Coreactive Materials and Methods for Three-Dimensional Printing

Patent metadata

Field	Value
Publication number	US-2017355865-A1
Application number	US-201515528205-A
Country	US
Kind code	A1
Filing date	Nov 24, 2015
Priority date	Nov 24, 2014
Publication date	Dec 14, 2017
Grant date	—

Abstract

Methods of printing a three-dimensional object using co-reactive components are disclosed. Thermosetting compositions for three-dimensional printing are also disclosed.

First claim

What is claimed is:

1 . A composition for three-dimensional printing, comprising:
a first component comprising a first functional group; and a second component comprising a second functional group, wherein the second functional group is reactive with the first functional group; and wherein at least one of the first functional group and the second functional group comprises a saturated functional group.

2 . The composition of claim 1 , wherein the composition is characterized by a shear storage modulus G′ and a shear loss modulus G″, wherein,
the initial G″/G′ ratio is less than 2;
the initial G′ is greater than 1,500;
the G′ at 6 minutes is greater than 500,000 Pa; and
the G″ at 6 minutes is greater than 400,000 Pa; wherein,
the initial G″/G′ ratio and the initial G′ refer to values measured within 30 seconds after the first component and the second component are mixed;
the G′ and G″ after 6 minutes refers to the values measured 6 minutes after the first component and the second component are mixed; and
the shear storage modulus G′ and the shear loss modulus G″ are measured using a rheometer with a gap from 1 mm to 2 mm, 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.

3 . The composition of claim 1 , wherein the composition is characterized by a shear storage modulus G′ and a shear loss modulus G″, wherein, the initial G″/G′ ratio is less than 1.5;
the initial G′ is greater than 2,000 Pa;
the G′ at 6 minutes is greater than 1,000,000 Pa; and
the G″ at 6 minutes is greater than 600,000 Pa.; wherein,
the initial G″/G′ ratio and the initial G′ refer to values measured within 30 seconds after the first component and the second component are mixed;
the G′ and G″ after 6 minutes refers to the values measured 6 minutes after the first component and the second component are mixed; and
the shear storage modulus G′ and the shear loss modulus G″ are measured using a rheometer with a gap from 1 mm to 2 mm, 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.

4 . The composition of claim 1 , wherein the composition is extrudable.

5 . The composition of claim 1 , wherein an initial equivalent ratio of the first functional group to the second functional group is from 1.5:1 to 1:1.5.

6 . The composition of claim 1 , wherein the composition is characterized by a viscosity from 5,000 cP to 5,000,000 cP, measured using a rheometer with a gap from 1 mm to 2 mm, a shear rate of 0.1 s −1 at a temperature of 25 C.

7 . The composition of claim 1 , wherein the composition comprises a thermosetting composition.

8 . The composition of claim 1 , wherein the composition is substantially free of solvent.

9 . The composition of claim 1 , wherein each of the first component and the second component comprise a monomer, a prepolymer, or a combination thereof.

10 . The composition of claim 1 , wherein the composition is characterized by a cross-sectional profile having a first portion and a second portion.

11 . The composition of claim 10 , wherein,
the first portion comprises a molar ratio of the first component to the second component greater than 1; and the second portion comprises a molar ratio of the first component to the second component less than 1.

12 . The composition of claim 10 , wherein the first portion and the second portion are on opposite sides of the cross-sectional profile.

13 . The composition of claim 10 , wherein,
the first portion comprises an equivalent ratio of the first functional group to the second functional group greater than 1; and the second portion comprises an equivalent ratio of the first functional group to the second functional group less than 1.

14 . The composition of claim 10 , wherein an equivalents ratio of the first component to the second component is not homogeneous throughout the cross-sectional profile.

15 . The composition of claim 10 , wherein an equivalents ratio of the first component to the second component is homogeneous throughout the cross-sectional profile.

16 . The composition of claim 1 , wherein each of the first functional group and the second functional group does not comprise an acrylate group or a methacrylate group.

17 . The composition of claim 1 , comprising a catalyst, wherein the catalyst catalyzes the reaction between the first functional group and the second functional group.

18 . The composition of claim 1 , wherein the composition is not curable using actinic radiation.

19 . The composition of claim 1 , wherein the saturated functional group comprises a hydroxyl, a thiol, a primary amine, a secondary amine, an epoxy, or a combination of any of the foregoing.

20 . The composition of claim 2 , wherein,
the first component comprises a polyol; and the second component comprises a polyisocyanate.

21 . The composition of claim 1 , wherein the composition is formulated for inkjet printing.

22 . A composition comprising:
a first component comprising a first functional group; and a second component comprising a second functional group, wherein,
the first component comprises a polyamine and the second component comprises a polyisocyanate;
the first component comprises a polyalkenyl compound and the second component comprises a polythiol;
the first component comprises a Michael addition acceptor and the second component comprises a Michael addition donor; or
a combination of any of the foregoing;
wherein the composition is characterized by a shear storage modulus G′ and a shear loss modulus G″, wherein,
the initial G″/G′ ratio is less than 2;
the initial G′ is greater than 1,500 Pa;
the G′ at 6 minutes is greater than 500,000 Pa; and
the G″ at 6 minutes after mixing is greater than 400,000 Pa; wherein,
the shear storage modulus G′ and the shear loss modulus G″ are measured using a rheometer with a gap from 1 mm to 2 mm, 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.

23 . A three-dimensional object formed using the composition of claim 1 .

24 . The three-dimensional object of claim 23 , wherein the three-dimensional object comprises a plurality of layers, wherein adjacent layers forming the three-dimensional object are covalently bonded.

Assignees

• Ppg Ind Ohio Inc

Inventors

• Fenn David R
• Olson Kurt G
• Rock Reza M
• Kutchko Cynthia
• Donaldson Susan F
• Sun Hao

Classifications

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B29C64/112 Primary

  using individual droplets, e.g. from jetting heads · CPC title

• C08G18/3225

  Polyamines · CPC title

• C08G18/325

  containing secondary or tertiary amino groups (C08G18/3228, C08G18/3234, C08G18/3246 take precedence) · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title