Thermoplastic Polyurethane Sinter Powder for 3D Printing
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Solution Overview
Problem
Three-dimensional shaped articles produced from existing sinter powders using thermoplastic polyurethane often face a trade-off between high energy return and high E-modulus, with most having either one but not both, which is undesirable for applications like the footwear market that requires both properties.
Innovation Solution
A sinter powder composition comprising 58.5% to 99.95% thermoplastic polyurethane, 0.05% to 1.5% flow agent, 0% to 5% organic additive, and 0% to 30% reinforcer, where the thermoplastic polyurethane is prepared by reacting isocyanate, isocyanate-reactive compounds, and chain extenders with limited aromatic moieties, optimizing the balance between energy return and E-modulus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If thermoplastic polyurethane is used in selective laser sintering, then high energy return is achieved, but E-modulus is low
Solution Approach 1:
The patent combines thermoplastic polyurethane with reinforcers (fibers, particles, or structural elements) to create a composite material that simultaneously achieves high energy return (≥55%) and high E-modulus (92-300 MPa). The reinforcer component provides the necessary stiffness while the thermoplastic polyurethane matrix maintains the energy return properties, resolving the trade-off between these two mechanical properties.
Solution Approach 2:
The patent modifies the chemical composition parameters of the thermoplastic polyurethane by limiting aromatic moieties to not more than 15 mol-% in each component (isocyanate, isocyanate-reactive compound, and chain extender). This parameter change optimizes the balance between energy return and E-modulus, allowing the material to achieve both high energy return (≥55%) and adequate stiffness (E-modulus 92-300 MPa) without relying solely on reinforcers.
2Strength
If aromatic moieties are increased in thermoplastic polyurethane components, then E-modulus is improved, but energy return decreases
Solution Approach 1:
The patent establishes an optimal parameter range by limiting aromatic moieties to not more than 15 mol-% in each component. This parameter constraint prevents excessive E-modulus increase that would compromise energy return, while still allowing sufficient aromatic content to maintain adequate stiffness. The balanced composition achieves both energy return (≥55%) and E-modulus (92-300 MPa) simultaneously.
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 sinter powder achieves a high energy return of ≥55% and an E-modulus in the range of 92 to 300 MPa, along with high elongation at break, making it suitable for applications requiring both properties.
Implementation Method 1
the thermoplastic polyurethane (A) is prepared by reacting at least one isocyanate (a), at least one isocyanate-reactive compound (b), and at least one chain extender (c)
Implementation Method 2
The sinter powder achieves a high energy return of ≥55% and an E-modulus in the range of 92 to 300 MPa
Data Source
AI summary
The present invention relates to a sinter powder (SP) comprising 58.5% to 99.95% by weight of at least one thermoplastic polyurethane (A), 0.05% to 1.5% by weight of at least one flow agent (B), 0% to 5% by weight of at least one organic additive (C), 0% to 5% by weight of at least one further additive (D) and 0% to 30% by weight of at least one reinforcer (E), based in each case on the sum total of the percentages by weight (A), (B), (C), (D) and (E), wherein the thermoplastic polyurethane (A) is prepared by reacting at least one isocyanate (a), at least one isocyanate-reactive compound (b), and at least one chain extender (c), and wherein components (a), (b) and (c) each comprise not more than 15 mol-% of aromatic moieties, based on the total amount of the respective component (a), (b) and (c). The present invention further relates to a method of producing the sinter powder (SP) and to the use of the sinter powder (SP) in a three-dimensional (3D) printing process. The present invention further relates to a three-dimensional shaped article comprising the thermoplastic polyurethane (A), to a method of producing a three-dimensional shaped article and to the use of the at least one thermoplastic polyurethane (A) in a three-dimensional (3D) printing process for producing a three-dimensional shaped article to improve the energy return of the three-dimensional shaped article.