Coreactive materials and methods for three-dimensional printing

Patent metadata

Field	Value
Publication number	US-2019169449-A1
Application number	US-201916269277-A
Country	US
Kind code	A1
Filing date	Feb 6, 2019
Priority date	Nov 24, 2014
Publication date	Jun 6, 2019
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 compound, wherein the first compound comprises at least one first functional group; and a second component comprising a second compound, wherein the second compound comprises at least one second functional group, wherein the at least one second functional group is reactive with the at least one first functional group; wherein at least one of the first functional group and the second functional group comprises a saturated functional group; and wherein each of the first functional group and the second functional group does not comprise an ethylenically unsaturated group.

2 . The composition of claim 1 , wherein the composition is characterized by: a viscosity less than 30 cP; a surface tension of 30 mN/m to 50 nM/m; a contact angle on glass of less than 20 degrees; and a contact angle on polyethylene terephthalate of less than 40 degrees.

3 . The composition of claim 1 , wherein each of the first component and the second component comprises less than 5 wt % solvent, wherein wt % is based on the total weight of each of the respective coreactive components.

4 . The composition of claim 1 , wherein an equivalents ratio of the at least one first functional group to the at least one second functional group is from 2:1 to 1:2.

5 . The composition of claim 1 , wherein the first compound and the second compound are capable of coreacting at a temperature less than 30° C.

6 . The composition of claim 1 , wherein each of the first component and the second component independently comprises:
a monomer having a molecular weight less than 600 Daltons; a prepolymer having a molecular weight with a range from 1,000 Daltons to 20,000 Daltons; or a combination thereof.

7 . The composition of claim 1 , wherein,
the composition comprises an additional coreactive component, wherein the additional coreactive component comprises a compound comprising at least one third functional group, wherein the at least one third functional group is different than the first functional group and the second functional group; and the third functional group is reactive with the first functional group or the second functional group.

8 . The composition of claim 7 , wherein a reaction rate of the third functional group with the first functional group or the second functional group is different than a reaction rate of the first functional group with the second functional group.

9 . The composition of claim 1 , wherein the composition comprises a filler.

10 . The composition of claim 9 , wherein the composition comprises from 1 wt % to 40 wt % of the filler.

11 . The composition of claim 9 , wherein the filler comprises a low density filler having a specific gravity less than 0.7.

12 . The composition of claim 9 , wherein the filler comprises an electrically conductive filler.

13 . The composition of claim 9 , wherein the filler comprises silica.

14 . The composition of claim 9 , wherein the filler comprises a magnetic filler.

15 . The composition of claim 1 , wherein the composition comprises a colorant.

16 . The composition of claim 1 , wherein the composition comprises carbon fiber, glass fiber, graphene, or a combination of any of the foregoing.

17 . The composition of claim 1 , wherein the composition comprises an amount of an electrically conductive filler sufficient to impart effective EMI/RFI resistance over a frequency range of 1 MHz to 18 GHz to a three-dimensional object.

18 . The composition of claim 1 , wherein the first component and the second component are mixed to form an extrusion comprising a cross-sectional profile.

19 . The composition of claim 18 , wherein the cross-sectional profile of the extrusion comprises a variable wt % ratio of the first component and the second component.

20 . The composition of claim 18 , wherein the cross-sectional profile of the extrusion comprises a variable mol % ratio of the first component and the second component.

21 . The composition of claim 18 , wherein the cross-sectional profile is configured to impart different properties to a object.

22 . The composition of claim 18 , wherein the cross-sectional profile is configured to impart solvent resistance to an outer portion of a object.

23 . The composition of claim 18 , wherein the cross-sectional profile is configured to impart electrical conductivity to an outer portion of a object.

24 . The composition of claim 18 , wherein the cross-sectional profile is configured to facilitate interlayer adhesion.

25 . The composition of claim 18 , wherein the cross-sectional profile is configured to facilitate covalent bonding between adjoining layers.

26 . The composition of claim 18 , wherein the cross-sectional profile is configured to control the rate of curing.

27 . The composition of claim 18 , wherein the cross-sectional profile of the extrusion is homogeneous.

28 . The composition of claim 18 , wherein the cross-sectional profile of the extrusion is inhomogeneous.

29 . An object formed using the composition of claim 1 .

30 . The object of claim 29 , wherein the object is formed by extruding the composition of claim 1 .

31 . The object of claim 29 , wherein the object comprises successive layers of the composition of claim 1 .

32 . The object of claim 31 , wherein the successive layers are covalently bonded to an adjoining layer.

33 . The object of claim 29 , wherein components of an underlying layer react with components of an adjoining layer.

34 . The object of claim 29 , wherein properties in one part of the object are different from the properties in another part of the object.

35 . The object of claim 29 , wherein the composition in one part of the object is different than the composition in another part of the object.

36 . The object of claim 35 , wherein the different compositions comprise a different wt % of the first component and the second component.

37 . The object of claim 35 , wherein the different compositions comprise a different equivalents ratio of the first functional group to the second functional group.

38 . The object of claim 35 , wherein the different compositions comprise a different type of filler, a different amount of filler, or a combination thereof.

39 . The object of claim 29 , wherein one part of the object has different chemical, physical, or thermal properties than another part of the object.

40 . The object of claim 29 comprising a cross-sectional profile wherein different portions of the cross-sectional profile contain (a) a mixture of the two components in a different molar or equivalents ratio, (b) one of the two coreactive components, or (c) a combination of thereof.

41 . The object of claim 29 , wherein a deposited layer comprises an excess of the first functional group and an adjoining layer comprises an excess of the second functional group.

42 . The object of claim 29 , wherein different parts of the object have different proportions of the first component and the second

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

• C08G2150/50

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

• C08G18/3228

  acyclic · CPC title

• C09D11/38

  characterised by non-macromolecular additives other than solvents, pigments or dyes · CPC title

• C08G18/4854 Primary

  Polyethers containing oxyalkylene groups having four carbon atoms in the alkylene group · CPC title