3D Printable Resin Composition for Isotropic Mechanical Strength
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Solution Overview
Problem
3D printed products often exhibit lower mechanical properties compared to traditionally processed materials due to anisotropy and intrinsic limitations in printable materials, which restrict their application in engineering products requiring isotropic reinforcement.
Innovation Solution
A resin composition comprising two monomeric or oligomeric components and a photoinitiator, where one component polymerizes faster to form a hard, cross-linked network that is interpenetrated by a second component, resulting in a polymer with enhanced mechanical properties through sequential polymerization and improved interface interaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If carbon-fiber reinforced plastics are added to enhance strength and modulus, then mechanical performance is improved, but inter-laminar shear strength remains low limiting engineering applications
Solution Approach 1:
The patent employs a composite material system consisting of carbon fibers embedded in a dual-monomer resin matrix. This composite structure combines the high strength and modulus of carbon fibers with the enhanced inter-laminar shear strength provided by the specific monomer combination, resolving the contradiction between achieving high strength and maintaining reliable inter-laminar bonding.
Solution Approach 2:
The patent modifies the resin composition parameters by specifically selecting monomers with particular functional groups and molecular structures that enhance inter-laminar shear strength. By changing the chemical composition parameters of the binder phase, the patent achieves improved inter-laminar bonding while maintaining the reinforcing effect of carbon fibers.
2Strength
If standard processing methods like injection molding are used, then mechanical properties are high, but production flexibility and complexity of structures are limited
Solution Approach 1:
The patent segments the material system into distinct functional components: carbon fibers for reinforcement, specific monomers for matrix formation and bonding, and photoinitiators for controlled curing. This segmentation allows each component to be optimized for its specific function while maintaining overall compatibility, enabling both high mechanical properties and processing flexibility.
Solution Approach 2:
The patent changes the physical state parameter of the resin from solid to liquid through careful selection of monomers and their ratios, enabling the material to be processed via 3D printing while achieving high mechanical properties after curing. This parameter change allows the material to flow during printing and then solidify into a structurally sound final product.
3Stability of the object's composition
If photopolymerization techniques are used to eliminate anisotropy, then isotropic mechanical properties are achieved, but mechanical performance remains poor for engineering applications
Solution Approach 1:
The patent creates a composite material system where carbon fibers provide reinforcement and the specific monomer combination provides both isotropic properties through photopolymerization and enhanced mechanical performance. The synergistic interaction between the reinforcement phase and matrix phase resolves the contradiction between achieving isotropy and maintaining high strength.
Solution Approach 2:
The patent changes the chemical composition parameters of the photopolymerizable resin by selecting specific monomers with appropriate functional groups and molecular weights. This parameter optimization enables the resin to achieve both complete photopolymerization for isotropic properties and sufficient mechanical strength for engineering applications.
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 resulting polymer exhibits superior mechanical strength and flexibility, surpassing individual component properties and market benchmarks like RenShape®SL 7820, with improved tensile modulus and flexure strength, and displays isotropic mechanical properties.
Implementation Method 1
A photoinitiator or photoinitiator system is required to convert photolytic energy into the reactive species, a radical or cation, which can drive the chain growth via radical or cationic mechanism.
Data Source
AI summary
This invention relates to a resin composition comprising at least one of a first monomeric or oligomeric component (A), at least one of a second monomeric or oligomeric component (B) and a photoinitiator. This invention also relates to a method of preparing a polymer from the resin composition, a polymer prepared from the resin composition, a method of forming a 3-dimensional printed article, and a kit comprising at least one of a first monomeric or oligomeric component (A), at least one of a second monomeric or oligomeric component (B) and a photoinitiator.