Water cure methods for producing three-dimensional objects from materials having multiple mechanisms of hardening

Patent metadata

Field	Value
Publication number	US-11299579-B2
Application number	US-202016803350-A
Country	US
Kind code	B2
Filing date	Feb 27, 2020
Priority date	Jun 23, 2014
Publication date	Apr 12, 2022
Grant date	Apr 12, 2022

Abstract

A method of forming a three-dimensional object (e.g. comprised of polyurethane, polyurea, or copolymer thereof) is carried out by: (a) providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; (b) filling the build region with a polymerizable liquid, the polymerizable liquid comprising a mixture of: (i) a light polymerizable liquid first component, and (ii) a second solidifiable component that is different from the first component; (c) irradiating the build region with light through the optically transparent member to form a solid blocked polymer scaffold and advancing the carrier away from the build surface to form a three-dimensional intermediate having the same shape as, or a shape to be imparted to, the three-dimensional object, with the intermediate containing the second solidifiable component; and then (d) contacting the three-dimensional intermediate to water to form the three-dimensional object.

First claim

We claim:

1. A method of forming a three-dimensional object, 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 the first component;
(c) irradiating said build region with light through said optically transparent member to form a solid polymer scaffold from the first component and advancing said carrier away from said build surface to form a three-dimensional intermediate having the same shape as, or a shape to be imparted to, said three-dimensional object, with said intermediate containing said second solidifiable component carried in the scaffold in unsolidified or uncured form; and then
(d) subsequent to the irradiating step, curing the second solidifiable component by contacting said three-dimensional intermediate to water, to form from said three-dimensional intermediate said three-dimensional object.

2. The method of claim 1 , wherein said water is in liquid, gas, or aerosol form.

3. The method of claim 1 , wherein said curing step (d) further comprises heating or microwave irradiating said three-dimensional intermediate concurrent with and/or subsequent to the contacting of said three-dimensional intermediate to water.

4. The method of claim 1 , wherein said three-dimensional object is comprised of polyurethane, polyurea, or a copolymer thereof, and the second solidifiable component comprises precursors to a polyurethane, polyurea, or a copolymer thereof.

5. The method of claim 4 , wherein the second solidifiable component comprises a blocked or reactive blocked diisocyanate.

6. The method of claim 4 , wherein the second solidifiable component comprises a diisocyanate that is not blocked with a blocking agent.

7. The method of claim 1 , wherein said three-dimensional object comprises (i) a linear thermoplastic polyurethane, polyurea, or copolymer thereof, (ii) a cross-linked thermoset polyurethane, polyurea, or copolymer thereof, or (iii) a combination thereof.

8. The method of claim 1 , wherein the second solidifiable component comprises precursors to a water-curable silicone resin.

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

10. The method of claim 1 , wherein the second solidifiable component comprises a polymerizable solid suspended in said first component, or solid thermoplastic or thermoset polymer particles suspended in said first component.

11. The method of claim 1 , wherein said three-dimensional intermediate is collapsible or compressible.

12. The method of claim 1 , wherein the solid polymer scaffold is discontinuous.

13. 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.

14. The method of claim 1 , said polymerizable liquid comprising a mixture of (i) a blocked or reactive blocked prepolymer, (ii) a chain extender, (iii) a photoinitiator, (iv) optionally a polyol and/or a polyamine, (v) optionally a reactive diluent, (vi) optionally a pigment or dye, and (vii) optionally a filler.

15. The method of claim 14 , wherein the blocked or reactive blocked prepolymer comprises a compound of the formula A-X-A, where X is a hydrocarbyl group and each A is an independently selected substituent of Formula (X):

where R is a hydrocarbyl group, R′ is O or NH, and Z is a blocking group, said blocking group optionally having a reactive terminal group.

16. The method of claim 14 , wherein the blocked or reactive blocked prepolymer comprises a blocked or reactive blocked diisocyanate.

17. The method of claim 14 , wherein the blocked or reactive blocked prepolymer comprises a reactive blocked diisocyanate blocked by reaction of a polyisocyanate oligomer with an amine (meth)acrylate, alcohol (meth)acrylate, maleimide, or n-vinylformamaide monomer blocking agent.

18. The method of claim 14 , wherein the blocked or reactive blocked prepolymer comprises a reactive blocked diisocyanate blocked by reaction of a polyisocyanate with a tertiary-butylaminoethyl methacrylate (TBAEMA), a tertiary pentylaminoethyl methacrylate (TPAEMA), a tertiary hexylaminoethyl methacrylate (THAEMA), a tertiary-butylaminopropyl methacrylate (TBAPMA), an acrylate analog thereof, or a mixture of two or more thereof.

19. The method of claim 18 , wherein the reactive diluent is present and copolymerizes with the reactive blocked diisocyanate during the irradiating step.

20. The method of claim 19 , wherein said reactive diluent comprises an acrylate, a methacrylate, a styrene, an acrylic acid, a vinylamide, a vinyl ether, a vinyl ester, polymers containing any one or more of the foregoing, or a combination of two or more of the foregoing.

21. The method of claim 14 , wherein the chain extender comprises a polyamine.

22. The method of claim 14 , wherein the chain extender comprises a polyol.

23. The method of claim 1 , wherein the method comprises repeating steps (b) and (c) to produce a subsequent polymerized region adhered to a previous polymerized region until the continued or repeated deposition of polymerized regions adhered to one another forms the three-dimensional intermediate.

Assignees

• Carbon Inc

Inventors

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

Classifications

• B29K2105/251

  Particles, powder or granules (expandable particles B29K2105/046) · CPC title

• B29K2105/0091

  IPN, i.e. interpenetrating polymer networks · CPC title

• B29K2105/0073

  Solution · CPC title

• B29C64/286

  Optical filters, e.g. masks · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title