Spherical CNM-Graft-Polymer Particles for Uniform SLS Packing

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Solution Overview

Problem

Existing additive manufacturing processes, particularly selective laser sintering, face challenges in uniformly incorporating fillers into thermoplastic polymers, leading to irregular properties and potential failure points in the final objects due to uneven distribution of carbon nanomaterial-polymer composites.

Innovation Solution

The development of highly spherical carbon nanomaterial-graft-polymer (CNM-g-polymer) particles with specific properties such as aerated density, circularity, and angle of repose, which are produced via in situ polymerization, ensuring even dispersion and improved mechanical properties in 3-D printed objects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If fillers are incorporated into thermoplastic polymers to improve physical properties, then the mechanical strength and functionality of the objects are enhanced, but the uniformity of distribution deteriorates leading to irregular properties and potential failure points

Engineering Contradiction:

Improvemechanical strengthVSAvoiduniformity of distribution

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The patent creates a composite material system where carbon nanomaterials are chemically grafted to polymer chains during in situ polymerization. This forms a unified CNM-g-polymer composite where the filler and matrix are covalently bonded, ensuring homogeneous distribution at the molecular level while maintaining enhanced mechanical properties.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The carbon nanomaterials are prepared and functionalized beforehand with reactive groups before polymerization. This preliminary action ensures that when polymerization occurs, the polymer chains automatically graft onto the nanomaterial surfaces, pre-establishing uniform distribution patterns before the material is used in additive manufacturing.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If conventional filler incorporation methods are used, then the manufacturing process is simple, but the flowability and sintering behavior for additive manufacturing deteriorate

Engineering Contradiction:

Improvesimplicity of incorporation processVSAvoidflowability

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The patent changes the fundamental parameter of filler-polymer interaction from physical mixing to chemical bonding. By modifying the chemical structure of the filler surface with reactive functional groups, the material transitions from requiring complex mixing processes to enabling simple one-step in situ polymerization, while simultaneously improving flowability through uniform particle morphology.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If fillers are added to polymer matrices, then new properties are imparted to the material, but the homogeneous incorporation into particulates deteriorates

Engineering Contradiction:

Improvenew propertiesVSAvoidhomogeneous incorporation

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent introduces reactive functional groups as intermediaries between the carbon nanomaterials and the polymer matrix. These functional groups act as connection points that facilitate uniform grafting during polymerization, serving as mediators that ensure homogeneous incorporation of the filler throughout the polymer particulates.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Strength

If carbon nanomaterials are incorporated into polymers, then mechanical properties are enhanced, but void spaces and poor packing increase

Engineering Contradiction:

Improvemechanical propertiesVSAvoidvoid spaces

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The in situ polymerization process naturally forms spherical CNM-g-polymer particulates with smooth surfaces and uniform sizes. This spherical morphology improves packing efficiency in powder beds for additive manufacturing, reducing void spaces between particles while maintaining the enhanced mechanical properties provided by the carbon nanomaterial grafts.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 CNM-g-polymer particles enhance the mechanical properties and flowability of 3-D printed objects, reducing void spaces and improving structural integrity by achieving better packing and distribution within the printing process.

Implementation Method 1

Methodology Applied

Scientific EffectIn situ polymerization: Photopolymerisation

Data Source

PatentUS12384867B2Spherical particles comprising carbon nanomaterial-graft-polymer and methods of production and uses thereof

Publication Date: 2025.08.12 XEROX CORP

AI summary

Highly spherical particles may comprise a thermoplastic polymer grafted to a carbon nanomaterial (CNM-g-polymer), wherein the particles have an aerated density of about 0.5 g/cm3 (preferably about 0.55 g/cm3) to about 0.8 g/cm3. Said CNM-g-polymer particles may be useful in a variety of applications including selective laser sintering additive manufacturing methods.