Composition and method for producing a molded body from a highly pure, transparent quartz glass by means of additive manufacturing

Patent metadata

Field	Value
Publication number	US-10954155-B2
Application number	US-201716339802-A
Country	US
Kind code	B2
Filing date	Oct 4, 2017
Priority date	Oct 6, 2016
Publication date	Mar 23, 2021
Grant date	Mar 23, 2021

Abstract

The present invention relates to a composition and a process for the production of a molding made of high-purity transparent quartz glass, by means of additive manufacturing.

First claim

What is claimed is:

1. A composition for the production of a molding made of high-purity transparent quartz glass, comprising the following components:
at least one polymerizable organic binder which at room temperature is present in liquid form;
a polymerization initiator or crosslinking agent, respectively, which, via supply of light or heat, initiates the polymerization or crosslinking of the at least one polymerizable organic binder; and
at least one type of spherical quartz glass particles, which are present in dispersed form in the at least one polymerizable organic binder and have a diameter ranging from 7 to 100 nm.

2. The composition as claimed in claim 1 , wherein the at least one polymerizable organic binder is a monoacrylate and/or a diacrylate.

3. The composition as claimed in claim 1 , further comprising a non-hardenable component, which at room temperature is present in solid or in viscous liquid form.

4. The composition as claimed in claim 1 , further comprising at least one second type of spherical quartz glass particles having a diameter ranging from 2 to 40 μm.

5. A process for the production of a molding made of high-purity transparent quartz glass, the process comprising the following steps:
(a) providing the composition as claimed in claim 1 in a device;
(b) hardening the at least one polymerizable organic binder contained in the composition via supply of light or heat, whereby a green part is obtained as a primary structure;
(c) separating potentially non-hardened at least one polymerizable organic binder, inclusive of the components contained therein, from the primary structure; and optionally at least once repeating the steps (a), (b) and optionally (c);
(d) optionally post-treating the primary structure by at least one process selected from the group consisting of structuring by means of a forming tool, irradiating with high-energy radiation and subsequent developing, milling, drilling, laminating, bonding, grinding, polishing, lapping, engraving and treating with heat or laser light;
(e) removing a non-hardenable component potentially present in the primary structure;
(f) debinding the primary structure by thermal treatment, whereby a brown part is obtained as porous secondary structure;
(g) optionally filling up the porous secondary structure with at least one filler; and
(h) sintering the porous secondary structure, whereby the molding is obtained.

6. The process as claimed in claim 5 , wherein removing the non-hardenable component if present in the primary structure in step (e) is carried out by thermal treatment at a temperature ranging from 50 to 300° C., by applying a reduced pressure or by solvent extraction.

7. The process as claimed in claim 5 , wherein debinding the primary structure in step (f) is carried out at a temperature ranging from 200 to 700° C.

8. The process as claimed in claim 5 , wherein sintering the porous secondary structure in step (h) is carried out at a temperature ranging from 700 to 1500° C. and at a pressure of at most 0.1 mbar.

9. The process as claimed in claim 5 , wherein the at least one filler in step (g) is selected from the group consisting of inorganic pigments, silicon-based precursors and titanium-based precursors.

10. The process as claimed in claim 5 , wherein the at least one polymerizable organic binder is a monoacrylate and/or a diacrylate.

11. The process as claimed in claim 5 , wherein the non-hardenable component, if present, exists in solid or in viscous liquid form at room temperature.

12. A molding made of high-purity transparent quartz glass, obtainable by the process as claimed in claim 5 .

13. The process as claimed in claim 5 , wherein the composition further comprises at least one second type of spherical quartz glass particles having a diameter ranging from 2 to 40 μm.

14. A process for the production of a molding made of high-purity transparent quartz glass, the process comprising the following steps:
(a) providing the composition for the production of a molding made of high-purity transparent quartz glass in a device, the composition comprising:
at least one polymerizable organic binder which at room temperature is present in liquid form;
a polymerization initiator or crosslinking agent, respectively, which, via supply of light or heat, initiates the polymerization or crosslinking of the at least one polymerizable organic binder;
at least one type of spherical quartz glass particles, which are present in dispersed form in the at least one polymerizable organic binder and have a diameter ranging from 7 to 100 nm; and
an optional non-hardening component;

(b) incompletely hardening the at least one polymerizable organic binder contained in the composition via supply of light or heat, whereby a green part is obtained as a primary structure;
(c) separating non-hardened at least one polymerizable organic binder, inclusive of the components contained therein, from the primary structure; and optionally at least once repeating the steps (a), (b) and (c);
(d) optionally post-treating the primary structure by at least one process selected from the group consisting of structuring by means of a forming tool, irradiating with high-energy radiation and subsequent developing, milling, drilling, laminating, bonding, grinding, polishing, lapping, engraving and treating with heat or laser light;
(e) removing the non-hardenable component if present in the primary structure;
(f) debinding the primary structure by thermal treatment, whereby a brown part is obtained as a porous secondary structure;
(g) optionally filling up the porous secondary structure with at least one filler; and
(h) sintering the porous secondary structure, whereby the molding is obtained.

15. The process as claimed in claim 14 , wherein removing the non-hardenable component if present in the primary structure in step (e) is carried out by thermal treatment at a temperature ranging from 50 to 300° C., by applying a reduced pressure or by solvent extraction.

16. The process as claimed in claim 14 , wherein debinding the primary structure in step (f) is carried out at a temperature ranging from 200 to 700° C.

17. The process as claimed in claim 14 , wherein sintering the porous secondary structure in step (h) is carried out at a temperature ranging from 700 to 1500° C. and at a pressure of at most 0.1 mbar.

18. The process as claimed in claim 14 , wherein the at least one filler in step (g) is selected from the group consisting of inorganic pigments, silicon-based precursors and titanium-based precursors.

19. The process as claimed in claim 14 , wherein the at least one polymerizable organic binder is a monoacrylate and/or a diacrylate.

20. The process as claimed in claim 14 , wherein the non-hardenable component, if present, exists in solid or in viscous liquid form at room temperature.

Assignees

• Karlsruher Inst Technologie

Inventors

• Rapp Bastian
• Kotz Frederik

Classifications

• B33Y40/20

  Post-treatment, e.g. curing, coating or polishing · CPC title

• B33Y70/10

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title

• C08L33/06

  of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical · CPC title

• C08K7/20

  Glass · CPC title

• C03B19/066 Primary

  for the production of quartz or fused silica articles (other processes specially adapted for the production of quartz or fused silica articles C03B20/00) · CPC title