WO2024178486A1 - Three-dimensional architected materials for energy absorption - Google Patents
Three-dimensional architected materials for energy absorption Download PDFInfo
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- WO2024178486A1 WO2024178486A1 PCT/CA2023/051285 CA2023051285W WO2024178486A1 WO 2024178486 A1 WO2024178486 A1 WO 2024178486A1 CA 2023051285 W CA2023051285 W CA 2023051285W WO 2024178486 A1 WO2024178486 A1 WO 2024178486A1
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- acrylate
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- ebecryl
- methacrylate
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J3/00—Processes of treating or compounding macromolecular substances
- C08J3/24—Crosslinking, e.g. vulcanising, of macromolecules
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y70/00—Materials specially adapted for additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F290/00—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups
- C08F290/02—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups on to polymers modified by introduction of unsaturated end groups
- C08F290/06—Polymers provided for in subclass C08G
- C08F290/067—Polyurethanes; Polyureas
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F41—WEAPONS
- F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
- F41H5/00—Armour; Armour plates
- F41H5/02—Plate construction
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2351/00—Characterised by the use of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers
- C08J2351/08—Characterised by the use of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers grafted on to macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2375/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
- C08J2375/04—Polyurethanes
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
- F16F7/00—Vibration-dampers; Shock-absorbers
Definitions
- THREE-DIMENSIONAL ARCHITECTED MATERIALS FOR ENERGY ABSORPTION CROSS-REFERENCE TO RELATED APPLICATIONS [0001] The present application claims the benefit of priority from co-pending U.S. Provisional Application No. 63/448,704, filed on February 28, 2023, the contents of which are incorporated herein by reference in their entirety.
- FIELD [0002] The present disclosure relates to a material having a three-dimensional shape. In particular, the material has a three-dimensional shape comprising a first phase and a second phase and having a concentration gradient interpenetrating polymer network.
- INTRODUCTION [0003] Currently, impact attenuating materials used in protective devices are not sufficiently efficient at absorbing impact forces throughout their volume.
- Foam and truss-based attenuation materials made by traditional manufacturing techniques are heavily limited in the morphologies of their internal cellular units. Furthermore, their monolithic composition and constant architectural parameters (e.g. strut thickness, radius and length) throughout the structure prevent location-specific fine tuning of dimensions for locally graded deformation modes. As a result, large volumes of material are required for desired performance, and 1 8784422 generally impacts cause inelastic deformation in the architectural features. This limits their utility to very few impacts.
- SUMMARY [0006] The present disclosure relates to a three-dimensional architected material having energy absorptive properties.
- the disclosure is directed to a material having a three-dimensional shape comprising: a) a first phase comprising a first crosslinked polymer; and b) a second phase comprising a concentration gradient interpenetrating polymer network comprising the first crosslinked polymer and a second polymer, the concentration gradient interpenetrating polymer network comprising the second polymer at a decreasing concentration along at least one axis within the first phase; and the three-dimensional shape of the material aids in energy absorption.
- the first crosslinked polymer has a different stiffness at low or high strain rates compared to the second polymer.
- the first crosslinked polymer has a stiffness at low or high strain rates different than that of the second polymer by at least 5%.
- the first crosslinked polymer is an elastomeric polymer.
- the elastomeric polymer is a polyurethane, polysiloxane (silicone), poly(meth)acrylate, polyether, polyamide, polyester, polythiol, or a combination thereof.
- the elastomeric polymer is an elastomeric polyurethane.
- the polyurethane is a urethane-based acrylate elastomer or an aromatic urethane-based acrylate elastomer.
- the urethane-based acrylate elastomer or aromatic urethane-based acrylate elastomer is formed from Ebecryl 8413, CN9021, CN973J75, Formlabs Flexible 80A, Ebecryl 231, Ebecryl 4491, Ebecryl 242, Ebecryl 270, Ebecryl 1271, Ebecryl 8411, Ebecryl 8413, Ebecryl 4827, CN9031, CN966J75, CN9782.
- the first crosslinked polymer is crosslinked with a crosslinker which is a di-, tri-, tetra-, or multifunctional (meth)acrylate, a crosslinker having vinyl moieties, a crosslinker having thiol moieties, a crosslinker having epoxy moieties, a crosslinker having amine moieties, a crosslinker having alcohol moieties, or a crosslinker having carboxylic acid moieties.
- a crosslinker which is a di-, tri-, tetra-, or multifunctional (meth)acrylate
- a crosslinker having vinyl moieties a crosslinker having thiol moieties
- a crosslinker having epoxy moieties a crosslinker having amine moieties
- a crosslinker having alcohol moieties or a crosslinker having carboxylic acid moieties.
- the 2 8784422 crosslinker is Eberly 8413, CN9021, CN973J75, Formlabs Flexible 80A, Ebecryl 231, Ebecryl 4491, Ebecryl 242, Ebecryl 270, Ebecryl 1271, Ebecryl 8411, Ebecryl 8413, Ebecryl 4827, CN9031, CN966J75, or CN9782.
- the urethane-based acrylate elastomer or aromatic urethane-based acrylate elastomer contains a reactive diluent comprising Ebecryl 113, 2-hydroxyethyl methacrylate, 2-hydroxyethyl acrylate, ethyl methacrylate, hydroxypropyl methacrylate, hydroxybutyl methacrylate, ethylene glycol methyl ether methacrylate, 1,6-hexanediol diacrylate, 2-hydroxy acrylate, isobornyl acrylate, glycidyl acrylate, glycidyl methacrylate, methacrylate, acrylate, 2- phenoxyethylacrylate, tert-butyl acrylate, n-butyl acrylate, ethyl acrylate, benzyl acrylate, methyl acrylate, lauryl acrylate, vinyl acrylate, isobutyl
- the elastomeric polymer is a liquid crystal elastomer.
- the liquid crystal elastomer is formed from a precursor material comprising a liquid crystal mesogen and a chain extender.
- the liquid crystal mesogen is a diacrylate and the chain extender is a dithiol and/or amine.
- the liquid crystal mesogen is 1,4-bis-[4-(6- acryloyloxyhexyloxy)benzoyloxy]-2-methylbenzene; 1,4-bis-[4-(3- acryloyloxypropyloxy)benzoyloxy]-2-methylbenzene; 4,4’-bis[9- (acryloyloxy)nonyloxy]azobenzene, benzoic acid; 4-[2-[(1-oxo-2-propen-1-yl)- oxy]ethoxy]-, 4-[2-[(1-oxo-2-propen-1-yl)oxy]ethoxy]phenyl ester; 4-((6-((1-oxo-2- propen-1-yl)oxy)hexyl)oxy)benzoic acid-1,1’-(1,4-phenylene) ester; 4-[4-[(1-oxo-2- propen-1-yl)oxy]butoxy]-1,1
- the liquid crystal elastomer is chain extended with 2,2’-(ethylenedioxy) diethanethiol, 1,3-propanedithiol, glycol di(3- mercaptoprpionate), allyl dithiol, pentaerythritol tetrakis (3-mercaptoprpionate), n- butylamine, 1,5-diaminopentane, furfurylamine, 5-amino-1-pentanol, 1,3,5-triallyl- 1,3,5-triazine,2,4,6(1H,3H,5H)-trione.
- the second polymer is a poly(meth)acrylate, polyurethane, polysiloxane (silicone), polyether, polyamide, polyester, polythiol, or a combination thereof.
- the poly(meth)acrylate is formed from 2- hydroxyethyl methacrylate, 2-hydroxyethyl acrylate, ethyl methacrylate, hydroxypropyl methacrylate, hydroxybutyl methacrylate, ethylene glycol methyl ether methacrylate, 1,6-hexanediol diacrylate, 2-hydroxy acrylate, isobornyl acrylate, glycidyl acrylate, glycidyl methacrylate, methacrylate, acrylate, 2- phenoxyethylacrylate, tert-butyl acrylate, n-butyl acrylate, ethyl acrylate, benzyl acrylate
- the poly(meth)acrylate is a crosslinked polymer.
- the three-dimensional shape is an architected material, a lattice composed of beams or surface elements, or a foam.
- the three-dimensional shape has a relative density of less than 50% (by volume).
- the material has an increase in toughness at densification and/or energy absorption efficiency under compression tests when compared to the random copolymer composed of the equivalent weight percent of precursor materials from the first and second polymers or a non-gradient interpenetrating polymer network.
- the material is for vibration damping, vibration isolation, acoustic damping, acoustic isolation, or impact attenuation.
- the material is an energy absorbing material.
- the concentration gradient is a continuous concentration gradient.
- the first crosslinked polymer is a 3D-printable polymer.
- the 3D-printable polymer is printable through 4 8784422 volumetric 3D printing, vat polymerization 3D printing, material jetting 3D printing, powder bed fusion, or material extrusion 3D printing.
- the second phase has a thickness between about 1% and 99% of the thickness of the first phase. In one embodiment, the second phase has a thickness between about 15% and 40% of the thickness of the first phase.
- the concentration gradient interpenetrating polymer network is a continuous concentration gradient interpenetrating polymer network.
- the first phase is adjacent to the second phase.
- the present disclosure also includes a process for preparing a material having a three-dimensional shape.
- the process comprises: a) 3D-printing a first cross-linked polymer in the form of the three-dimensional shape to form a first phase comprising the first crosslinked polymer; b) exposing at least a portion of the first cross-linked polymer in the form of the three-dimensional shape to a liquid precursor comprising second polymer precursors, wherein the second polymer precursors diffuse into the first cross-linked polymer to obtain the first cross-linked polymer in the form of the three-dimensional shape with a decreasing concentration gradient of the second polymer precursor in the first cross-linked polymer to form a second phase within the first phase; and c) polymerizing the second polymer precursors to form the second polymer and to obtain the material having a concentration gradient interpenetrating polymer network.
- the 3D-printed first cross-linked polymer is formed by: - polymerizing and cross-linking first polymer precursors in the presence of a cross-linker and a photoinitiator, by exposing the first polymer precursors to light radiation during three-dimensional printing to obtain the first cross-linked polymer in the form of the three-dimensional shape; or 5 8784422 - extruding first polymer precursors, in the presence of a cross-linker, through a nozzle to obtain the first crosslinked polymer in the form of the three-dimensional shape.
- the light radiation is UV light, visible light or near-infrared light.
- the first cross-linked polymer in the form of the three-dimensional shape is soaked or immersed in the liquid precursor mixture.
- the second polymer precursors in step (c) are polymerized by exposing to radiation. In one embodiment, the radiation is heat or light radiation.
- the first crosslinked polymer has a different stiffness at low or high strain rates compared to the second polymer. In a further embodiment, the first crosslinked polymer has a stiffness at low or high strain rates different than that of the second polymer by at least 5%.
- the first crosslinked polymer is an elastomeric polymer.
- the elastomeric polymer is a polyurethane, polysiloxane (silicone), poly(meth)acrylate, polyether, polyamide, polyester, polythiol, or a combination thereof.
- the elastomeric polymer is an elastomeric polyurethane.
- the polyurethane is a urethane- based acrylate elastomer or an aromatic urethane-based acrylate elastomer.
- the urethane-based acrylate elastomer or aromatic urethane- based acrylate elastomer is formed from Ebecryl 8413, CN9021, CN973J75, Formlabs Flexible 80A, Ebecryl 231, Ebecryl 4491, Ebecryl 242, Ebecryl 270, Ebecryl 1271, Ebecryl 8411, Ebecryl 8413, Ebecryl 4827, CN9031, CN966J75, CN9782.
- the crosslinker is a di-, tri-, tetra-, or multifunctional (meth)acrylate, a crosslinker having vinyl moieties, a crosslinker having thiol moieties, a crosslinker having epoxy moieties, a crosslinker having amine moieties, a crosslinker having alcohol moieties, or a crosslinker having carboxylic acid moieties.
- the crosslinker is Ebecryl 8413, CN9021, CN973J75, Formlabs Flexible 80A, Ebecryl 231, Ebecryl 4491, Ebecryl 242, Ebecryl 6 8784422 270, Ebecryl 1271, Ebecryl 8411, Ebecryl 8413, Ebecryl 4827, CN9031, CN966J75, or CN9782.
- the urethane-based acrylate elastomer or aromatic urethane-based acrylate elastomer contains a reactive diluent comprising Ebecryl 113, 2-hydroxyethyl methacrylate, 2-hydroxyethyl acrylate, ethyl methacrylate, hydroxypropyl methacrylate, hydroxybutyl methacrylate, ethylene glycol methyl ether methacrylate, 1,6-hexanediol diacrylate, 2-hydroxy acrylate, isobornyl acrylate, glycidyl acrylate, glycidyl methacrylate, methacrylate, acrylate, 2- phenoxyethylacrylate, tert-butyl acrylate, n-butyl acrylate, ethyl acrylate, benzyl acrylate, methyl acrylate, lauryl acrylate, vinyl acrylate, isobutyl acrylate, Ebecryl
- the elastomeric polymer is a liquid crystal elastomer.
- the liquid crystal elastomer is formed from a precursor material comprising a liquid crystal mesogen and a chain extender.
- the liquid crystal mesogen is a diacrylate and the chain extender is a dithiol and/or amine.
- the liquid crystal mesogen is 1,4-bis-[4-(6- acryloyloxyhexyloxy)benzoyloxy]-2-methylbenzene; 1,4-bis-[4-(3- acryloyloxypropyloxy)benzoyloxy]-2-methylbenzene; 4,4’-bis[9- (acryloyloxy)nonyloxy]azobenzene, benzoic acid; 4-[2-[(1-oxo-2-propen-1-yl)- oxy]ethoxy]-, 4-[2-[(1-oxo-2-propen-1-yl)oxy]ethoxy]phenyl ester; 4-((6-((1-oxo-2- propen-1-yl)oxy)hexyl)oxy)benzoic acid-1,1’-(1,4-phenylene) ester; 4-[4-[(1-oxo-2- propen-1-yl)oxy]butoxy]-1,1
- the liquid crystal elastomer is chain extended with 2,2’-(ethylenedioxy) diethanethiol, 1,3-propanedithiol, glycol di(3- mercaptoprpionate), allyl dithiol, pentaerythritol tetrakis (3-mercaptoprpionate), n- butylamine, 1,5-diaminopentane, furfurylamine, 5-amino-1-pentanol, 1,3,5-triallyl- 1,3,5-triazine,2,4,6(1H,3H,5H)-trione.
- the second polymer precursors are monomers of the second polymer.
- the second polymer is a poly(meth)acrylate, polyurethane, polysiloxane (silicone), polyether, polyamide, polyester, polythiol, copolymers thereof or combinations thereof.
- the poly(meth)acrylate is formed from 2-hydroxyethyl methacrylate, 2- hydroxyethyl acrylate, ethyl methacrylate, hydroxypropyl methacrylate, hydroxybutyl methacrylate, ethylene glycol methyl ether methacrylate, 1,6-hexanediol diacrylate, 2-hydroxy acrylate, isobornyl acrylate, glycidyl acrylate, glycidyl methacrylate, methacrylate, acrylate, 2-phenoxyethylacrylate, tert-butyl acrylate, n-butyl acrylate, ethyl acrylate, benzyl acrylate, methyl acrylate, lauryl acrylate, vinyl acrylate, isobutyl acrylate, (2-methoxyethyl) acrylate, 2-ethylhexyl acrylate, ethylene glycol phenyl ether
- the poly(meth)acrylate is a crosslinked polymer.
- the three-dimensional shape is an architected material, a lattice composed of beams or surface elements, or a foam.
- the three-dimensional shape has a density of less than 50% (by volume).
- the material is for vibration damping, vibration isolation, acoustic damping, acoustic isolation, or impact attenuation.
- the material is an energy absorbing material.
- the concentration gradient interpenetrating polymer network is a continuous concentration gradient interpenetrating polymer network.
- the 3D-printable polymer is printable through volumetric 3D printing, vat polymerization 3D printing, material jetting 3D printing, powder bed fusion, or material extrusion 3D printing.
- FIG. 1 is a schematic representation of a method of forming an interpenetrating polymer network (IPN) within a 3D printed lattice.
- Figure 2 shows a) Fluorescence microscopy images of the cross- sections of interpenetrating polymer network (IPN) rods with 2-hydroxyethyl methacrylate (HEMA) and 1,6-hexanediol diacrylate (HDDA) as the second polymer, showing increasing thickness of the IPN second phase with increasing immersion time between 5 and 60 min.
- HEMA 2-hydroxyethyl methacrylate
- HDDA 1,6-hexanediol diacrylate
- HEMA second polymer in one aspect of the disclosure; b) Diffusion ratio of HEMA second polymer into first polymer (Ebecryl rods, length 10 mm, width 4 mm, and thickness 1 mm) calculated from thickness of IPN second phase with fluorescent dye in fluorescence microscopy images with different immersion times in one aspect of the disclosure; c) Increase in weight percent (wt %) of the second polymer (HEMA circles and HDDA squares) with increasing immersion time for rods with a diameter of 1.25 mm (length of 12 mm).
- FIG. 1 shows fluorescence microscopy images of the cross-sections of IPN rods with HEMA and HDDA as the second polymer, showing increasing thickness of the IPN second phase with increasing immersion time between 15 min and 2 days in one aspect of the disclosure;
- Figure 4 are graphs showing a) Change in weight percent (wt %) of secondary polymer (HEMA circles and HDDA squares) as a function of original design file rod diameter (fixed length of 24 mm) with an immersion time of 15 min. in one aspect of the disclosure.
- Figure 5 is a graph showing tensile tests of rectangular rods composed of first crosslinked polymer (Ebecryl), concentration gradient interpenetrating polymer network with HEMA as the second polymer, concentration gradient interpenetrating polymer network with HDDA as the second polymer, and a copolymer of HDDA and Ebecryl in one aspect of the disclosure.
- Figure 6 shows compression test stress-strain curves for a) Kelvin lattices composed of Ebecryl as the first crosslinked polymer immersed in HEMA second polymer precursor, b) Octet lattices composed of Ebecryl as the first crosslinked polymer immersed in HDDA second polymer precursor, and c) Kelvin lattices composed of Formlabs Flexible 80A as the first crosslinked polymer immersed in HEMA second polymer precursor (see Table 2) in one aspect of the disclosure; [0052] Figure 7 shows compression test stress-strain curves for Kelvin and octet lattices composed of only HDDA as the first crosslinked polymer.
- Figure 8 shows a) Compression test stress-strain curves and b) toughness at densification for Kelvin lattices immersed in HEMA second polymer precursor material for 15 min and cured with varying conditions (constant 405 nm cure at 45 °C for 60 min, constant 405 nm cure at 60 °C for 60 min, and 1000 UV flashes).
- Figure 9 shows compression test stress-strain curves and mechanical properties with different lattice unit cell type and secondary polymers comparing first crosslinked polymer (Ebecryl, solid line), IPN (dotted line), and copolymer (dashed line).
- the lattice parameters tested are HEMA (a and b, solid bar plots in e and f) and HDDA (c and d, hashed bar plots in e and f) as the second polymer immersed for 15 min and Kelvin (a, c, and e) and Octet (b, d, and f) lattice unit cells (see Table 4) in one aspect of the disclosure.
- Figure 10 shows compression test stress-strain curves for Kelvin and Octet lattices with HEMA and HDDA IPNs (solid line) compared to the first crosslinked polymer (Ebecryl, dotted line) and the equivalent copolymer (- - dashed 10 8784422 line) lattices as well as the Ebecryl and copolymer lattices scaled to similar dimensions as the IPN lattices (-- dashed and - -- dashed lines, respectively) (see Table 5) in one aspect of the disclosure;
- Figure 11 shows a) Multi-scale hierarchical lattice designs of Octet-Octet (left image) and Kelvin-Octet (right image) lattices with and without HEMA IPN (left and right lattices in each image, respectively) b) Stress-strain curves from compression tests of Kelvin-Octet and Octet-Octet (OO)
- Figure 12 shows stress-strain curves from compression tests on a) Kelvin and b) Octet lattices composed of soft urethane polymer (Ebecryl) with and without HEMA IPN, varying the number of unit cells per area from 2x2x2 to 7x7x7 (Kelvin) or to 4x4x4 (Octet) (see Table 7) in one aspect of the disclosure;
- Figure 13 shows stress-strain curves from compression tests on Kelvin lattices composed of soft urethane polymer (Ebecryl) with and without HEMA, hydroxypropyl methacrylate (HPMA), or hydroxybutyl methacrylate (HBMA) IPN cured at 65 °C for 60 min (see Table 8).
- Figure 14 shows stress-strain curves from compression tests on a) Kelvin and b) Octet lattices composed of soft urethane polymer (CN973J75, Ebecryl 242N, or CN9021) with and without HEMA or HDDA as the second polymer in the IPN (see Table 9) in one aspect of the disclosure.
- DESCRIPTION OF VARIOUS EMBODIMENTS [0060] DEFINITIONS [0061] Unless otherwise indicated, the definitions and embodiments described in this and other sections are intended to be applicable to all embodiments and aspects of the present disclosure herein described for which they are suitable as would be understood by a person skilled in the art.
- a “third” component is different from the other, first, and second components, and further enumerated or “additional” components are similarly different.
- the words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), "including” (and any form of including, such as “include” and “includes”) or “containing” (and any form of containing, such as “contain” and “contains”) are inclusive or open-ended and do not exclude additional, unrecited elements or process steps.
- the terms “about”, “substantially” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. These terms of degree should be construed as including a deviation of at least ⁇ 5% of the modified term if this deviation would not negate the 12 8784422 meaning of the word it modifies or unless the context suggests otherwise to a person skilled in the art.
- the term “material” as used herein refers to a polymeric material having a three-dimensional shape. In some examples, such a material may aid or improve energy absorption such as impact attenuation.
- first cross-linked polymer refers to any polymer comprised of chains of repeating monomeric units in which the chains are bonded or cross-linked together.
- second polymer refers to a polymer which is interlaced into the first polymer forming the interpenetrating polymer network.
- IPN interpenetrating polymer network
- concentration gradient refers to the amount of second polymer as a function of position along at least one axis or direction within the first polymer, resulting in a gradient of physical and/or chemical properties.
- continuous concentration gradient refers to a concentration gradient in which the concentration of the second polymer continuously decreases along an axis of the first polymer without a phase boundary (i.e. no interface).
- the concentration 13 8784422 gradient or profile of the second polymer (within the first polymer) need not be continuous; for example, the gradient may be stepwise, and the like.
- strain rate refers to the change in strain or deformation over time during a mechanical test (i.e. tensile, bending, or compression testing).
- stiffness refers to the degree to which deflection or deformation is resisted with an applied force. It is complementary to flexibility in that a low stiffness material has high flexibility.
- elastomeric polymer refers to a polymer that has weak intermolecular forces, has a glass transition temperature below room temperature, is lightly crosslinked, is amorphous, and displays both viscous and elastic properties under deformation, such as low Young’s modulus, low stiffness, high flexibility, and high elongation at break (high failure strain).
- architected material refers to materials in periodic, graded, or stochastic cellular structures composed of surface and/or beam elements combined with open spaces designed to impart properties not achievable with the individual materials. In one embodiment, it is the chemistry and structure that contribute to its overall properties, and the structure design may have hierarchy with multi-scale cellular topology.
- Lattices are cellular materials with repeated patterns or unit cells contained in a certain volume and comprise of beams, plates, or surfaces that are arranged in an ordered or random pattern.
- relative density refers to the ratio of the density (mass per unit volume) of the three-dimensional architected material to the density of a full block of the material without open spaces and a cellular structure and is expressed as a percentage or ratio, with 1.0 being no architected material design or open spaces.
- THREE-DIMENSIONAL MATERIALS [0083] The present disclosure relates to three-dimensional materials having improved energy absorption properties comprising a first cross-linked polymer and a second polymer.
- the three-dimensional materials are comprised of 14 8784422 an interpenetrating polymer network having a concentration gradient of the second polymer in the first cross-linked polymer.
- the 3D shapes comprising the interpenetrating polymer networks (IPNs) (such as lattices) have spatial gradients in their material properties.
- the gradients in material properties include properties such as stiffness, elastic modulus, hydrophobicity, hydrophilicity, strength, resilience to biodegradation, thermal conductivity, and refractive index.
- the materials can be used as a coating for protection against corrosion, improve the dampening of acoustic waves or forming metamaterials that can be used to manipulate electromagnetic waves with graded permittivity or refractive indices.
- the material comprises, for example, lattices with IPN morphology to improve energy absorption, such as impact resistance.
- lattices with IPN morphology to improve energy absorption, such as impact resistance.
- architected materials such as lattices, in which the material is composed of IPNs and have lattice features (e.g. struts) with variable material stiffness, resulting in materials and structures capable of repeatable, cyclic re- loading for multi-hit impact attenuation.
- the architected materials have improved energy absorption and are single use materials with the material breaking or degrading after an initial impact.
- the architected material is a material with hierarchical architectures with multi-scale cellular topology.
- the present disclosure is directed to a material having a three-dimensional shape comprising: a) a first phase comprising a first cross-linked polymer; and b) a second phase comprising a concentration gradient interpenetrating polymer network comprising the first crosslinked polymer and a second polymer, the concentration gradient interpenetrating polymer network comprising the second polymer at a decreasing concentration along at least one axis or direction within first phase; and the three-dimensional shape of the material aids in energy absorption.
- the first crosslinked polymer has a different stiffness at low or high strain rates compared to the second polymer.
- the first and second polymers have a difference in stiffness that may or may not depend 15 8784422 on the rate of material deformation (strain rate).
- the first crosslinked polymer has a stiffness at low or high strain rates different than that of the second polymer by at least 5% (percent difference).
- the first crosslinked polymer has a stiffness at low or high strain rates different than that of the second polymer in a range of about 10% to about 500%, or about 50% to about 400%, or about 100% to about 300% (percent difference).
- the first cross-linked polymer and the second polymer have a difference in stiffness at low or high strain rates of over 2,000 MPa, or over 1,000 MPa, or over 500 MPa, or over 100 MPa, or over 10 MPa.
- the first crosslinked polymer is an elastomeric polymer.
- the elastomeric polymer is a polyurethane, polysiloxane (silicone), poly(meth)acrylate, polyether, polyamide, polyester, polythiol, copolymers thereof or combinations thereof.
- the elastomeric polymer is an elastomeric polyurethane.
- the polyurethane is a urethane-based acrylate elastomer or an aromatic urethane-based acrylate elastomer.
- the urethane-based acrylate elastomer or aromatic urethane-based acrylate elastomer is formed from Ebecryl 8413, CN9021, CN973J75, Formlabs Flexible 80A, Ebecryl 231, Ebecryl 4491, Ebecryl 242, Ebecryl 270, Ebecryl 1271, Ebecryl 8411, Ebecryl 8413, Ebecryl 4827, CN9031, CN966J75, CN9782 and are supplied from Allnex® or Sartomer® or Formlabs®.
- the first crosslinked polymer is crosslinked with a crosslinker which is a di-, tri-, tetra-, or multifunctional (meth)acrylate, a crosslinker having vinyl moieties, a crosslinker having thiol moieties, a crosslinker having epoxy moieties, a crosslinker having amine moieties, a crosslinker having alcohol moieties, or a crosslinker having carboxylic acid moieties.
- a crosslinker which is a di-, tri-, tetra-, or multifunctional (meth)acrylate
- a crosslinker having vinyl moieties a crosslinker having thiol moieties
- a crosslinker having epoxy moieties a crosslinker having amine moieties
- a crosslinker having alcohol moieties or a crosslinker having carboxylic acid moieties.
- the crosslinker is Ebecryl 8413, CN9021, CN973J75, Formlabs Flexible 80A, Ebecryl 231, Ebecryl 4491, Ebecryl 242, Ebecryl 270, Ebecryl 1271, Ebecryl 8411, Ebecryl 8413, Ebecryl 4827, CN9031, CN966J75, or CN9782.
- the urethane-based acrylate elastomer or aromatic urethane-based acrylate elastomer contains a reactive diluent comprising Ebecryl 113, 2-hydroxyethyl methacrylate, 2-hydroxyethyl acrylate, ethyl 16 8784422 methacrylate, hydroxypropyl methacrylate, hydroxybutyl methacrylate, ethylene glycol methyl ether methacrylate, 1,6-hexanediol diacrylate, 2-hydroxy acrylate, isobornyl acrylate, glycidyl acrylate, glycidyl methacrylate, methacrylate, acrylate, 2- phenoxyethylacrylate, tert-butyl acrylate, n-butyl acrylate, ethyl acrylate, benzyl acrylate, methyl acrylate, lauryl acrylate, vinyl acrylate,
- the elastomeric polymer is a liquid crystal elastomer.
- the liquid crystal elastomer is formed from a precursor material comprising a liquid crystal mesogen and a chain extender.
- the liquid crystal mesogen is a diacrylate and the chain extender is a dithiol and/or amine.
- the liquid crystal mesogen is 1,4-bis-[4-(6-acryloyloxyhexyloxy)benzoyloxy]-2-methylbenzene; 1,4- bis-[4-(3-acryloyloxypropyloxy)benzoyloxy]-2-methylbenzene; 4,4’-bis[9- (acryloyloxy)nonyloxy]azobenzene, benzoic acid; 4-[2-[(1-oxo-2-propen-1-yl)- oxy]ethoxy]-, 4-[2-[(1-oxo-2-propen-1-yl)oxy]ethoxy]phenyl ester; 4-((6-((1-oxo-2- propen-1-yl)oxy)hexyl)oxy)benzoic acid-1,1’-(1,4-phenylene) ester; 4-[4-[(1-oxo-2- propen-1-yl)oxy]butoxy]-1,1’-(2-
- the liquid crystal elastomer is chain extended with 2,2’-(ethylenedioxy) diethanethiol, 1,3-propanedithiol, glycol di(3-mercaptoprpionate), allyl dithiol, pentaerythritol tetrakis (3-mercaptoprpionate), n-butylamine, 1,5-diaminopentane, furfurylamine, 5-amino-1-pentanol, 1,3,5-triallyl-1,3,5-triazine,2,4,6(1H,3H,5H)- trione.
- the second polymer is a poly(meth)acrylate, polyurethane, polysiloxane (silicone), polyether, polyamide, polyester, polythiol, copolymers thereof or combinations thereof.
- the poly(meth)acrylate is formed from 2- hydroxyethyl methacrylate, 2-hydroxyethyl acrylate, ethyl methacrylate, hydroxypropyl methacrylate, hydroxybutyl methacrylate, ethylene glycol methyl ether methacrylate, 1,6-hexanediol diacrylate, 2-hydroxy acrylate, isobornyl acrylate, 17 8784422 glycidyl acrylate, glycidyl methacrylate, methacrylate, acrylate, 2- phenoxyethylacrylate, tert-butyl acrylate, n-butyl acrylate, ethyl acrylate, benzyl acrylate, methyl acrylate, lauryl acrylate, vinyl acrylate, isobutyl acrylate, (2- methoxyethyl) acrylate, 2-ethylhexyl acrylate, ethylene glycol methyl ether meth
- the poly(meth)acrylate is a crosslinked polymer.
- the three-dimensional shape is an architected material, a lattice composed of beams or surface elements, or a foam.
- the types of lattices include triple periodic minimal surface (TPMS)-, beam-, honeycomb-, and plate-based. Examples of unit cells in beam-based lattices include simple cubic, body centred cubic, face centred cubic, diamond, fluorite, octet, truncated cube, truncated octahedron, Kelvin, isotruss, re-entrant, or Weaire-Phelan.
- the three-dimensional shape is a sheet, filament or fiber.
- the three-dimensional shape has a relative density of less than 50%.
- the three-dimensional shape has a relative density of less than 50% and is a functional architected material having energy absorptive properties.
- the material has an increase in toughness at densification and/or energy absorption efficiency under compression tests when compared to the random copolymer composed of the equivalent weight percent of precursor materials from the first and second polymers or a non-gradient interpenetrating polymer network.
- the material is for vibration damping, vibration isolation, acoustic damping, acoustic isolation, or impact attenuation.
- the material is an energy absorbing material.
- the concentration gradient is a continuous concentration gradient, whereby the IPN has no phase boundary between the first phase and the second phase or polymer. In one embodiment, a continuously decreasing amount of second polymer precursors are able to diffuse or penetrate deeper or farther into the first cross-linked polymer.
- the concentration gradient interpenetrating polymer network is a continuous concentration gradient interpenetrating polymer network.
- the concentration gradient IPN decreases continuously along one axis or direction of the first phase, and generally in the direction in which the second polymers diffused.
- the first phase will have a three-dimensional shape and the three-dimensional shape will have a surface which will be in contact with the second polymer precursors which will diffuse into the first phase along the axis or direction of diffusion resulting in the continuous concentration gradient interpenetrating polymer network.
- the second polymer precursors form the second polymer (once polymerized) which is interlaced within the first polymer forming the interpenetrating polymer network.
- the continuous concentration gradient interpenetrating polymer network is for example, a core-shell continuous interpenetrating polymer network.
- the first crosslinked polymer is a 3D-printable polymer having a three-dimensional shape, such as lattice structure with struts that have a core of a first cross-linked polymer and an outer shell of an IPN made of the first cross-linked polymer and a second polymer.
- the stiffness of the lattice will be uniform.
- the stiffness of the lattice struts will vary spatially.
- the core (or the first phase) has lower stiffness and the shell (or the second phase) has a higher stiffness.
- the IPN comprises a continuum between hard and soft phases that together provide high toughness and failure resistance, without a major compromise in stiffness or strength.
- the IPN is a graded composition of the struts, with a core-shell morphology.
- the stiffer polymer phase (the shell or second phase) forms a strong, rigid shell that places the 19 8784422 load-bearing material away from the neutral bending axis of each strut.
- the core contained within the core (the core or first phase) is a softer elastomeric phase, which helps to damp the impact energy and provides shape recovery and energy return to the beam.
- the core (or the first phase) has a higher stiffness and the shell (or the second phase) has a lower stiffness.
- the stiffer polymer phase forms a strong, rigid core, and a second softer elastomeric phase as a shell.
- the 3D-printable polymer is printable through volumetric 3D printing, vat polymerization 3D printing, material jetting 3D printing, powder bed fusion, material extrusion 3D printing, and the like.
- the second phase has a thickness between about 1% and 99% of the thickness of the first phase. In another embodiment, the second phase has a thickness between about 15% and 40% of the thickness of the first phase.
- the material of the present disclosure having a three-dimensional shape is useful for energy absorption and impact attenuation, for example, in helmets, crash protection for vehicles, blast impact, protective armour, playground or protective flooring surfaces, bioscaffolds or thermal management in heat exchangers.
- PROCESS FOR PREPARING MATERIALS [00107] The present disclosure is also directed to a process for preparing the material having a three-dimensional shape.
- the process comprises three- dimensionally printing a first cross-linked polymer into a desired shape and exposing at least a portion (or all) of the shape to second polymer precursors which diffuse into the first-cross-linked polymer resulting in the concentration gradient interpenetrating polymer network.
- the present disclosure includes a process for preparing a material having a three-dimensional shape, the process comprising: a) 3D-printing a first cross-linked polymer in the form of the three- dimensional shape to form a first phase comprising the first crosslinked polymer; b) exposing at least a portion of the first cross-linked polymer in the form of the three-dimensional shape to a liquid precursor comprising second polymer 20 8784422 precursors, wherein the second polymer precursors diffuse into the first cross-linked polymer to obtain the first cross-linked polymer in the form of the three-dimensional shape with a decreasing concentration gradient of the second polymer precursor in the first cross-linked polymer to form a second phase within the first phase; and c) polymerizing the second polymer precursors to form the second polymer and to obtain the material having a concentration gradient interpenetrating polymer network.
- the 3D-printed first cross-linked polymer is formed by: i) polymerizing and cross-linking first polymer precursors in the presence of a cross-linker and a photoinitiator, by exposing the first polymer precursors to light radiation during three-dimensional printing to obtain the first cross-linked polymer in the form of the three-dimensional shape; or ii) extruding first polymer precursors, in the presence of a cross-linker, through a nozzle to obtain the first crosslinked polymer in the form of the three- dimensional shape.
- the light radiation in step (i) is UV light, visible light or near-infrared light.
- the first cross-linked polymer in the form of the three-dimensional shape is soaked or immersed in the liquid precursor mixture.
- the first cross-linked polymer in the form of the three- dimensional shape is immersed or soaked partly or fully in the liquid precursor mixture, which results in the second polymer precursors diffusing into the first-cross- linked polymer.
- the liquid precursor comprising the second polymer precursors is a liquid precursor mixture comprising the second polymer precursors, and for example, a photoinitiator.
- the mechanical properties of the materials having a three-dimensional shape is varied to a desired property based on the selection of the first-cross-linked polymer and the second polymer and their mechanical properties, degree of cross-linking, as well as the degree of diffusion (soaking or immersion time) and polymerization of the polymers (light dose).
- the stiffness, strength, elongation at failure, and energy absorption (toughness) of the materials can be varied based on a selection of these variables.
- the second polymer precursors in step (c) are polymerized by exposing the precursors to radiation.
- the radiation in step (c) is heat or light radiation.
- the first crosslinked polymer has a different stiffness at low or high strain rates compared to the second polymer.
- the first and second polymers have a difference in stiffness that may or may not depend on the rate of material deformation (strain rate).
- the first crosslinked polymer has a stiffness at low or high strain rates different than that of the second polymer by at least 5% (percent difference).
- the first crosslinked polymer has a stiffness at low or high strain rates different than that of the second polymer in a range of about 10% to about 500%, or about 50% to about 400%, or about 100% to about 300% (percent difference).
- the first cross-linked polymer and the second polymer have a difference in stiffness at low or high strain rates of over 2,000 MPa, or over 1,000 MPa, or over 500 MPa, or over 100 MPa, or over 10 MPa.
- the first crosslinked polymer is an elastomeric polymer.
- the elastomeric polymer is a polyurethane, polysiloxane (silicone), poly(meth)acrylate, polyether, polyamide, polyester, polythiol, or a combination thereof.
- the elastomeric polymer is an elastomeric polyurethane.
- the polyurethane is a urethane- based acrylate elastomer or an aromatic urethane-based acrylate elastomer.
- the urethane-based acrylate elastomer or aromatic urethane- based acrylate elastomer is formed from Ebecryl 8413, CN9021, CN973J75, Formlabs Flexible 80A, Ebecryl 231, Ebecryl 4491, Ebecryl 242, Ebecryl 270, Ebecryl 1271, Ebecryl 8411, Ebecryl 8413, Ebecryl 4827, CN9031, CN966J75, CN9782.
- the crosslinker is a di-, tri-, tetra-, or multifunctional (meth)acrylate, a crosslinker having vinyl moieties, a crosslinker having thiol moieties, a crosslinker having epoxy moieties, a crosslinker 22 8784422 having amine moieties, a crosslinker having alcohol moieties, or a crosslinker having carboxylic acid moieties.
- the crosslinker is Ebecryl 8413, CN9021, CN973J75, Formlabs Flexible 80A, Ebecryl 231, Ebecryl 4491, Ebecryl 242, Ebecryl 270, Ebecryl 1271, Ebecryl 8411, Ebecryl 8413, Ebecryl 4827, CN9031, CN966J75, or CN9782.
- the urethane-based acrylate elastomer or aromatic urethane-based acrylate elastomer contains a reactive diluent comprising Ebecryl 113, 2-hydroxyethyl methacrylate, 2-hydroxyethyl acrylate, ethyl methacrylate, hydroxypropyl methacrylate, hydroxybutyl methacrylate, ethylene glycol methyl ether methacrylate, 1,6-hexanediol diacrylate, 2-hydroxy acrylate, isobornyl acrylate, glycidyl acrylate, glycidyl methacrylate, methacrylate, acrylate, 2- phenoxyethylacrylate, tert-butyl acrylate, n-butyl acrylate, ethyl acrylate, benzyl acrylate, methyl acrylate, lauryl acrylate, vinyl acrylate, isobuty
- the elastomeric polymer is a liquid crystal elastomer.
- the liquid crystal elastomer is formed from a precursor material comprising a liquid crystal mesogen and a chain extender.
- the liquid crystal mesogen is a diacrylate and the chain extender is a dithiol and/or amine.
- the liquid crystal mesogen is 1,4-bis- [4-(6-acryloyloxyhexyloxy)benzoyloxy]-2-methylbenzene; 1,4-bis-[4-(3- acryloyloxypropyloxy)benzoyloxy]-2-methylbenzene; 4,4’-bis[9- (acryloyloxy)nonyloxy]azobenzene, benzoic acid; 4-[2-[(1-oxo-2-propen-1-yl)- oxy]ethoxy]-, 4-[2-[(1-oxo-2-propen-1-yl)oxy]ethoxy]phenyl ester; 4-((6-((1-oxo-2- propen-1-yl)oxy)hexyl)oxy)benzoic acid-1,1’-(1,4-phenylene) ester; 4-[4-[(1-oxo-2- propen-1-yl)oxy]butoxy]-1,1’-(
- the liquid crystal elastomer is chain extended with 2,2’-(ethylenedioxy) diethanethiol, 1,3-propanedithiol, glycol di(3-mercaptoprpionate), allyl dithiol, pentaerythritol tetrakis (3-mercaptoprpionate), 23 8784422 n-butylamine, 1,5-diaminopentane, furfurylamine, 5-amino-1-pentanol, 1,3,5-triallyl- 1,3,5-triazine,2,4,6(1H,3H,5H)-trione.
- the second polymer precursors are monomers of the second polymer.
- the second polymer is a poly(meth)acrylate, polyurethane, polysiloxane (silicone), polyether, polyamide, polyester, polythiol, copolymers thereof or combinations thereof.
- the poly(meth)acrylate is formed from 2-hydroxyethyl methacrylate, 2-hydroxyethyl acrylate, ethyl methacrylate, hydroxypropyl methacrylate, hydroxybutyl methacrylate, ethylene glycol methyl ether methacrylate, 1,6-hexanediol diacrylate, 2-hydroxy acrylate, isobornyl acrylate, glycidyl acrylate, glycidyl methacrylate, methacrylate, acrylate, 2-phenoxyethylacrylate, tert-butyl acrylate, n-butyl acrylate, ethyl acrylate, benzyl acrylate, methyl acrylate, lauryl acrylate, vinyl acrylate, isobutyl acrylate, (2-methoxyethyl) acrylate, 2-ethylhexyl acrylate, ethylene glycol phenyl ether acrylate,
- the photoinitiator is ethyl (2,4,6- trimethylbenzoyl) phenylphosphinate, benzoyl peroxide, camphorquinone, diphenyl (2,4,6-trimethylbenzoyl)phosphine oxide, phenylbis(2,4,6- trimethylbenzoyl)phosphine oxide, 2-hydroxy-4’-(2-hydroxyethoxy)-2- methylpropiophenone.
- the photoinitiator is present in the range of about 0.1 to about 5.0 wt % in the photoinitiator/monomer mixture.
- the poly(meth)acrylate is a crosslinked polymer.
- the three-dimensional shape is an architected material, a lattice composed of beams or surface elements, or a foam. [00124] In another embodiment, three-dimensional shape has a relative density of less than 50%. [00125] In one embodiment, the material is for vibration damping, vibration isolation, acoustic damping, acoustic isolation, or impact attenuation. [00126] In another embodiment, the material is an energy absorbing material. [00127] In one embodiment, the concentration gradient interpenetrating polymer network is a continuous concentration gradient interpenetrating polymer network.
- the 3D-printable polymer is printable through volumetric 3D printing, vat polymerization 3D printing, material jetting 3D printing, powder bed fusion, or material extrusion 3D printing.
- Example 1 [00133] First Crosslinked Polymer Precursor Mixture Preparation: The Ebecryl elastomer photoresin was prepared by combining 1 wt % (weight percent) ethyl (2,4,6-trimethylbenzoyl) phenylphosphinate (TPO-L, Oakwood Products, Inc.) as the photoinitiator, 45 wt % Ebecryl 8413 (Allnex) as the crosslinker monomer, and 45 wt % Ebecryl 113 (Allnex) and 9 wt % isobornyl acrylate (technical grade, contains 200 ppm monomethyl ether hydroquinone as inhibitor, Sigma-Alrich Canada Co.) as reactive diluent monomers (the monomer weight ratio was 5:5:1) (Table 1).
- the mixture was then combined using a planetary centrifugal mixer (THINKY ARE-310) for 10 min at 2000 rpm followed by 30 s at 2200 rpm.
- the first crosslinked polymer precursor mixture was stored in the fridge until use. Before using, it was brought to room temperature by mixing for 2 min at 2000 rpm followed by 30 s at 2200 rpm.
- Second Polymer Precursor Preparation The photoinitator, TPO-L (1 wt %) was combined with 99 wt % monomer (2-hydroxyethyl methacrylate (HEMA, 25 8784422 contains ⁇ 250 ppm monomethyl ether hydroquinone as inhibitor, 97%, Sigma-Alrich Canada Co.) or 1,6-hexanediol diacrylate (HDDA, 99% stab., Thermo Scientific)) (Table 1). The mixture was mixed using a planetary mixer for 2 min at 2000 rpm followed by 30 s at 2200 rpm. The mixture was stored in the fridge until use.
- HEMA 2-hydroxyethyl methacrylate
- HDDA 1,6-hexanediol diacrylate
- 3D Printing of the First Crosslinked Polymer An Asiga Max X UV385 Digital Light Processing (DLP) printer with a 385 nm LED light source was used for printing all lattices and rod samples. The samples were printed using a light intensity of 25 mW/cm 2 , a slice thickness of 0.100 mm, exposure time of 1.938 s, burn-in (initial layers) exposure time of 15.684 s, 1 burn-in layer, and heater temperature set to 30 °C to warm the precursor mixture in the 1 L build tray.
- DLP Digital Light Processing
- the printed objects were immersed in ethanol (95 % vol., Commercial Alcohols by Greenfield Global) and sonicated for 10 min in order to remove residual uncured precursor material.
- the washing step was repeated twice more with new ethanol replenished in between.
- the washed samples were dried for 24 hours, then postcured with 1000 UV flashes in an Otoflash G171 UV light flash cure box (300 to 700 nm light) with nitrogen atmosphere purge.
- This 3D printing step is depicted in the first step in Figure 1.
- the washing step in ethanol was skipped and the samples were left to remove residual precursor material for 24 hours before curing with 1000 UV flashes.
- the sample was then cured with a Formlabs Form Cure box (405 nm light) at constant temperature and time or with 1000 UV flashes with the Otoflash.
- the lattices are 3D printed with the first 26 8784422 crosslinked polymer followed by immersion in a second polymer precursor.
- the degree of diffusion of the second polymer precursor depends on the chemistry of the 3D printed first crosslinked polymer, the second polymer precursor, and the immersion time.
- the second polymer precursor is then cured in the 3D lattice.
- the struts within the final 3D printed lattice contain a concentration gradient interpenetrating polymer network.
- Example 2 Second Polymer with Fluorescent Dye Preparation: To observe the formation of a concentration gradient interpenetrating polymer network, a fluorescent dye was added to the second polymer precursor and allowed to diffuse into the first crosslinked polymer along with the second polymer precursor.
- the Fluorescent dye stock solution was first prepared by dissolving Fluorescein isothiocyanate isomer I (FITC, ⁇ 90%, Sigma-Alrich Canada Co.) in anhydrous ethanol at a concentration of 15 mg/mL with 5 min of sonication (Cole-Parmer Ultrasonic Cleaner).
- Fluorescent imaging samples were prepared by cutting each concentration gradient interpenetrating polymer network sample into 5 blocks. The fluorescence microscopy images were captured by scanning each cross-section of the block on an inverted microscope (IX81, Olympus Life Science) using a 4 ⁇ object lens and FITC optical filter. With a 120 W fluorescence light source set to 100% output power, the exposure time was set as 300 ms for Ebecryl/FITC-HEMA IPN samples, and 900 ms for Ebecryl/FITC-HDDA IPN samples using InVitro microscope 27 8784422 automation software.
- Cylindrical rods with different diameters, 1.00, 1.25, 1.50, 1.75, and 2.00 mm, with a length of 24 mm were printed on a base of 37.50 x 25.00 x 1.5 mm for testing the effect of the size of the first crosslinked polymer on the formation of the concentration gradient interpenetrating polymer network.
- Both HEMA and HDDA IPN samples showed a clear Ebecryl inner phase and outer phase containing the second polymer and FITC dye for 5 min, 15 min, and 60 min of immersion time ( Figure 1 a, b, and Figure 2).
- the second polymer precursor with FITC dye After 2 days of immersion time, the second polymer precursor with FITC dye fully diffused into the Ebecryl first crosslinked polymer.
- the increasing diffusion time of second polymer precursor also leads to the dimensional increase of the samples. Hence, diffusion ratio is calculated to exclude the effect of sample expansion.
- the diffusion ratio of HEMA IPN samples increases with increasing immersion time, indicating the thicker IPN outer phase being formed with longer immersion times. A similar trend is observed with HDDA IPN samples.
- Example 3 29 8784422 [00148] Copolymer Precursor Material Preparation: To determine if the change in mechanical properties is due to the concentration gradient interpenetrating polymer network or the introduction of the second polymer precursor materials into the 3D structure, a “copolymer” of the first crosslinked polymer and second polymer was 3D printed. The copolymer consisted of a mixture of the first crosslinked polymer and second polymer in the same weight ratio as formed with the concentration gradient interpenetrating polymer network (Table 1).
- Premixed first crosslinked polymer and second polymer precursor materials were combined in the same weight ratio and mixed using a planetary mixer for 10 min at 2000 rpm followed by 30 s at 2200 rpm.
- the equivalent concentration gradient interpenetrating polymer network was 15 wt % HEMA
- 15 wt % HEMA second polymer precursor material was combined with 85 wt % Ebecryl first crosslinked polymer precursor material to create the copolymer precursor material.
- the copolymer precursor material was stored in the fridge and warmed using the planetary mixer before being used, followed by 3D printing.
- the exposure time was instead set to 10.000 s with 2 burn-in layers.
- Rectangular rods of 12 x 2 x 0.5 mm in dimensions were printed vertically for tensile test measurements (Diastron Fibre Micrometer).
- Preliminary tensile tests on rectangular struts show a wide range of mechanical properties achievable by varying the type of second polymer used for forming the IPN. Behavior ranges from the elastomeric first crosslinked polymer, to a very rigid, strong and brittle IPN when long immersion times with the crosslinker, 1,6-hexanediol diacrylate (HDDA) are used.
- HDDA 1,6-hexanediol diacrylate
- Using linear polymers in the IPN such as those made from 2-hydroxyethyl methacrylate (HEMA), unlocks highly important intermediate performance spaces.
- HEMA 2-hydroxyethyl methacrylate
- IPNs that benefit in strength and elastic modulus (peak stress and slope of curves), yet conserve much of the ductility and elongation enabled by the soft first crosslinked polymer. This leads to an excellent balance between strength and toughness (energy absorption, area under the curve).
- the intermediate IPN behavior is also characterized by strain hardening, or increasing slope during yielding, which indicates a self-strengthening mechanism likely imparted by the covalently intertwined interface.
- Example 4 Compression Tests of 3D Printed Lattices: Lattices comprising of the concentration gradient interpenetrating polymer network and copolymers were fabricated to evaluate the energy absorption properties. Kelvin and Octet lattices were tested with 2x2x2 unit cells and computer aided design (CAD) files with dimensions of 24.99 x 24.99 x 24.99 mm, and strut sizes of 1.25 mm.
- CAD computer aided design
- the relative densities of the Kelvin and octet lattices were 0.07 and 0.14, respectively.
- the concentration gradient IPN has a significant effect on the lattice material's mechanical properties.
- the stress- strain curve and mechanical properties were observed with different immersion times ( Figure 5, Table 2).
- Kelvin lattices composed of elastomeric Ebecryl first crosslinked polymer were immersed in HEMA for 5, 15, 30, and 60 min and had increasing toughness at densification with increasing soaking times with an over 300-fold increase in toughness with the thickest IPN shell (60 min immersion time) compared to the elastomeric first crosslinked polymer.
- the HEMA Kelvin lattices also fully reformed after compression tests, exhibiting ideal properties for multi-hit energy absorbing materials. Similar results were also observed when the elastomeric first crosslinked polymer was replaced with a commercial elastomeric, Formlabs Flexible 80A.
- Octet lattices were also fabricated with an HDDA concentration gradient IPN and found to have the highest toughness as a result of both the stretching- dominated octet lattice geometry, higher relative density of the lattice, and the highly crosslinked, stiffer HDDA second polymer. Again, increased immersion time raised the energy absorption by over 180-times greater than the same lattice composed of 31 8784422 only the elastomeric first polymer. However, with increasing amounts of HDDA and a larger HDDA concentration gradient IPN outer phase, larger drops in load bearing capacity were observed, particularly with 60 min of immersion time in HDDA. This is a result of the octet lattice geometry.
- a toughness at densification of 35.13 ⁇ 0.76 kJ/m 3 was achieved by curing HDDA with 1000 flashes of UV light compared to 12.05 ⁇ 0.11 kJ/m 3 by curing HDDA at a constant exposure to 405 nm light at 65 °C for 60 min.
- Polymerizing the second polymer with the more intense 1000 flashes of UV light lead to a greater extent of polymerization and higher crosslink density for HDDA.
- With the 32 8784422 higher extent of polymerization via 1000 flashes of UV light a different shape of the stress-strain curve was observed with a high peak stress dropping down with the collapse of struts compared to the more ideal “flat” curve with constant curing.
- Constant curing conditions for 60 min at 45 °C for HEMA and 65 °C for HDDA second polymers were predominantly used as the lattices had more uniform curing (visually observed both before and during compression tests) and mechanical properties from compression tests were more consistent between repeat samples. But light intensity and extent of polymerization provides another handle to tune mechanical properties and energy absorption of IPN lattices.
- Kelvin and octet lattices were fabricated with copolymers of Ebecryl and HEMA or HDDA to confirm the improved energy absorption properties were a result of the concentration gradient IPN and not the incorporation of HEMA or HDDA in the polymer material ( Figure 9, Table 4). All four IPN lattices, Kelvin and octet with HEMA and HDDA as the second polymer, surpassed the toughness of the corresponding copolymer lattices.
- the octet HEMA concentration gradient IPN lattice had a toughness at densification of 33.94 ⁇ 2.16 kJ/m 3 compared to 4.92 ⁇ 0.32 kJ/m 3 for the octet HEMA copolymer, both with similar wt % HEMA in the material.
- all four concentration gradient IPN lattices have higher maximum efficiencies and stiffness compared to the equivalent copolymers, demonstrating their superior performance as energy absorbers.
- the toughness increases for both HDDA concentration gradient IPN and copolymer octet lattices compared to the respective Kelvin lattices.
- the toughness and stiffness are greater for the HDDA concentration gradient IPN octet lattice than the HEMA concentration gradient IPN octet lattice likely due to the ability for HDDA to crosslink and higher diffusivity of HDDA for the same 15 min immersion time (higher wt % HDDA than HEMA in lattices).
- the stiffer 33 8784422 HDDA concentration gradient IPN seems to have less of an effect with the bending- dominated Kelvin lattice as the toughness is lower than that of the HEMA IPN Kelvin lattice. But this difference between HEMA and HDDA concentration gradient IPN lattices can be tuned with the extent of polymerization and crosslinking as seen previously with the higher energy absorption of HDDA concentration gradient IPNs cured with 1000 UV flashes. Again, lattices composed of HDDA as the first crosslinked polymer display poor energy absorption with both Kelvin and octet lattice geometries as significant fracturing occurs with catastrophic drops in load bearing capacity and destruction of the lattice (Figure 7, Table 4).
- the first and second phase IPN structure leads to enhanced stiffening and dissipation of energy throughout the lattices and can be easily tuned for the desired application with type of second polymer, thickness of outer phase, and lattice geometry.
- the concentration gradient-IPN lattices show minimal to no failure due to the gradient in properties and less abrupt material interface that is able to distribute the stress.
- Example 5 Scaling of First Crosslinked Polymer Lattices and Copolymer Lattice to the Same Size as the Concentration gradient IPN Lattices: It was observed that as more mass is added to the elastomer first crosslinked polymer lattice with the formation of the concentration gradient-IPN, the dimensions of the lattice increase.
- Ebecryl and copolymer lattices were scaled and printed to be similar in size to the IPN lattices ( Figure 10, Table 5).
- the scaling factor was determined from the average percent difference in dimensions between the concentration gradient IPN and elastomeric or copolymer lattices, which was then applied to the CAD file before printing.
- the elastomeric and copolymer lattices printed with the scaled CAD file resulted in similar overall volume to the concentration gradient IPN lattices.
- the mechanical properties of the Ebecryl first crosslinked polymer lattices scaled to be similar size to the HDDA and HEMA concentration gradient IPN lattices were very similar to the original sized Ebecryl first crosslinked polymer lattices.
- the toughness decreased compared to the original HEMA copolymer lattices, for both Kelvin and octet lattices, predominantly due to the lower stiffness.
- HEMA is a monofunctional monomer, it decreases the amount of crosslinking in the copolymer compared to the 34 8784422 Ebecryl monomers, contributing to a lower stiffness material.
- the scaled HDDA copolymer octet lattice had similar toughness to the HDDA concentration gradient IPN octet lattice, but could be tuned with degree of cure of the HDDA second polymer in the IPN outer phase.
- Example 6 Concentration gradient IPN Lattices with Hierarchical and Other Lattice Geometries: Multi-scale hierarchical lattice designs can be thought of lattices within the struts of another larger lattice ( Figure 11a, Table 6). It was theorized that extending the deformation modes with two hierarchical stages of elastic collapse would further improve energy absorption properties. For example, multi-scale lattices with a first order Octet lattice and second order Kelvin or Octet lattice were printed and tested with Formlabs Flexible 80A first crosslinked polymer with and without concentration gradient IPN ( Figure 11a, b).
- Kelvin and Octet lattices were printed with unit cells of 2x2x2 and 7x7x7 (Kelvin) or 4x4x4 (Octet) while keeping the relative density constant at 0.15 and overall dimensions of 25.18x25.18x25.00 mm.
- a second set of lattices was also immersed in HEMA second polymer to create concentration gradient IPN lattices in order to further optimize the energy absorption (Figure 12, Table 7).
- HEMA hydroxypropyl methacrylate
- EMA ethyl methacrylate
- HPMA hydroxypropyl methacrylate
- EMA ethyl methacrylate
- the HEMA, HPMA, and EMA concentration gradient IPN lattices contained similar wt % second polymer ( ⁇ 14 wt %), but exhibited different mechanical properties ( Figure 13, Table 8).
- the HPMA concentration gradient IPN lattices had the highest stiffness and toughness, while the EMA concentration gradient IPN lattices had the lowest, with HEMA concentration gradient IPN in between.
- Example 9 Effect of Stiffer First Crosslinked Polymer on Concentration gradient IPN Lattices: The soft urethane-based Ebecryl elastomer first crosslinked polymer was replaced with a series of other stiffer urethane-based polymers to determine the ability to create a concentration gradient IPN lattice and alter energy absorption.3D printed Kelvin and octet lattices were 3D printed with commercial first crosslinked polymer precursor materials CN973J75, Ebecryl 242N, or CN9021, diluted with an appropriate amount of isobornyl acrylate as a reactive diluent to 37 8784422 decrease the viscosity to enable 3D printing (Table 1).
- the concentration gradient IPN increases stiffness and toughness with all first crosslinked polymers tested ( Figure 14, Table 9).
- the HDDA second polymer precursor material also diffused more into the first crosslinked polymers more quickly than HEMA polymer second precursor material (higher wt % second polymer), but it varied whether the HDDA or HEMA concentration gradient IPN lattices had the highest toughness and energy absorption. Overall, these results show that the concentration gradient IPN can improve energy absorption properties with stiffer first crosslinked polymers.
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Non-Patent Citations (5)
| Title |
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| "Interpenetrating Polymer Networks", vol. 239, 5 May 1994, AMERICAN CHEMICAL SOCIETY, ISSN: 0065-2393, article SOPHIEA DANIEL, KLEMPNER DANIEL, SENDIJAREVIC VAHID, SUTHAR B., FRISCH K. C.: "Interpenetrating Polymer Networks as Energy-Absorbing Materials", pages: 39 - 75, XP093208782, DOI: 10.1021/ba-1994-0239.ch002 * |
| KARABANOVA L., PISSIS P., KANAPITSAS A., LUTSYK E.: "Thermodynamic state, temperature transitions, and broadband dielectric relaxation behavior in gradient interpenetrating polymer networks", JOURNAL OF APPLIED POLYMER SCIENCE, JOHN WILEY & SONS, INC., US, vol. 68, no. 1, 4 April 1998 (1998-04-04), US , pages 161 - 171, XP093208774, ISSN: 0021-8995, DOI: 10.1002/(SICI)1097-4628(19980404)68:1<161::AID-APP18>3.0.CO;2-3 * |
| KARABANOVA LYUDMILA V., MIKHALOVSKY SERGEY V., LLOYD ANDREW W., BOITEUX GISELE, SERGEEVA LYUDMILA M., NOVIKOVA TAMARA I., LUTSYK E: "Gradient semi-interpenetrating polymer networks based on polyurethane and poly(vinyl pyrrolidone)", JOURNAL OF MATERIALS CHEMISTRY, ROYAL SOCIETY OF CHEMISTRY, GB, vol. 15, no. 4, 1 January 2005 (2005-01-01), GB , pages 499, XP093208778, ISSN: 0959-9428, DOI: 10.1039/b410178b * |
| KUANG XIAO, CHEN KAIJUAN, DUNN CONNER K., WU JIANGTAO, LI VINCENT C. F., QI H. JERRY: "3D Printing of Highly Stretchable, Shape-Memory, and Self-Healing Elastomer toward Novel 4D Printing", APPLIED MATERIALS & INTERFACES, AMERICAN CHEMICAL SOCIETY, US, vol. 10, no. 8, 28 February 2018 (2018-02-28), US , pages 7381 - 7388, XP055789866, ISSN: 1944-8244, DOI: 10.1021/acsami.7b18265 * |
| LV XUESONG, HUANG ZHIXIONG, SHI MINXIAN, FAN YUN, GAO GUANBIN: "Composition Distribution, Damping and Thermal Properties of the Thickness-Continuous Gradient Epoxy/Polyurethane Interpenetrating Polymer Networks", APPLIED SCIENCES, MDPI SWITZERLAND, vol. 7, no. 2, pages 135, XP093208779, ISSN: 2076-3417, DOI: 10.3390/app7020135 * |
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| CN119684664A (en) * | 2024-12-18 | 2025-03-25 | 天津大学 | A method for preparing boron nitride-doped liquid crystal elastomer foam |
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