Reactive Vinyl Binder Chemistry for Monolithic 3D Powder Printing
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Solution Overview
Problem
Current three-dimensional printing technologies face challenges in effectively bonding solid particles across layers, particularly in achieving strong and integral monolithic structures using liquid binders, which can result in suboptimal adherence and structural integrity.
Innovation Solution
The use of a 1,1-di-activated vinyl compound or its multifunctional form as a liquid binder, which infiltrates between solid particles and reacts to solidify, binding both the particles within each cross-sectional layer and bonding successive layers together, forming a monolithic and integral three-dimensional article.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional liquid binders are used in three-dimensional printing, then the printing process can be completed, but the bonding strength between cross-sectional layers is insufficient and structural integrity is compromised
Solution Approach 1:
The patent changes the chemical parameters of the binder by using 1,1-di-activated vinyl compounds instead of conventional binders. This chemical parameter change enables strong covalent bonding between particles and layers, resolving the contradiction between bonding strength and structural integrity.
Solution Approach 2:
The patent creates a composite material system where the 1,1-di-activated vinyl compound binder forms a integrated network with the solid particles. This composite approach ensures both strong layer bonding and overall structural integrity throughout the printed article.
2Strength
If conventional binders are used, then the process is simple, but the adherence between particles and layers is suboptimal
Solution Approach 1:
The patent replaces conventional physical bonding mechanisms with chemical bonding mechanisms. The 1,1-di-activated vinyl compounds undergo polymerization reactions that create strong chemical bonds between particles, substituting weak physical adhesion with strong chemical adherence.
Solution Approach 2:
The patent changes the chemical reactivity parameters of the binder system. The di-activated vinyl groups are highly reactive and undergo rapid polymerization, enabling strong particle adherence through chemical bonding rather than relying on complex multi-component systems.
3Adaptability or versatility
If weak bonding is achieved with conventional binders, then support structures are needed for complex features, but this increases article complexity and processing steps
Solution Approach 1:
The patent extracts the need for separate support structures by achieving sufficiently strong bonding with the 1,1-di-activated vinyl compound binder. The strong chemical bonds provide inherent structural support, allowing complex features to be printed without additional support infrastructure.
Solution Approach 2:
The patent changes the bonding strength parameter to a level where self-supporting structures can form during printing. The high reactivity and strong bonding of the di-activated vinyl compounds enable overhangs and complex geometries to be supported by the printed material itself rather than requiring separate support structures.
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 enhances the bonding between cross-sectional layers, resulting in a strong and integral three-dimensional article with improved structural integrity and adherence, allowing for the creation of complex features without separate support structures.
Implementation Method 1
The 1,1-di-activated vinyl compound, or multifunctional form thereof, or combination thereof, is reacted to solidify the liquid binder and bind the solid particles in the first cross-sectional layer of the article
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A process for producing an article by three-dimensional printing includes applying a 1,1-di-activated vinyl compound-containing liquid binder over a predetermined area of a layer of solid particles. The liquid binder infiltrates gaps between the solid particles to form a first cross-sectional layer of an article, and the 1,1-di-activated vinyl compound reacts to solidify the liquid binder and bind the solid particles in the first cross-sectional layer of the article. Also provided is an article produced by the three-dimensional printing process, set forth herein.