Additive manufacturing using reactive compositions

Patent metadata

Field	Value
Publication number	US-12384097-B2
Application number	US-201816639877-A
Country	US
Kind code	B2
Filing date	Aug 17, 2018
Priority date	Aug 18, 2017
Publication date	Aug 12, 2025
Grant date	Aug 12, 2025

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 method of reactive additive manufacturing, comprising:
providing a first component comprising a first compound into a first pump;
providing a second component comprising a second compound into a second pump,
wherein the first compound is reactive with the second compound;

pumping the first component from the first pump, and pumping the second component from the second pump through a mixer to provide a first coreactive composition; and
depositing, by coextrusion, the first coreactive composition and a second coreactive composition;
wherein the second coreactive composition comprises a compound that is reactive with the first component, the second component, or both the first and second components;
wherein the first coreactive composition and the second coreactive composition are reactive at a temperature of less than 50° C.; and
wherein the first component has a first viscosity;
the second component has a second viscosity,
wherein the first viscosity is within ±20% of the second viscosity,
wherein viscosity is measured using an Anton Paar MCR 30 rheometer with a 1 mm gap at a plate temperature of 25° C. and a shear rate of 100 sec·1; and

wherein the first coreactive composition and the second coreactive composition each have a tack free time of greater than 4 minutes.

2. The method of claim 1 , wherein each of the first pump and the second pump comprises a progressive cavity pump.

3. The method of claim 1 , wherein, the first component comprises two or more first compounds; and the second component comprises two or more second compounds.

4. The method of claim 3 , wherein, the two or more first compounds comprise an average functionality of a first functional group from 2 to 6; and
the two or more second compounds comprise an average functionality of a second functional group from 2 to 6, wherein the first functional group is reactive with the second functional group.

5. The method of claim 1 , wherein the first component, the second component, or both the first and second components independently comprise a viscosity from 200 centipoise to 20,000,000 centipoise, measured using an Anton Paar MCR 302 rheometer with a gap from 1 mm at 25° C. and a shear rate of 100 sec·1.

6. The method of claim 1 , wherein,
the first compound comprises a first monomer, a first prepolymer, or a combination thereof;
the second compound comprises a second monomer, a second prepolymer, or a combination thereof; and
the first monomer and the first prepolymer is reactive with the second monomer and the second prepolymer.

7. The method of claim 1 , wherein,
the first compound comprises at least one first prepolymer;
the second compound comprises at least one second prepolymer; and
the at least one first prepolymer is reactive with the at least one second prepolymer.

8. The method of claim 1 , wherein the first compound comprises a polyamine and the second compound comprises a polyisocyanate.

9. The method of claim 1 , wherein the first compound comprises a polyalkenyl compound and the second compound comprises a polythiol.

10. The method of claim 1 , wherein the first compound comprises a Michael acceptor and the second compound comprises a Michael donor.

11. The method of claim 1 , wherein the first compound comprises a polyepoxide and the second compound comprises a polythiol.

12. The method of claim 1 , wherein the first compound comprises a polyepoxide and the second compound comprises a polyamine.

13. The method of claim 1 , wherein the coreactive composition comprises a dynamic viscosity from 200 centipoise to 20,000,000 centipoise, wherein the dynamic viscosity is measured using an Anton Paar MCR 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.

14. The method of claim 1 , wherein the coreactive composition is characterized by a gel time less than 5 minutes at 25° C.

15. The method of claim 1 , wherein the first component, the second component, or both the first and second components independently comprise from 0.1 vol % to 95 vol % of a filler, wherein vol % is based on the total weight of the first component or the second component.

16. The method of claim 1 , wherein depositing comprises extrusion.

17. An object formed using the method of claim 1 .

18. The object of claim 17 , wherein the object provides an attenuation of at least 10 dB within a frequency range between 1 MHz to 18 GHz.

19. The object of claim 17 , wherein the object is characterized by a specific gravity less than 0.9.

20. The method of claim 1 , wherein the first component, the second component, or both the first and second components independently comprise from 0.1 wt. % to 15 wt. % of a filler configured to modify at least one of the first viscosity, the second viscosity, and a combination of the first viscosity and second viscosity, wherein wt. % is based on the total weight of the first component or the second component.

Assignees

• Ppg Ind Ohio Inc

Inventors

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

Classifications

• C08L63/00

  Compositions of epoxy resins; Compositions of derivatives of epoxy resins · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• C08K3/36

  Silica · 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

• C08L75/02

  Polyureas · CPC title