Ring-Structured Curable Composition for High-HDT, Rigid 3D Prints
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Solution Overview
Problem
Existing UV-curable photopolymers used in 3D printing lack the thermal and mechanical properties required for real-world applications, particularly in automotive components that need high heat deflection temperature (HDT) and mechanical rigidity.
Innovation Solution
A curable composition comprising ethylenically unsaturated groups with isocyanurate and/or tricyclodecane ring structures, along with a photo-initiator, achieving an average glass transition temperature (Tg,av) of at least 373.15K, which results in 3D-printed objects with HDT of at least 100°C and excellent mechanical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional UV-curable photopolymers are used for 3D printing, then the printing process can be completed, but the resulting objects lack sufficient thermal and mechanical properties for real applications
Solution Approach 1:
The patent employs composite photopolymer formulations combining multiple components: (A) photopolymerizable compounds with specific functional groups (acrylate, methacrylate, vinyl), (B) oligomers with controlled molecular weights and functional groups, and (C) monomers with ethylenically unsaturated bonds. This composite approach enables simultaneous achievement of high HDT (≥100°C), excellent mechanical strength, and proper printability, resolving the contradiction between material performance and applicability.
Solution Approach 2:
The patent systematically adjusts critical parameters including: glass transition temperature (Tg ≥ 373.15K), HDT (≥100°C), molecular weight ranges, functional group ratios, and crosslinking density. By controlling these parameters within specific ranges, the formulation achieves both high thermal-mechanical performance and suitability for 3D printing processes, transforming conventional photopolymers into application-ready materials.
2Reliability
If photopolymers with high HDT and mechanical strength are developed, then real applications become possible, but the formulation complexity increases
Solution Approach 1:
The patent assigns specific functional roles to different formulation components: Component (A) provides base polymerization and basic mechanical properties, Component (B) contributes to crosslinking density and thermal stability, and Component (C) enhances flexibility and processability. This functional segmentation allows each component to be optimized independently for its specific role, managing overall formulation complexity while achieving high HDT and mechanical performance.
Solution Approach 2:
The patent employs multifunctional compounds that simultaneously provide multiple desired properties. For example, certain oligomers and monomers contribute to both crosslinking (improving strength) and flexibility (improving processability). The photopolymerizable compounds serve both as structural building blocks and as sources of ethylenically unsaturated groups for crosslinking, reducing the need for separate additives and simplifying the overall formulation.
3Temperature
If the glass transition temperature is increased to at least 373.15K, then the heat deflection temperature reaches at least 100°C, but the material becomes more rigid and harder to process
Solution Approach 1:
The patent creates a dynamic formulation system where the photopolymer composition transitions from a processable liquid state during printing to a rigid solid state after curing. The specific combination of oligomers and monomers with controlled molecular weights ensures adequate viscosity and flow characteristics during the printing process, while the same formulation achieves HDT ≥100°C and Tg ≥373.15K upon complete curing, effectively managing the contradiction between processability and final performance.
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 composition enables 3D-printed objects with high HDT and mechanical rigidity, suitable for automotive applications such as interior parts and connectors, by leveraging the structural integrity and thermal stability of isocyanurate and tricyclodecane ring structures.
Implementation Method 1
UV-curable photopolymer is a class of 3D-printable materials which have been widely used... (B) at least one photo-initiator... wherein the curable composition is cured by UV irradiation
Data Source
AI summary
The present invention relates to a curable composition, which comprises: (A) at least one component containing an ethylenically unsaturated group, wherein component (A) comprises a component (A1) containing a structure (K) selected from an isocyanurate structure and/or a tricyclodecane ring structure; and (B) at least one photo-initiator, wherein the average glass transition temperature (Tg,av) calculated from the curable composition using the following Fox's equation is at least 373.15K, preferably at least 393.15K, more preferably at least 423.15K, wherein Tg,i is the glass transition temperature in Kelvin of the homopolymer of component (i) constituting component (A), and w, is the mass fraction of component (i) in component (A); to a process of forming a 3D-printed object from the same and a 3D-printed object prepared therefrom. The 3D-printed object obtained from the curable composition of the present invention has high HDT and excellent mechanical performances.1Tg,av=∑wiTg,i