Water Soluble Polymer Support for Additive Manufacturing
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Solution Overview
Problem
Current additive manufacturing techniques face limitations due to the lack of suitable support materials and methods, particularly for printing complex geometries, as existing support materials are often difficult to remove and incompatible with hydrophobic polymers, leading to restricted object design types and inefficient printing processes.
Innovation Solution
The development of water-soluble polymer compositions, combining a water-soluble polymer like butenediol vinylalcohol copolymer with a sugar such as trehalose, which can dissolve in room temperature water, provide improved stiffness, adhesion, and rheological properties, enabling their use as support materials for high-temperature thermoplastics in additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional support materials (same material as printed object) are used, then support structures can be erected effectively, but support material removal becomes time-consuming and difficult
Solution Approach 1:
The patent extracts the support material removal process from the printed object by using a dissolvable support material that can be selectively removed through dissolution in water or aqueous solutions, separating the support function from the final product and enabling easy removal without mechanical intervention
Solution Approach 2:
The patent changes the chemical parameters of the support material by incorporating hydrophilic polymers and water-soluble additives that transform the support material from water-resistant to water-soluble, enabling dissolution-based removal and dramatically reducing cleanup time
2Adaptability or versatility
If hydrophobic polymers are used as support materials, then certain printing applications are enabled, but compatibility with support materials and printed base resin becomes problematic
Solution Approach 1:
The patent creates composite support materials combining hydrophilic polymers (polyvinyl alcohol, polyacrylonitrile) with water-soluble additives (sugars, salts), achieving both water solubility for easy removal and compatibility with various printed materials including hydrophobic polymers
Solution Approach 2:
The patent uses water-soluble polymers as intermediary materials that bridge the gap between hydrophobic printed objects and the aqueous removal environment, enabling both printing of hydrophobic materials and subsequent water-based support removal
3Ease of operation
If water soluble polymers are used as support materials, then easy removal is achieved, but the materials are brittle and not suited for conventional filament type additive manufacturing
Solution Approach 1:
The patent formulates composite filaments combining water-soluble polymers with plasticizers and water-soluble additives that provide flexibility and processability during extrusion while maintaining water solubility for support removal, resolving the brittleness issue
Solution Approach 2:
The patent changes the physical parameters of water-soluble polymers by adding plasticizers and modifiers that increase flexibility and reduce brittleness, enabling conventional filament extrusion processes while preserving the water-soluble characteristic
4Reliability
If sugars are used as water soluble additives, then water solubility and adhesion are improved, but sugars are heat sensitive and caramelize or degrade above melting temperatures
Solution Approach 1:
The patent optimizes the concentration and type of sugar additives to balance water solubility with thermal stability, using sugars as secondary additives rather than primary components, thereby achieving adequate water solubility while limiting caramelization and degradation
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
These compositions allow for the successful printing of complex geometries by providing a support material that is easily removable and compatible with both hydrophilic and hydrophobic polymers, enhancing the printability of high-temperature thermoplastics and reducing the time and effort required for support material removal.
Implementation Method 1
Water soluble polymer compositions, including a water soluble polymer (e.g., butenediol vinylalcohol copolymer (BVOH)) and a sugar (e.g., trehalose), can dissolve in room temperature water
Implementation Method 2
the sugar may be imparting pressure sensitive characteristics to facilitate improved adhesion at printing temperatures, as described by the Dahlquist Criterion
Data Source
AI summary
A water soluble polymer composition includes a water soluble polymer and a sugar and may be used as a support in additive manufacturing processes.