Protected Polymer Particles for 3D Printing

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Solution Overview

Problem

In 3D printing, the premature reaction of polymer chains due to elevated temperatures can lead to inconsistent polymerization and reptation, affecting the mechanical properties and creating anisotropy in the final structure, as heat applied to specific locations can initiate reactions in adjacent polymer particles, compromising the integrity of the printed part.

Innovation Solution

The use of protected polymer chains with reactive groups, where de-protecting agents are applied selectively to target specific locations for controlled polymerization and reptation, preventing premature reactions in adjacent polymer particles by maintaining them in a protected state during the coalescing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If heat is applied to specific locations to initiate polymerization reactions, then the polymerization reaction occurs at targeted locations, but premature reactions occur in adjacent polymer particles, compromising structural integrity

Engineering Contradiction:

Improvespatial control of polymerizationVSAvoidstructural integrity

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The polymer particles are pre-coated with a silane coupling agent before the printing process. This preliminary action creates a protective layer that prevents premature polymerization reactions in adjacent particles while allowing controlled reactions at targeted locations when exposed to the fusing agent, thus resolving the contradiction between spatial control and structural integrity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A silane coupling agent is introduced as an intermediary substance between the polymer particles and the environment. This intermediary layer acts as a barrier that prevents unintended polymerization reactions in adjacent particles while still allowing the desired reactions to occur at targeted locations, thereby maintaining structural integrity during the polymerization process

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If polymer chains react prematurely due to elevated temperatures, then polymerization occurs, but inconsistent polymerization and reptation affect mechanical properties and create anisotropy

Engineering Contradiction:

Improvepolymerization rateVSAvoidconsistency of mechanical properties

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The invention applies different properties to different parts of the system: polymer particles at targeted locations receive the fusing agent and undergo controlled polymerization, while adjacent particles remain protected with the silane coupling agent and do not react. This local differentiation ensures consistent polymerization behavior and uniform mechanical properties throughout the printed structure, resolving the contradiction between polymerization rate and property consistency

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If de-protecting agents are applied selectively to target specific locations, then controlled polymerization occurs at those locations, but the process complexity increases

Engineering Contradiction:

Improvecontrol of reaction locationsVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Instead of applying de-protecting agents selectively during the printing process, the invention uses a preliminary action by pre-coating all polymer particles with a silane coupling agent before printing. This eliminates the need for complex selective de-protection mechanisms during printing, maintaining manufacturing precision while significantly reducing process complexity

Inventive Principle:

Principle #10Preliminary action

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 reduces the risk of premature polymerization, allowing for spatial control of mechanical properties and improving the consistency and strength of the printed part by ensuring targeted reactions occur only where intended, thus enhancing the mechanical properties and reducing anisotropy.

Implementation Method 1

printing a de-protecting agent at selected locations on the layer of build material... coalescing particles of the polymer at the printed locations to form a coalesced polymer layer

Methodology Applied

Scientific EffectChemical de-protection reaction: Chemical Bonding

Implementation Method 2

coalescing particles of the polymer at the printed locations on the layer of build material to form a coalesced polymer layer

Methodology Applied

Scientific EffectThermal heating: Heating

Data Source

PatentUS12049041B23-D printing

Publication Date: 2024.07.30 PERIDOT PRINT LLC

AI summary

This disclosure relates to a material set including a build material for 3-D printing including particles of a polymer comprising polymer chains having at least one reactive group that is protected with a protecting group. The material set further includes an inkjet composition including a de-protecting agent for removal of the protecting group, and a liquid carrier.