Methods for producing a dental mold, dental implant or dental aligner from materials having multiple mechanisms of hardening

Patent metadata

Field	Value
Publication number	US-10647879-B2
Application number	US-201815963550-A
Country	US
Kind code	B2
Filing date	Apr 26, 2018
Priority date	Jun 23, 2014
Publication date	May 12, 2020
Grant date	May 12, 2020

Abstract

A polymerizable liquid, or resin, useful for the production by additive manufacturing of a three-dimensional object of polyurethane, polyurea, or a copolymer thereof, is described. The resin includes at least one of (i) a blocked or reactive blocked prepolymer, (ii) a blocked or reactive blocked diisocyanate, or (iii) a blocked or reactive blocked diisocyanate chain extender.

First claim

We claim:

1. A method of forming a three-dimensional object, wherein said three-dimensional object is a dental mold, dental implant or dental aligner, comprising:
(a) providing a carrier and an optically transparent member having a build surface, said carrier and said build surface defining a build region therebetween;
(b) filling said build region with a polymerizable liquid, said polymerizable liquid comprising a mixture of (i) a light polymerizable liquid first component, and (ii) a second solidifiable component that is different from said first component;
(c) irradiating said build region with light through said optically transparent member to form a solid polymer scaffold from said first component and also advancing said carrier away from said build surface to form a three-dimensional intermediate having a shape of said dental mold, dental implant or dental aligner, said three-dimensional intermediate containing said second solidifiable component carried in said solid polymer scaffold in unsolidified and/or uncured form; and
(d) subsequent to said irradiating step, heating, microwave irradiating, or both heating and microwave irradiating, said second solidifiable component in said three-dimensional intermediate to form said dental mold, dental implant or dental aligner,
wherein said forming comprises bottom-up stereolithography.

2. The method of claim 1 , wherein said second solidifiable component comprises a polymerizable liquid solubilized in or suspended in said first component.

3. The method of claim 1 , wherein said second solidifiable component comprises:
(i) a polymerizable solid suspended in said first component;
(ii) a polymerizable solid solubilized in said first component; or
(iii) a polymer solubilized in said first component.

4. The method of claim 1 , wherein said three-dimensional object comprises a polymer blend, interpenetrating polymer network, semi-interpenetrating polymer network, or sequential interpenetrating polymer network formed from said first component and said second solidifiable component.

5. The method of claim 1 , wherein step (d) is carried out by heating said second solidifiable component.

6. The method of claim 5 , wherein: said second solidifiable component comprises the precursors to a polyurethane, polyurea, or copolymer thereof, a silicone resin, an epoxy resin, a cyanate ester resin, or a natural rubber.

7. A dental mold, dental implant or dental aligner three-dimensional object produced by a method comprising:
(a) providing a carrier and an optically transparent member having a build surface, said carrier and said build surface defining a build region therebetween;
(b) filling said build region with a polymerizable liquid, said polymerizable liquid comprising a mixture of (i) a light polymerizable liquid first component, and (ii) a second solidifiable component that is different from said first component;
(c) irradiating said build region with light through said optically transparent member to form a solid polymer scaffold from said first component and also advancing said carrier away from said build surface to form a three-dimensional intermediate having a shape of said dental mold, dental implant or dental aligner, said three-dimensional intermediate containing said second solidifiable component carried in said solid polymer scaffold in unsolidified and/or uncured form; and
(d) subsequent to said irradiating step, heating, microwave irradiating, or both heating and microwave irradiating, said second solidifiable component in said three-dimensional intermediate to form said dental mold, dental implant or dental aligner,
wherein said forming comprises bottom-up stereolithography, and
wherein said first component comprises monomers and/or prepolymers polymerizable upon exposure to actinic radiation or light, and a reactive diluent.

8. The object of claim 7 , wherein the object is a dental mold.

9. The object of claim 7 , wherein the object is a dental implant.

10. The object of claim 7 , wherein the object is a dental aligner.

11. The object of claim 7 , wherein the object substantially conforms to the shape of a tooth.

12. The object of claim 7 , wherein said object comprises a copolymer formed from the monomers and/or prepolymers polymerizable upon exposure to actinic radiation or light and the reactive diluent.

13. The object of claim 7 , wherein said first component comprises a blocked or reactive blocked prepolymer.

Assignees

• Carbon Inc

Inventors

• Rolland Jason P
• Chen Kai
• Poelma Justin
• Goodrich James
• Pinschmidt Robert
• Desimone Joseph M
• Robeson Lloyd M

Classifications

• C08K5/0041

  Optical brightening agents, organic pigments · CPC title

• C08G18/755

  and at least one isocyanate or isothiocyanate group linked to a secondary carbon atom of the cycloaliphatic ring, e.g. isophorone diisocyanate · CPC title

• C08G18/4854

  Polyethers containing oxyalkylene groups having four carbon atoms in the alkylene group · CPC title

• C08G18/73

  acyclic · CPC title

• C08G18/758

  containing two or more cycloaliphatic rings · CPC title