameter change makes the polymer matrix more open and receptive to coating penetration, enabling strong adhesion without compromising the structural integrity of the base object.
2Productivity
If a polymer shaped object is produced by 3D printing with a curable composition, then production efficiency is improved, but the surface has uneven stepped shapes
Solution Approach 1:
The polymer shaped object is prepared in a partially cured state immediately after 3D printing, before the surface defects become permanent. This timing allows the coating to be applied while the polymer matrix is still somewhat pliable, enabling the coating to fill and smooth the stepped surfaces.
Solution Approach 2:
The polymer coating acts as an intermediary layer that fills the uneven stepped surfaces of the 3D printed object. The coating material flows into and smooths over the surface irregularities, providing a finished surface that compensates for the limitations of additive manufacturing.
3Stability of the object's composition
If a polymer shaped object is fully cured before coating application, then structural stability is improved, but coating penetration and adhesion are reduced
Solution Approach 1:
The curing parameter is precisely controlled to achieve a partially cured state rather than full curing. This intermediate state maintains sufficient structural stability for handling while keeping the polymer matrix sufficiently open to allow coating penetration and strong adhesion.
Solution Approach 2:
The object is prepared in a controlled partially cured state as a preliminary step before coating application. This controlled state is maintained just long enough to apply the coating effectively, then final curing is completed to achieve both strong adhesion and structural stability.
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 effectively suppresses the stripping of the polymer coating, ensuring a strong bond between the coating and the base object, enhancing the surface characteristics and durability of the polymer member.
Implementation Method 1
a curable composition including an organic compound having a functional group which reacts with energy rays
Implementation Method 2
3D printing in which a cured product is deposited in layer-by-layer fashion
Data Source
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AI summary
To suppress peeling off of a polymer coating in a polymer member formed to have the polymer coating provided on a surface of a polymer shaped object, performed are: a curing step of causing a curable composition to be cured by energy rays to prepare the polymer shaped object; a coating step of forming the polymer coating on the polymer shaped object; and a post-curing step of irradiating the polymer shaped object with the energy rays after the coating step, wherein, in the curing step, the polymer shaped object in which a reactive functional group is left is prepared.