Ultrasoft, stretchable, reversible elastomers for direct-write printing deformable structures

Patent metadata

Field	Value
Publication number	US-2024239941-A1
Application number	US-202118018848-A
Country	US
Kind code	A1
Filing date	Apr 23, 2021
Priority date	Jul 31, 2020
Publication date	Jul 18, 2024
Grant date	—

Abstract

Existing feedstock for additive manufacturing is mostly stiff, fragile plastics. We report a class of 3D printable, ultrasoft and stretchable elastomers by exploiting the self-assembly of responsive bottlebrush-based triblock copolymers. The microphase separation of the architecturally and chemically distinct blocks results in physically crosslinked networks that are stimuli-reversible, enabling their use for in-situ direct-write printing soft, elastic, and deformable 3D structures. The elastomers are 100% solvent-reprocessable yet thermostable within a wide range of temperature. Moreover, they exhibit an extensibility up to 600% and a Young's modulus low to ˜10 2 Pa, 10 6 times softer than plastics and more than 100 times softer than all existing 3D printable elastomers.

First claim

What is claimed is:

1 . A triblock copolymer comprising:
a linear polymer wherein said linear polymer creates glassy domains within said triblock copolymer, and a bottlebrush polymer, wherein said bottlebrush polymer connects said glassy domains.

2 . A triblock copolymer comprising:
a linear polymer, wherein said linear polymer is poly(benzyl methacrylate); and a bottlebrush polymer, wherein said bottlebrush polymer is comprised of polydimethylsiloxane side chains, wherein said bottlebrush polymer is situated between two of said linear polymers.

3 . A method of making a triblock copolymer, comprising:
synthesizing a bottlebrush polymer, and adding one or more of said linear polymer to said bottlebrush polymer to yield said triblock copolymer.

4 . The method of claim 3 , wherein said synthesizing of said bottlebrush polymer is via free radical polymerization.

5 . The method of claim 4 , wherein synthesizing is via atom transfer radical polymerization (ATRP).

6 . The method of claim 4 , wherein said atom transfer radical polymerization (ATRP) is activator regenerated electron transfer (ARGET), initiators for continuous activator regeneration (ICAR ATRP), supplemental activator and reducing agent (SARA ATRP), and electrochemically mediated ATRP.

7 . The method in claim 3 , wherein starting materials of said bottlebrush polymer are ethylene bis(2-bromoisobutyrate) and monomethacryloxypropyl terminated polydimethylsiloxane.

8 . The method in claim 3 , wherein said synthesizing includes a catalyst solution.

9 . The method of claim 8 , wherein said catalyst solution is comprised of:
Me 6 TREN and CuBr 2 ; Me 6 TREN and CuCl 2 ; or Me 6 TREN, CuCl 2 and CuBr 2 .

10 . The method of claim 8 , further comprising removing oxygen after said synthesis.

11 . The method of claim 10 , further comprising adding a reducing agent.

12 . The method of claim 11 , wherein said reducing agent is: Sn(EH) 2 in xylene or Sn(EH) 2 in toluene.

13 . The method of claim 3 , further comprising heating during said synthesis and said addition of said one or more of said linear polymer.

14 . The method of claim 13 , where said heating is in the range of about 50 to about 70 degrees Celsius.

15 . The method of claim 3 , wherein said synthesizing of said triblock copolymer is via free radical polymerization.

16 . The method of claim 15 , wherein synthesizing is via atom transfer radical polymerization (ATRP).

17 . The method of claim 15 , wherein said atom transfer radical polymerization (ATRP) is activator regenerated electron transfer (ARGET), initiators for continuous activator regeneration (ICAR ATRP), supplemental activator and reducing agent (SARA ATRP), and electrochemically mediated ATRP.

18 . The method in claim 15 , wherein starting materials are benzyl methacrylate, and a macroinitiator.

19 . The method in claim 15 , wherein said synthesizing includes a catalyst solution.

20 . The method of claim 15 , wherein said catalyst solution is comprised of: Me 6 TREN and CuBr 2 ;
Me 6 TREN and CuCl 2 ; or Me 6 TREN, CuCl 2 and CuBr 2 .

21 . The method of claim 15 , further comprising removing oxygen after said synthesizing.

22 . The method of claim 21 , further comprising a reducing agent.

23 . The method of claim 22 , wherein said reducing agent is Sn(EH) 2 in xylene or Sn(EH) 2 in toluene.

24 . The method of claim 15 , further comprising heating during said synthesis and said addition of said one or more of said linear polymer.

25 . The method of claim 24 , where said heating is in the range of about 50 to about 70 degrees Celsius.

26 . The method of claim 24 , where said heating is in the range of about 60 degrees Celsius.

27 . A polymer network comprising a plurality of triblock copolymers, wherein:
said bottlebrush polymers configured to operate as elastic network strands; and said linear polymers aggregate to form spherical glassy domains.

28 . The polymer network of claim 27 , wherein said spherical glassy domains engage in a dissociation at high temperature or in the presence of solvent, resulting in a solid-to-liquid transition of the network.

29 . The polymer network of claim 28 , wherein said dissociation is reversible.

30 . An article comprising the polymer network of claim 27 .

31 . The article of claim 30 , wherein said article is a solvent-free elastomer.

32 . The article of claim 30 , wherein said article is a gyroid.

33 . The article of claim 30 , wherein said article exhibits an extensibility up to 600%.

34 . The article of claim 30 , wherein said article has a Young's modulus minimum of about 100 Pa.

35 . The article of claim 30 , wherein said article is thermostable between the temperatures of about −125° C. and about 180° C.

36 . The article of claim 30 , wherein said article is 3D printable.

37 . The article of claim 30 , wherein said article contributes structurally to a medical device.

38 . The article of claim 37 , wherein said medical device is implantable.

39 . The article of claim 30 , wherein said article constitutes a portion of a vocal cord prosthesis apparatus.

40 . The article of claim 30 , wherein said article constitutes a permanent filler for vesicoureteral reflux.

41 . A method for synthesizing a polymer network of said triblock copolymers of claim 27 comprising removing solvent.

42 . A method for 3D printing an elastomer, comprising:
adding a solvent to polymer network at a specified pressure in a chamber of a 3D printer apparatus; transferring said polymer network with said solvent from a printer nozzle of said 3D printer apparatus; and wherein said solvent evaporates after exiting said nozzle and the glassy domains of said polymer network reassociate.

Assignees

• Univ Virginia Patent Foundation

Inventors

• Cai Liheng
• Nian Shifeng
• Zhu Jinchang

Classifications

• C08L53/005

  Modified block copolymers · CPC title

• C08F2438/01

  Atom Transfer Radical Polymerization [ATRP] or reverse ATRP · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• C08F293/005 Primary

  using free radical "living" or "controlled" polymerisation, e.g. using a complexing agent · CPC title