Polypropylene Block Copolymer 3D Printing Fusing Agent

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Solution Overview

Problem

Current 3D printing technologies face challenges in efficiently fusing and coalescing polymer build materials, particularly with polyolefin-based compositions, due to limitations in thermal merging and binding mechanisms, which affect the quality and strength of the final printed parts.

Innovation Solution

A three-dimensional printing composition comprising a thermoplastic polymer powder composition with a polypropylene block copolymer, an infrared absorbing fusing agent, and a detailing agent, where the fusing agent penetrates voids and spreads on the polymer surface to convert radiation into thermal energy, facilitating thermal merging and binding of the polymer build material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If thermal merging and binding mechanisms are used to fuse polymer build materials, then the polymer layers can be coalesced to form solid parts, but the fusion quality and strength are insufficient particularly with polyolefin-based compositions

Engineering Contradiction:

Improvefusion strengthVSAvoidfusion reliability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent introduces a fusing agent as an intermediary substance that mediates the fusion process between polymer particles. The fusing agent penetrates voids between particles and spreads on the exterior surface, facilitating thermal merging and binding. This intermediary approach resolves the contradiction by providing a chemical bridge that enhances fusion strength and reliability for polyolefin-based compositions that are difficult to fuse using thermal mechanisms alone.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent modifies the chemical composition parameters of the build material by incorporating specific additives (fusing agents, detailings agents, and other compounds) into the polyolefin matrix. These parameter changes enable the polymer to achieve better fusion characteristics, transforming the material properties to overcome the inherent limitations of polyolefin thermal merging and binding.

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If conventional binders or adhesives are used to bind build materials together, then material coalescence can be achieved, but the mechanical properties and quality of printed parts are compromised

Engineering Contradiction:

Improvematerial coalescenceVSAvoidmechanical properties

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

The patent replaces conventional mechanical binding methods (adhesives and binders) with a thermal-fusion mechanism enhanced by chemical additives. Instead of relying on external adhesive materials to bind particles, the system uses controlled thermal energy combined with fusing agents that promote direct particle-to-particle fusion, thereby maintaining mechanical properties while achieving stable material coalescence.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates a composite build material system consisting of polyolefin base material combined with specially formulated fusing agents and detailing agents. This composite approach allows the material to exhibit both stable coalescence (through the polymer matrix) and improved mechanical properties (through the functional additives that enhance fusion without compromising strength).

Inventive Principle:

Principle #40Composite materials

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 solution enhances the fusion and coalescence of polymer layers, resulting in stronger and more reliable three-dimensional printed parts with improved mechanical properties, such as tensile strength, and a broader processing window for the thermoplastic polymer powder composition.

Implementation Method 1

the fusing agent comprises at least one infrared absorbing compound... capable of absorbing radiation and converting the absorbed radiation to thermal energy

Methodology Applied

Scientific EffectInfrared radiation absorption and thermal energy conversion: Absorption (EM radiation)

Implementation Method 2

In the patterned region, the fusing agent is capable of at least partially penetrating into voids between the polymer build material particles, and is also capable of spreading onto the exterior surface

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 3

at least partial melting may be accomplished using heat-assisted extrusion... the mechanism for material coalescence may depend upon the type of build material used

Methodology Applied

Scientific EffectThermal melting: Melting

Data Source

PatentUS11745417B2Three-dimensional printing

Publication Date: 2023.09.05 PERIDOT PRINT LLC

AI summary

This disclosure describes compositions, kits, methods, systems, and three-dimensional parts. According to an example, described herein is a polymeric powder build material comprising a thermoplastic polymer powder composition, wherein the thermoplastic polymer powder composition comprises a polypropylene block copolymer made from a polymerizing propylene and ethylene or butylene or 1-pentene or 1-hexene or 1-octene or 4-methyl-1-pentene and polypropylene homopolymers.