Additive manufacturing using polyurea materials

Patent metadata

Field	Value
Publication number	US-10864673-B2
Application number	US-201916423474-A
Country	US
Kind code	B2
Filing date	May 28, 2019
Priority date	Aug 18, 2017
Publication date	Dec 15, 2020
Grant date	Dec 15, 2020

Abstract

Methods of additive manufacture using coreactive components are disclosed. Thermosetting compositions for additive manufacturing are also disclosed.

First claim

What is claimed is:

1. A reactive additive manufacturing composition, comprising:
a first component comprising a polyisocyanate and having a first viscosity; and
a second component comprising a polyamine and having a second viscosity,
wherein the reactive additive manufacturing composition is characterized by a tack free time of greater than 3 minutes, and
wherein the first viscosity is within ±20% of the second viscosity; wherein the viscosity is measured using an Anton Paar MCR 301 or 302 rheometer with a 25 mm-diameter parallel plate spindle, an oscillation frequency of 1 Hz and amplitude of 0.3%, and with a rheometer plate temperature of 25° C.

2. The composition of claim 1 , wherein,
the polyisocyanate comprises a polyisocyanate monomer, a polyisocyanate prepolymer, or a combination thereof; and
the polyamine comprises a polyamine monomer, a polyamine prepolymer, or a combination thereof.

3. The composition of claim 2 , wherein,
each of the polyisocyanate monomer and the polyamine monomer independently has a molecular weight less than 600 Daltons; and
each of the polyisocyanate prepolymer and the polyamine prepolymer independently has a molecular weight from 1,000 Daltons to 20,000 Daltons.

4. The composition of claim 1 , wherein the reactive additive manufacturing composition comprises a polymeric rheology modifier.

5. The composition of claim 4 , wherein the polymeric rheology modifier comprises a reactive polymeric rheology modifier.

6. The composition of claim 4 , wherein the polymeric rheology modifier is selected from a polyethylene, a polyethylene/ethylene copolymer, a polypropylene/ethylene copolymer, and a combination of any of the foregoing.

7. The composition of claim 4 , wherein each of the first component and the second component independently comprises from 1 wt % to 20 wt % of the polymeric rheology modifier, wherein wt % is based on the total weight of the first component or the second component.

8. The composition of claim 1 , wherein the reactive additive manufacturing composition comprises from 0.1 wt % to 40 wt % of a filler, wherein wt % is based on the total weight of the reactive additive manufacturing composition.

9. The composition of claim 8 , wherein the filler comprises an inorganic filler, an organic filler, a low-density filler, an electrically conductive filler, magnetic filler, or a combination of any of the foregoing.

10. An object formed using the reactive additive manufacturing composition of claim 1 .

11. The object of claim 10 , wherein the object comprises a plurality of layers, wherein adjacent layers forming the object are covalently bonded.

12. A method of reactive additive manufacturing using a reactive additive manufacturing composition, wherein,
the reactive additive manufacturing composition comprises:
a first component comprising a polyisocyanate and having a first viscosity; and
a second component comprising a polyamine and having a second viscosity,
wherein the reactive additive manufacturing composition is characterized by a tack free time of greater than 3 minutes; and

the method comprises:
providing the first component into a first pump;
providing the second component into a second pump, wherein the second prepolymer is reactive with the first prepolymer;
pumping the first component from the first pump, and the second component from the second pump through a mixer to provide a reactive additive manufacturing composition; and
depositing the reactive additive manufacturing composition through a nozzle connected to the mixer.

13. The method of claim 12 , wherein each of the first pump and the second pump independently comprises a syringe pump, a peristaltic pump, or a progressive cavity pump.

14. The method of claim 12 , wherein the mixer comprises a static mixer, a dynamic mixer, or a combination thereof.

15. The method of claim 12 , wherein depositing comprises extruding the reactive additive manufacturing composition.

16. The method of claim 12 , wherein pumping comprises extruding each of the first component and the second component into the mixer.

17. The method of claim 12 , wherein,
the method comprises extruding the reactive additive manufacturing composition to form an extrudate; and
a cross-sectional profile of the extrudate is characterized by a variable ratio of the first component to the second component.

18. The method of claim 17 , wherein the ratio refers to the mol % ratio of the coreactive components in the extrudate.

19. The method of claim 17 , wherein the ratio refers to the equivalents ratio of the functional groups in the extrudate.

20. The method of claim 17 , wherein the ratio refers to the wt % ratio of the coreactive components in the extrudate.

21. The method of claim 17 , wherein a surface of the extrudate has an excess of one or more functional groups.

22. The method of claim 12 , wherein depositing comprises depositing the reactive additive manufacturing composition from a single nozzle.

23. The method of claim 12 , wherein depositing comprises spraying the reactive additive manufacturing composition.

24. An object fabricated using the method of claim 12 .

25. A reactive additive manufacturing composition, comprising:
a first component comprising a polyisocyanate and having a first viscosity; and
a second component comprising a polyamine and having a second viscosity,
wherein the reactive additive manufacturing composition is characterized by a tack free time of greater than 3 minutes, and
wherein the reactive additive manufacturing composition comprises a polymeric rheology modifier.

26. The composition of claim 25 , wherein the polymeric rheology modifier is selected from a polyethylene, a polyethylene/ethylene copolymer, a polypropylene/ethylene copolymer, and a combination of any of the foregoing.

27. The composition of claim 25 , wherein each of the first component and the second component independently comprises from 1 wt % to 20 wt % of the polymeric rheology modifier, wherein wt % is based on the total weight of the first component or the second component.

28. The composition of claim 25 , wherein the reactive additive manufacturing composition comprises from 0.1 wt % to 40 wt % of a filler, wherein wt % is based on the total weight of the reactive additive manufacturing composition.

29. The composition of claim 28 , wherein the filler comprises an inorganic filler, an organic filler, a low-density filler, an electrically conductive filler, magnetic filler, or a combination of any of the foregoing.

30. An object formed using the reactive additive manufacturing composition of claim 25 .

31. The object of claim 30 , wherein the object comprises a plurality of layers, wherein adjacent layers forming the object are covalently bonded.

32. An object formed from a reactive additive manufacturing composition, wherein the reactive additive manufacturing composition comprises:
a first component comprising a polyisocyanate and having a first viscosity; and
a second component comprising a polyamine and having a second viscosity,
wherein the reactive additive manufacturing composition is characterized by a tack free time of greater than 3 minutes, and
wherein the object comprises a plurality of layers, wherein adjacent layers forming the object are covalently bo

Assignees

• Ppg Ind Ohio Inc

Inventors

• Fenn David Robert
• Olson Kurt G
• Rock Reza M
• Kutchko Cynthia
• Donaldson Susan
• Fogl Anthony J

Classifications

• C09D175/04

  Polyurethanes · CPC title

• C09D175/02

  Polyureas · CPC title

• C08K3/36

  Silica · CPC title

• C08K3/046

  Carbon nanorods, nanowires, nanoplatelets or nanofibres · CPC title

• C08G2150/50

  Compositions for coatings applied by spraying at least two streams of reaction components · CPC title