Thermoset 3D Printed Parts with Phase Change Material
Solution Overview
Problem
Current additive manufacturing techniques, such as Fused Filament Fabrication and Stereolithography, face limitations in incorporating phase change materials into thermoset polymers, particularly for applications requiring temperature ranges below the decomposition point of these materials, and struggle with complex part geometries and support structure removal.
Innovation Solution
A method involving the dispensing of a mixture containing an organic reactive material and phase change material through a nozzle to form a thermoset material with the phase change material, allowing for the creation of additive manufactured parts that undergo phase changes at useful temperatures, enabling applications like heat transient mitigation and shape modification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If Fused Filament Fabrication (FFF) is used to manufacture parts, then complex geometries can be achieved, but the materials are limited to thermoplastics and require elevated temperatures that make it difficult to incorporate phase change materials
Solution Approach 1:
The patent changes the fundamental manufacturing parameter from thermal melting (FFF) to photocuring (SLA), enabling the incorporation of phase change materials without requiring elevated temperatures that would melt or degrade them
Solution Approach 2:
The patent creates a composite resin system combining thermoset polymers with phase change materials, where the thermoset matrix encapsulates and protects the phase change material while the photocurable component enables low-temperature manufacturing
2Temperature
If Stereolithography (SLA) is used to manufacture thermoset parts, then low temperatures can be maintained, but it is difficult to incorporate additives like phase change materials into the photocurable resin
Solution Approach 1:
The patent modifies the resin composition locally by incorporating phase change material particles into specific regions of the photocurable resin, allowing the resin to maintain its photocurability while gaining the thermal energy storage capability of the phase change material
Solution Approach 2:
The patent develops a composite photocurable resin system that combines thermoset polymers with phase change materials, creating a multi-functional material that can be processed at low temperatures while incorporating the desired phase change properties
3Strength
If thermoset polymers are used in additive manufacturing, then high strength and heat resistance can be achieved, but the manufacturing process requires temperatures that cause the phase change material to decompose
Solution Approach 1:
The patent replaces thermal curing with photocuring, substituting a chemical reaction initiated by light absorption instead of heat, thereby achieving thermoset polymer formation without exposing the phase change material to decomposing temperatures
Solution Approach 2:
The patent changes the curing mechanism from thermal to photonic initiation, allowing thermoset polymers to be formed at ambient temperatures that preserve the phase change material's integrity
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
Enables the production of parts that can undergo phase changes at temperatures below their decomposition point, allowing for heat management, shape retention, and recovery, suitable for applications such as noise suppression, vibration mitigation, and complex geometries without the need for elevated temperatures during manufacturing.
Implementation Method 1
the phase change material undergoes a phase change at a temperature less than where the thermoset material decomposes
Implementation Method 2
allowing the organic reactive material to react forming a thermoset material
Data Source
AI summary
An additive manufactured article is comprised of at least two adhered layers of extrudates (120) comprised of a thermoset material having therein a phase change material, wherein the phase change material undergoes a phase change at a temperature less than where the thermoset material decomposes. The article may be made by dispensing a mixture comprised of an organic reactive material and phase change material forming extrudates that are 3D printed into an article having multiple layers of extrudates bound together and then allowing the organic reactive material to react forming a thermoset material having therein the phase change material to form the additive manufactured article. The shape of the article may be changed by heating to a temperature above the temperature where the phase change material undergoes a phase change while applying a force and then cooling below the phase change temperature. Likewise, the original shape may be returned by merely heating above the phase change temperature and then cooling in the absence of a force being applied.