Polyurethane Dental Cutter Composite Strength Uniformity
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Solution Overview
Problem
Existing polyurethane-based composite materials for dental cutting work face challenges in achieving uniformity, strength, and water resistance, particularly when using methods described in Patent Literature 3.
Innovation Solution
A method involving a polyaddition reaction step followed by a radical polymerization step, using a diol compound with radically polymerizable groups and a diisocyanate compound, along with a polymerizable monomer and a filler, to form a polyurethane-based composite material with controlled molecular weight and filler content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a polyurethane-based composite material is produced using the method described in Patent Literature 3, then strength and water resistance are improved, but uniformity of the cured body deteriorates
Solution Approach 1:
The patent changes the molecular weight parameter of the polyurethane component to a specific range (1,500-5,000) and adjusts the filler content parameter (60-85 mass%) to achieve both high strength and uniformity. This parameter optimization resolves the contradiction by finding the optimal balance point where strength is maximized while uniformity is maintained.
Solution Approach 2:
The patent creates a composite material system combining polyurethane component (A) with filler (D) in specific ratios. This composite approach allows the material to achieve both strength enhancement from the filler and uniformity from the optimized polyurethane matrix structure, resolving the contradiction between strength and uniformity.
2Strength
If filler content is increased to improve strength, then strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent performs preliminary classification of filler particles by size and type before mixing, and pre-prepares the polyurethane component with controlled molecular weight. This preliminary action ensures that when filler is added at high content (60-85 mass%), the mixing process remains manageable and manufacturing complexity is reduced despite the high filler loading.
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 method produces a polyurethane-based composite material that is not only strong and water-resistant but also uniform, with excellent bonding properties, making it suitable for dental cutting work.
Implementation Method 1
a polyaddition reaction step of subjecting a diol compound (a1) having one or more radically polymerizable groups and a diisocyanate compound (a2) to a polyaddition reaction
Implementation Method 2
a radical polymerization step of performing radical polymerization using a radically polymerizable raw material composition after completion of the polyaddition reaction step
Data Source
AI summary
To produce a cured body excellent in strength, water resistance, and uniformity, provided is a method of producing a polyurethane-based composite material, including: a polyaddition reaction step of performing a polyaddition reaction in a first raw material composition containing a radically polymerizable monomer (B) free from causing a polyaddition reaction with any of a radically polymerizable diol compound (a1) and a diisocyanate compound (a2), to thereby form a polyurethane component (A) having a number average molecular weight of from 1,500 to 5,000; a second raw material composition-preparing step of preparing a second raw material composition containing the component A, the component B, a radical polymerization initiator, and a filler; and a radical polymerization step of performing radical polymerization using the second raw material composition after completion of the polyaddition reaction step and the second raw material composition-preparing step, wherein a ratio R represented by the following equation 1 is from 20 mass% to 80 mass%: Equation 1 R=100×B/[a1+a2+A+B], where a1, a2, A, and B represent the contents (parts by mass) of the component a1, the component a2, the component A, and the component B in the second raw material composition.