Thermosetting AM Composition for Low-Warp Large-Scale Curing
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Solution Overview
Problem
Large-scale polymer additive manufacturing faces challenges in printing and curing thermosetting materials without pre-heating or secondary energy exposure, leading to issues like warping and deformation due to thermal gradients.
Innovation Solution
The development of additive manufacturing compositions comprising a thermosetting material with a cross-linkable component and a free-radical initiator that cure without substantial deformation, controlling peak exotherm temperatures and enthalpy change to minimize thermal stress, using a series of layers that release heat to each other during curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermosetting materials are used for additive manufacturing, then material strength and structural integrity are improved, but thermal gradients cause warping and deformation during curing
Solution Approach 1:
The patent modifies the chemical composition parameters of the thermosetting material by incorporating specific additives and modifiers that alter the curing characteristics. These parameter changes reduce the exothermic heat release during curing and lower the glass transition temperature, thereby minimizing thermal gradients and preventing warping while maintaining material strength
Solution Approach 2:
The patent creates a composite material system by combining thermosetting polymers with specific additives, fillers, and modifiers. This composite approach allows the material to exhibit both high strength properties and reduced thermal stress during curing, resolving the contradiction between material strength and dimensional accuracy
2Reliability
If conventional thermosetting materials are cured, then structural integrity is achieved, but peak exotherm temperatures cause thermal stress and deformation
Solution Approach 1:
The patent changes the curing kinetics parameters by selecting specific catalysts and modifiers that reduce the peak exotherm temperature during the curing process. This parameter modification allows the material to achieve complete curing and structural integrity while maintaining lower temperatures that prevent thermal stress and deformation
Solution Approach 2:
The patent employs a multi-stage curing process with periodic temperature increases and holds, allowing the material to cure progressively. This periodic action distributes the exothermic heat release over time, preventing sudden temperature spikes while ensuring complete structural integrity
3Reliability
If pre-heating or secondary energy sources are used for curing, then curing completeness is improved, but process complexity and cost increase
Solution Approach 1:
The patent formulates the thermosetting material with self-curing capabilities through the selection of appropriate initiators, catalysts, and curing agents. The material generates and manages its own curing process through controlled exothermic reactions, eliminating the need for external pre-heating or secondary energy sources while ensuring complete curing
Solution Approach 2:
The patent extracts the curing function from external energy sources and embeds it within the material composition itself. By incorporating self-curing chemical systems, the patent removes the complexity of external heating equipment and energy supply systems while maintaining curing completeness
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 production of large-scale objects with reduced warpage and deformation by managing thermal stress, eliminating the need for pre-heating or secondary energy sources, and reducing complexity and cost.
Implementation Method 1
an initiator of free-radical cross-linking
Implementation Method 2
the composition cures without substantial deformation... controlling peak exotherm temperatures and enthalpy change to minimize thermal stress
Data Source
AI summary
A thermosetting composition comprising a crosslinkable component such as a vinyl ester and/or an unsaturated polyester, and an initiator component, such as cumene hydroperoxide or BPO or blends of cumene hydroperoxide and methyl ethyl ketone peroxide. The composition is suitable to be used in additive manufacturing to form objects such as molds or prototypes.