Polymer Slurry Manufacturing for High-Filler Additive Extrusion
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Solution Overview
Problem
Existing methods for incorporating additives into highly viscous polymers, such as synthetic rubbers and vinyl copolymer elastomers, are limited by the high viscosity of these materials, which restricts the amount of filler that can be added and damages mixing devices, and these polymers are too viscous for additive manufacturing.
Innovation Solution
A slurry is formed by dissolving polymers in a solvent to reduce viscosity, allowing for the incorporation of higher percentages of additives and enabling additive manufacturing or molding of high-hardness polymers, with a solvent-to-polymer ratio of 3:2 to 4:1, and subsequent curing to remove the solvent and restore the polymer's original viscosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical mixing processes such as high shear mixing or roll milling are used to incorporate additives into highly viscous polymers, then mixing can be achieved, but the polymer can break due to the force required or the mixing device can become damaged
Solution Approach 1:
The patent changes the physical state parameter of the polymer by dissolving it in a solvent to transform it from a highly viscous state to a low-viscosity slurry state. This parameter change allows additives to be incorporated without subjecting the polymer to damaging mechanical forces, thus preserving polymer integrity while achieving thorough mixing.
Solution Approach 2:
The patent introduces a solvent as an intermediary substance that facilitates the mixing process. The solvent acts as a mediator between the polymer and additives, enabling the formation of a homogeneous slurry without requiring direct mechanical contact between the polymer and mixing equipment, thereby preventing polymer breakdown and device damage.
2Quantity of substance
If the amount of filler added to highly viscous polymers is increased, then the desired properties can be achieved, but the mixing device or roll mill itself can become damaged
Solution Approach 1:
By changing the viscosity parameter of the polymer through solvent dissolution, the patent enables the incorporation of high percentages of filler (greater than 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% by weight) without overloading or damaging the mixing device. The low-viscosity slurry state accommodates large filler quantities while maintaining device integrity.
3Strength
If high viscosity and/or high hardness polymers are used, then the desired mechanical properties can be achieved, but they are too viscous to be extruded via an additive manufacturing device
Solution Approach 1:
The patent applies parameter changes by dissolving high-viscosity, high-hardness polymers in solvents to create low-viscosity slurries that are extrudable through additive manufacturing devices. After extrusion, the solvent is removed through curing, restoring the polymer to its original high-hardness state. This enables polymers with Shore durometer values greater than 90 Shore A to be manufactured additively.
4Ease of manufacture
If a slurry with solvent is used to reduce viscosity for additive manufacturing, then extrudability is improved, but the solvent must be removed after manufacturing
Solution Approach 1:
The patent utilizes phase transitions of the solvent (evaporation or decomposition) during a curing process to remove the solvent from the extruded part. This phase transition approach efficiently eliminates the solvent without requiring additional complex removal equipment, converting the manufacturing process into a single-step extrusion followed by curing.
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
Enables the additive manufacturing of high-hardness polymers with increased additive content, improving mechanical strength, flexibility, and control over the properties of the final part, while reducing the need for roll mills and compression presses.
Implementation Method 1
The polymer may be soluble in the solvent such that mixing the polymer with the solvent dissolves the polymer and produces the slurry
Implementation Method 2
a curing device for curing the part to remove the solvent
Implementation Method 3
the curing may involve heating the part to a temperature at which the solvent evaporates or decomposes
Data Source
AI summary
Systems and methods for forming a slurry and manufacturing a part with the slurry are disclosed. The slurry may comprise a solvent, a polymer soluble in the solvent, and additives insoluble in the solvent. The polymer may be dissolved in the solvent such that the slurry has a lower viscosity than a viscosity of the polymer, which may enable the slurry to flow and be utilized by a manufacturing device. Once manufactured, the solvent may be removed from the slurry material, and the manufactured part may have the original viscosity of the polymer.