Thermoplastic Elastomer Polyketone Blend for 3D Printing
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Solution Overview
Problem
Thermoplastic elastomers (TPEs) face challenges in additive manufacturing, such as water absorption, warping, and sticking issues during the printing process, particularly when using Bowden extruders, limiting their commercial success in fused filament fabrication (FFF).
Innovation Solution
Blending thermoplastic elastomers with aliphatic ketones increases the elastic modulus and reduces friction, maintaining elastomeric properties, allowing for successful printing with Bowden tube-equipped 3D printers by forming a composition with dispersed polyketone domains within a continuous thermoplastic elastomer phase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If thermoplastic elastomers are used in FFF additive manufacturing, then elastomeric properties are achieved, but sticking to feed apparatus and difficulty in printing occur
Solution Approach 1:
The patent modifies the material composition by blending TPE with aliphatic polyketone in specific ratios (10-90 wt% TPE, 90-10 wt% polyketone), changing the physical and chemical parameters of the filament to reduce stickiness while preserving elastomeric properties
Solution Approach 2:
The invention creates a composite material system combining two distinct polymer phases - TPE continuous phase and polyketone dispersed domains - where each component contributes different properties: TPE provides elastomeric characteristics while polyketone reduces friction and sticking
2Strength
If TPE filaments are made flexible for elastomeric properties, then elasticity is improved, but sticking to Bowden tube increases
Solution Approach 1:
The patent adjusts the friction coefficient parameter by incorporating aliphatic polyketone, which has inherently lower surface energy and reduced adhesion properties, allowing flexible TPE to pass through Bowden tubes without excessive sticking
Solution Approach 2:
The composite structure creates a multi-phase material where polyketone domains dispersed in TPE matrix provide low-friction characteristics that counteract the sticking tendency of flexible elastomeric material
3Strength
If aliphatic polyketone is blended with TPE to increase elastic modulus, then stiffness increases, but material complexity increases
Solution Approach 1:
The patent optimizes the composition ratio of TPE to aliphatic polyketone within specific ranges (10-90 wt% TPE) to achieve the desired elastic modulus increase while maintaining processability and avoiding excessive material complexity
Solution Approach 2:
The invention creates a heterogeneous structure with polyketone dispersed domains distributed within the TPE continuous phase, where each phase performs its specific function: TPE provides flexibility and polyketone provides stiffness enhancement
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 blended composition facilitates the additive manufacturing of elastomeric articles by enhancing stiffness and reducing stickiness, enabling reliable printing without compromising elongation, thus overcoming previous printing difficulties.
Implementation Method 1
thermal plastic elastomeric copolymers (TPEs) when blended with an aliphatic ketone the elastic modulus increases (become stiffer)
Implementation Method 2
the coefficient of friction decreases (becomes less sticky)
Implementation Method 3
heating and extruding the composition of the 1st aspect through a print head to form an extrudate
Implementation Method 4
controllably depositing the extrudate into multiple fused layers to form the additive manufactured article
Data Source
AI summary
A composition useful for additive manufacturing is comprised of a thermoplastic elastomer blended with an aliphatic polyketone, wherein the thermoplastic elastomer is a continuous phase having dispersed therein separated domains of polyketone. The composition is useful for additive printing methods employing heating and extrusion of the composition to form extrudates that are printed an article comprised of fused layers of the composition. The composition facilitates the formation of extrusion based elastomeric additive manufactured articles.