Reformable Resin Materials for Rigid, Low-Stress Additive Manufacturing
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Solution Overview
Problem
Existing thermoplastic materials used in additive manufacturing face issues such as incompatibility with secondary materials like epoxy-based adhesives and expandable foams, and lack of structural rigidity, necessitating the need for materials that exhibit attractive bonding characteristics and mechanical properties suitable for layer-by-layer fabrication.
Innovation Solution
The use of reformable resin materials with a polymer backbone containing ether linkages and optional pendant hydroxyl moieties, derived from epoxide-containing reactants, which can transform from a non-tacky to a tacky state upon heating, allowing adhesive bonding without cross-linking between layers, and exhibit thermoplastic and thermoset characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If typical thermoplastics are used in additive manufacturing, then ease of processing is improved, but bonding characteristics and structural rigidity deteriorate
Solution Approach 1:
The patent uses a composite material system consisting of a thermoplastic polyether base polymer combined with epoxy functional groups. This composite structure provides both the processing ease of thermoplastics and the bonding characteristics of epoxy thermosets, resolving the contradiction between ease of manufacture and strength.
Solution Approach 2:
The patent modifies the chemical parameters of thermoplastic materials by introducing epoxide functionality and ether linkages into the polymer backbone. This parameter change transforms the material properties to achieve both thermoplastic processability and thermoset-like mechanical properties, including improved bonding characteristics.
2Ease of manufacture
If typical thermoplastics are used in additive manufacturing, then ease of processing is improved, but structural rigidity deteriorates
Solution Approach 1:
The patent employs a composite polymeric material combining thermoplastic polyether chains with epoxy functional groups that provide structural rigidity. This composite structure maintains ease of processing while significantly improving structural rigidity and mechanical stability.
Solution Approach 2:
The patent changes the chemical composition parameters by incorporating epoxy functional groups and ether linkages into the thermoplastic polymer structure. This modifies the material to exhibit enhanced structural rigidity and mechanical properties while retaining thermoplastic processing characteristics.
3Strength
If epoxy-based materials are used to improve bonding characteristics, then strength is improved, but ease of processing deteriorates
Solution Approach 1:
The patent changes the physical and chemical parameters of epoxy-based materials by creating a thermoplastic polyether epoxy composite. This parameter change enables the material to be processed like thermoplastics (melt processing, extrusion) while maintaining the bonding characteristics of epoxy materials.
Solution Approach 2:
The patent creates a dynamic material system that can transition between different states - processing in a melted state like thermoplastics and exhibiting thermoset-like bonding characteristics when cured. This dynamic behavior resolves the contradiction between ease of processing and bonding strength.
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 materials enable layer-by-layer additive manufacturing with stable structures devoid of internal stresses, achieving tensile strengths, elongation, and modulus comparable to epoxy thermosets, while maintaining high deposition rates and minimal thermal stress.
Implementation Method 1
at least one processing (e.g., elevated temperature processing) characteristic typically associated with thermoplastic materials (e.g., a glass transition temperature)
Implementation Method 2
capable of transforming from a generally non-tacky first state to a second state in which the material is softened, upon application of heat
Implementation Method 3
to a third state in which the material is harder than when in the second state but remains able to further soften upon application of heat
Data Source
AI summary
The present teachings contemplate additive manufacturing of articles, such as articles made by layer-by-layer deposition of one or more reformable resin polymeric feed material.