Zirconium Catalysts for Low Viscosity Additive Manufacturing Resins
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Solution Overview
Problem
Dual cure additive manufacturing resins using bismuth or tin catalysts face issues such as hazing due to water interaction, residual metal contamination, and increased viscosity, which affect durability and printability.
Innovation Solution
The use of zirconium catalysts to produce (meth)acrylate blocked polyurethanes (ABPUs) with reduced viscosity, maintaining lower resin viscosity during printing and improving handling and printability, while avoiding residual metal contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bismuth catalysts are used to produce ABPUs, then the resin can be made, but the resin becomes hazy over time due to catalyst interaction with water
Solution Approach 1:
The patent changes the catalyst type from bismuth to zirconium, altering the chemical parameter of the catalyst system. This parameter change resolves the hazing issue while maintaining catalytic functionality, as zirconium catalysts do not exhibit the same water interaction problems as bismuth catalysts.
Solution Approach 2:
The patent employs a catalyst system where the zirconium catalyst is used in controlled amounts and its potential deactivation or side reactions do not compromise the final product quality. The catalyst performs its function during ABPU synthesis and does not persist as a harmful residual in the final resin.
2Ease of manufacture
If tin catalysts are used to produce ABPUs, then the resin can be made, but residual tin contaminates the final product and accelerates ester group hydrolysis
Solution Approach 1:
The patent changes the catalyst type from tin to zirconium, altering the chemical parameter of the catalyst system. This parameter change eliminates residual metal contamination issues while maintaining catalytic efficiency during ABPU production.
Solution Approach 2:
The zirconium catalyst is used effectively during the synthesis process and does not persist as harmful residual tin contamination in the final resin product, solving the contamination problem while maintaining manufacturing efficiency.
3Ease of manufacture
If bismuth or tin catalysts are used, then ABPUs can be produced, but the resin viscosity increases and printability decreases
Solution Approach 1:
The patent changes the catalyst type from bismuth/tin to zirconium, altering the chemical parameter of the catalyst system. This parameter change results in ABPUs with substantially reduced viscosities, improving resin flow and printability during additive manufacturing while maintaining ABPU production capability.
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
Zirconium-based ABPUs result in resins with lower viscosities and improved long-term durability and printability, addressing the limitations of bismuth and tin catalysts in dual cure resins.
Implementation Method 1
zirconium catalysts can be used to make an ABPU
Implementation Method 2
when the zirconium-based ABPU is combined with a polyol and/or polyamine, the resin maintains a lower viscosity over the time of the printing process
Implementation Method 3
the bismuth catalysts can cause resins to become hazy over time, as the catalyst interacts with water and (apparently) precipitates
Implementation Method 4
Residual tin in final parts can also result in accelerated ester group hydrolysis over time, decreasing the long-term durability
Data Source
AI summary
Provided herein are methods of making (meth)acrylate blocked polyurethanes with zirconium catalysts, dual cure resins containing (meth)acrylate blocked polyurethanes and zirconium catalysts, methods of using the same in additive manufacturing, and products made therefrom.