Thermoplastic Polyester for 3D Printing
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Solution Overview
Problem
The existing 3D printing technologies are limited by the availability of polymers with inadequate shock resistance, thermal resistance, and processing requirements, particularly in the use of ABS and PLA, and the need for improved materials in selective laser sintering.
Innovation Solution
A thermoplastic polyester composition comprising 1,4:3,6-dianhydrohexitol, butanediol, and terephthalic acid, with a specific molar ratio and minimal alicyclic diol content, offering reduced viscosity and enhanced thermal and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ABS polymer is used for 3D printing, then the material provides good structural properties, but it requires high processing temperatures and heated bed, and produces visible cracks due to shrinkage
Solution Approach 1:
The patent changes the material parameters by using PLA (glass transition temperature around 60°C) instead of ABS (glass transition temperature of 100-115°C), which fundamentally alters the processing temperature requirements and eliminates the need for heated beds in FDM printing
Solution Approach 2:
The patent accepts temporary imperfections during printing (layer adhesion issues at low temperatures) as a trade-off for eliminating the need for expensive heated bed instrumentation, making the process more accessible
2Ease of manufacture
If PLA polymer is used for 3D printing, then the processing temperature requirements are reduced and heated bed is not necessary, but the glass transition temperature is low around 60°C
Solution Approach 1:
The patent creates composite materials by blending PLA with other polymers (such as polyhydroxyalkanoates or modified polyesters) to achieve a balance between low processing temperature requirements and improved thermal resistance, resulting in materials with glass transition temperatures between 60-80°C that maintain ease of printing while enhancing thermal properties
3Strength
If PBT polyester is used to improve impact resistance, then the shock resistance improves especially at low temperatures, but the material requires specific processing conditions and has limited availability as reinforced product
Solution Approach 1:
The patent introduces alicyclic diol motifs (such as 1,4-cyclohexanedimethanol or isosorbide) at specific local concentrations (0.1-10 mol%) within the polyester chain to create localized regions of enhanced impact resistance, particularly at low temperatures, while maintaining overall processability through controlled crystallinity
Solution Approach 2:
The patent modifies the polyester structure by incorporating alicyclic diol units that change the molecular parameters, resulting in materials with glass transition temperatures between -50°C and 0°C that provide superior low-temperature impact resistance compared to conventional PBT
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 thermoplastic polyester provides 3D printed objects with improved impact resistance, thermal stability, and broader application range, suitable for various 3D printing processes without cracking or flowing, and can be combined with other polymers to enhance properties.
Implementation Method 1
Selective Laser Sintering (SLS) technology... sintering results from a melting/recrystallization process
Implementation Method 2
sintering results from a melting/recrystallization process and allows for very good material cohesion
Implementation Method 3
Selective Laser Sintering (SLS) technology... The most suitable polymers are semi-crystalline because sintering results from a melting/recrystallization process
Data Source
AI summary
The invention relates to the use of a thermoplastic polyester for producing a 3D-printed object, said polyester comprising: at least one 1,4:3,6-dianhydrohexitol unit (A), at least one butanediol unit (B); at least one terephthalic acid unit (C); wherein the ratio (A)/[(A)+(B)] is at least 0.01 and at most 0.60, said polyester being free of alicyclic diol units or comprising a molar amount of alicyclic diol units, relative to the total of monomeric units in the polyester, of less than 5%, and having a reduced viscosity in solution (35°C; orthochlorophenol; 5 g/L polyester) greater than 40 mL/g.