Reactor for Photopolymerizable Material Prepolymerization
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Solution Overview
Problem
Current 3D printing technologies for building components lack an efficient method for large-scale prepolymerization of photopolymerizable materials within the device housing, leading to suboptimal adhesive properties and environmental resistance, and require external prepolymerization stages outside the device.
Innovation Solution
A reactor system with a cylindrical housing, an auger, and light emitting units for photopolymerization, along with sensors and a control unit to monitor and adjust viscosity and light intensity, ensuring precise prepolymerization within the device, allowing for improved control over the polymerization process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If photopolymerizable material is processed externally outside the device, then the device structure remains simple, but adhesive properties and environmental resistance are suboptimal
Solution Approach 1:
The patent combines the prepolymerization function with the main 3D printing device by integrating light emitting units, housing, and control systems into a single unified apparatus. This merging eliminates the need for external prepolymerization equipment while achieving improved adhesive properties and environmental resistance through controlled internal processing.
Solution Approach 2:
The device performs preliminary prepolymerization action on the photopolymerizable material before the actual 3D printing process. By using light emitting units to initiate partial polymerization within the housing, the material achieves optimal adhesive properties and environmental resistance prior to deposition, ensuring better performance of the final printed object.
2Manufacturing precision
If light emitting units are added to the device housing, then prepolymerization control is improved, but device complexity increases
Solution Approach 1:
The housing structure serves multiple functions: it contains the photopolymerizable material during processing, provides structural support for light emitting units, and acts as a reaction chamber for prepolymerization. This multi-functionality reduces the need for additional specialized components, thereby limiting the increase in device complexity while maintaining improved prepolymerization control.
Solution Approach 2:
The device incorporates sensors and control units that monitor the prepolymerization process in real-time and provide feedback to adjust light emitting unit operation. This feedback mechanism enables precise control over the degree of polymerization, ensuring optimal material properties while automating the process to reduce operational complexity.
3Reliability
If viscosity is increased through prepolymerization, then adhesive properties improve, but material flow characteristics change
Solution Approach 1:
The device employs dynamic control of the prepolymerization process by adjusting light intensity and exposure time based on real-time viscosity measurements. This dynamic adjustment allows the system to achieve the optimal balance between adhesive properties (requiring higher viscosity) and material flow characteristics (requiring lower viscosity), adapting the processing conditions to maintain both properties within acceptable ranges.
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 system enables the production of 3D-printable prepolymerized materials with enhanced viscosity, adhesive properties, and reduced shrinkage, facilitating the creation of large-sized construction objects with improved environmental resistance and efficiency.
Implementation Method 1
A reactor system with a cylindrical housing, an auger, and light emitting units for photopolymerization
Data Source
AI summary
Systems, devices, and methods are provided for producing a 3d-printable prepolymerized material. A device can include a reactor having a body including a housing having an exterior, and interior cavity, an input end, and an output end opposite of the input end, the output end comprising an opening, a loading hopper operably connected to the interior cavity of the housing, an auger supported within the interior cavity of the housing, a driving motor operably connected to the body configured to drive the auger; and a light emitting unit operably connected to the exterior of the housing.