RF Curing of Thermally Cross-Linkable Polymers to Prevent Warping
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Solution Overview
Problem
Existing additive manufacturing techniques using photo curable resins face limitations in achieving desired mechanical and electrical properties, and are prone to warping due to long curing times with heat application, necessitating the use of thermally cross-linkable materials that can be cured uniformly and efficiently.
Innovation Solution
Incorporating electromagnetic radiation susceptors into thermally cross-linkable polymeric materials and using an electromagnetic energy generator to apply RF energy for controlled heating and curing, allowing for rapid and uniform cross-linking of the materials during the additive manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermally cross-linkable materials are used in additive manufacturing, then superior mechanical and electrical properties are achieved, but warping and defects occur due to long curing times and heat application
Solution Approach 1:
The patent replaces conventional thermal curing systems with an electromagnetic radiation curing system. The electromagnetic energy applicator delivers targeted electromagnetic radiation (such as microwave or radio frequency energy) to the printed layers, enabling rapid cross-linking without prolonged thermal exposure. This substitution of the curing mechanism eliminates warping while achieving superior mechanical properties.
Solution Approach 2:
The patent incorporates electromagnetic radiation susceptors into the thermally cross-linkable material formulation before printing. These susceptors are pre-distributed throughout the material, enabling immediate and uniform energy absorption and cross-linking upon electromagnetic radiation application. This preliminary preparation allows rapid curing without the long thermal exposure times that cause warping.
2Stability of the object's composition
If conventional thermal curing is used, then cross-linking of materials is achieved, but long curing times cause warping and defects
Solution Approach 1:
The patent replaces thermal conduction-based curing with electromagnetic radiation-based curing. The electromagnetic energy applicator directly couples energy to the material through electromagnetic fields, which are absorbed by susceptors and converted to heat rapidly and uniformly throughout the printed layer. This eliminates the slow thermal diffusion process, reducing curing time from hours to minutes or seconds while achieving complete cross-linking.
Solution Approach 2:
The patent changes the fundamental curing parameter from thermal conduction to electromagnetic radiation absorption. By formulating materials with electromagnetic radiation susceptors and applying corresponding electromagnetic energy, the curing process achieves rapid and uniform cross-linking throughout the material volume, dramatically reducing curing time while maintaining complete cross-linking stability.
3Loss of time
If photo curable resins are used, then rapid curing is achieved, but desired mechanical and electrical properties are not obtained
Solution Approach 1:
The patent develops composite materials combining thermally cross-linkable polymers with electromagnetic radiation susceptors. This composite formulation enables the material to respond to electromagnetic radiation for rapid curing while maintaining the superior mechanical and electrical properties characteristic of thermally cured materials. The susceptor particles are distributed throughout the polymer matrix, creating a composite that achieves both rapid processing and high performance.
Solution Approach 2:
The patent changes the curing mechanism parameter from photopolymerization to electromagnetic radiation-induced thermal cross-linking. This parameter change allows the use of high-performance thermally cross-linkable materials while achieving rapid curing times comparable to photo curable resins. The electromagnetic radiation provides the energy needed for rapid cross-linking without compromising the superior properties of thermally cured materials.
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 method enables the production of 3D parts with superior mechanical and electrical properties, avoiding warping and long curing times, while expanding the range of materials available for additive manufacturing, including thermoset and thermoplastic materials, with precise control over heating and curing.
Implementation Method 1
An electromagnetic energy applicator to supply electromagnetic energy to the thermally cross-linkable material and at least one electromagnetic energy susceptor in the thermally cross-linkable material to cause heating of the at least one electromagnetic energy susceptor material
Implementation Method 2
predetermined cross-linking of the at least one cross-linkable polymeric material
Data Source
AI summary
The invention relates to additive manufacturing systems and methods using thermally cross-linkable materials. The thermally cross-linkable material includes at least one thermally cross-linkable polymeric material and an amount of at least one electromagnetic energy susceptor therein. A system with at least one print head and an electromagnetic energy generator is provided to produce electromagnetic energy in the area of the thermally cross-linkable material after being dispensed from the print head. This causes heating of the electromagnetic energy susceptor to cause curing of the thermally cross-linkable material.