ROMP 3D Inkjet Printing via Segmented Catalyst System
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Solution Overview
Problem
Current 3D inkjet printing technologies face limitations in using Ring-Opening Metathesis Polymerization (ROMP) formulations due to rapid curing at ambient conditions, which restricts their application in 3D inkjet processes requiring specific viscosity ranges for inkjet printing heads.
Innovation Solution
The method involves employing a catalyst system with a pre-catalyst and an activator for ROMP, where at least one formulation contains a Ruthenium-based pre-catalyst and another contains the activator, allowing for controlled polymerization and maintaining suitable viscosity for inkjet printing, using bidentate Schiff base ligands and specific activators like trichlorododecyl silane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ROMP formulations are used in 3D inkjet printing, then high thermal resistance and toughness are achieved, but rapid curing at ambient conditions causes premature polymerization during jetting
Solution Approach 1:
The catalyst system is segmented into two separate formulations: one containing the pre-catalyst and another containing the activator. These formulations are jetted separately and only mix after deposition on the substrate, preventing premature polymerization during the jetting process while enabling ROMP curing to achieve high toughness in the final object
Solution Approach 2:
A dormant pre-catalyst species acts as an intermediary that requires activation by a separate activator component to initiate polymerization. This intermediary state allows the formulation to remain stable during jetting and storage, then activate rapidly after deposition to achieve the desired curing and mechanical properties
2Temperature
If ROMP formulations are used in 3D inkjet printing, then high thermal resistance is achieved, but viscosity becomes unsuitable for inkjet printing heads due to rapid curing
Solution Approach 1:
The catalyst system is divided into separate pre-catalyst and activator formulations, each maintaining suitable viscosity for inkjet printing individually. This segmentation allows both formulations to be jetted through standard print heads without clogging, then mixed and cured on the substrate to achieve high thermal resistance
Solution Approach 2:
The viscosity parameters of the formulations are optimized by controlling the concentration and state of the pre-catalyst and activator components. By maintaining the pre-catalyst in a dormant state and separating it from the activator, the formulations achieve viscosity ranges suitable for inkjet printing while retaining the ability to cure and provide high thermal resistance
3Productivity
If catalyst is added to ROMP monomer before jetting, then polymerization is initiated, but viscosity increases and causes clogging of inkjet printing heads
Solution Approach 1:
The catalyst system is segmented into dormant pre-catalyst and activator components that are jetted separately. This prevents the polymerization reaction from occurring during the jetting process, maintaining low viscosity and preventing head clogging, while enabling rapid polymerization initiation after the formulations mix on the substrate
Solution Approach 2:
The pre-catalyst is prepared in a dormant, inactive state before jetting, allowing it to be stored and jetted without initiating polymerization. The activation step is performed preliminarily planned but delayed until after deposition, ensuring viscosity remains suitable for printing while polymerization is ready to initiate rapidly when needed
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 approach enables the use of ROMP-based materials in 3D inkjet printing, achieving high thermal resistance, toughness, and chemical resistance while preventing premature polymerization during jetting, thus overcoming the viscosity and reactivity challenges.
Implementation Method 1
employing a catalyst system with a pre-catalyst and an activator for ROMP, where at least one formulation contains a Ruthenium-based pre-catalyst and another contains the activator, allowing for controlled polymerization
Data Source
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AI summary
Methods for fabricating three-dimensional objects by 3D-inkjet printing technology are provided. The methods utilize curable materials that polymerize via ring- opening metathesis polymerization (ROMP) for fabricating the object, in combination with acid-activatable pre-catalyst and an acid generator activator. Kits containing modeling material formulations usable in the methods are also provided.