Visible-Light Photocurable Resin for Rapid 3D Polymerization
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Solution Overview
Problem
Existing 3D printing methods using visible light photocuring have not been effectively demonstrated for stereolithography or digital light processing, lacking efficient compositions and methods to utilize low energy visible LEDs for rapid polymerization.
Innovation Solution
Development of photocurable compositions comprising specific photosensitizers, co-initiators, and co-monomers that absorb in the visible light spectrum, enabling polymerization using LEDs with wavelengths from 400 nm to 1400 nm, including xanthene, squaraine, boron-dipyrromethene, cyanine, and porphyrin derivatives, along with borate and diphenyliodonium salts, to induce rapid polymerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high energy ultraviolet light is used for photocuring, then rapid polymerization and short build times are achieved, but energy consumption increases and biocompatibility decreases
Solution Approach 1:
The patent changes the wavelength parameter of the light source from ultraviolet to visible light range (400-1400 nm), specifically utilizing LEDs in the blue, green, and red regions. This parameter change enables the use of lower energy light sources while maintaining or improving polymerization efficiency through photosensitizers that are activated by visible light wavelengths.
Solution Approach 2:
The patent introduces photosensitizers as intermediary substances that absorb visible light and transfer energy to initiate polymerization. These photosensitizers act as mediators between the low-energy visible light source and the polymerization process, enabling rapid curing without requiring high-energy ultraviolet light.
2Productivity
If high energy ultraviolet light is used for photocuring, then rapid polymerization is achieved, but biocompatibility and functional group tolerance decrease
Solution Approach 1:
The patent changes the energy parameter of the light source from high-energy ultraviolet to lower-energy visible light. This parameter change reduces the harmful effects on biological tissues while maintaining polymerization capability through the use of photosensitizers that are sensitive to visible light wavelengths.
3Adaptability or versatility
If conventional photocuring compositions are used, then existing 3D printing processes work, but visible light absorption is insufficient for rapid polymerization
Solution Approach 1:
The patent modifies the optical parameters of the composition by incorporating photosensitizers with specific absorption bands in the visible light range (400-1400 nm). This enables the composition to efficiently absorb energy from visible light sources including LEDs, achieving rapid polymerization while maintaining compatibility with various light source types.
Solution Approach 2:
The patent creates a composite photopolymerization system combining monomers, photosensitizers, and co-initiators. This composite formulation enables efficient visible light absorption and energy transfer to achieve rapid polymerization, addressing the insufficiency of conventional single-component systems.
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
Facilitates rapid polymerization with reduced energy consumption, improved biocompatibility, and enhanced depth of penetration, allowing for next-generation designer material fabrication in 3D printing.
Implementation Method 1
photocurable compositions comprising: a (co)monomer, a photosensitizer having an absorption band, wherein at least a portion of the absorption band is located at one or more wavelength from 400 nm to 1400 nm
Implementation Method 2
a photosensitizer having an absorption band, wherein at least a portion of the absorption band is located at one or more wavelength from 400 nm to 1400 nm
Data Source
AI summary
Disclosed herein are photocurable compositions and methods of use thereof. The photocurable compositions comprise: a (co)monomer; a photosensitizer having an absorption hand, wherein at least a portion of the absorption band is located at one or more wavelength from 400 nm to 1400 nm, and wherein the photosensitizer comprises a xanthene, a squaraine, a boron-dipyrromethene, a cyanine, a porphyrin, or a combination thereof; an acceptor co-initiator comprising a diphenyliodonium salt; and a donor co-initiator comprising a borate salt. The photocurable compositions optionally further comprise a crosslinker, an opacifier, a solvent, an oxygen scavenger, a radical scavenger, or a combination thereof. Also disclosed herein are methods of forming a (co)polymer from the photocurable compositions disclosed herein, methods of forming an object via additive manufacturing using the photocurable compositions disclosed herein, articles of manufacture comprising a cured product of the photocurable compositions disclosed herein, and methods of use thereof.