Additive manufacturing using polyurea materials

Patent metadata

Field	Value
Publication number	US-2019283313-A1
Application number	US-201916423474-A
Country	US
Kind code	A1
Filing date	May 28, 2019
Priority date	Aug 18, 2017
Publication date	Sep 19, 2019
Grant date	—

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 reactive additive manufacturing composition, comprising:
a first component comprising a polyisocyanate and having a first viscosity; and a second component comprising a polyamine and having a second viscosity, wherein the composition is characterized by a tack free time of greater than 3 minutes.

2 . The composition of claim 1 , wherein,
the polyisocyanate comprises a polyisocyanate monomer, a polyisocyanate prepolymer, or a combination thereof; and the polyamine comprises a polyamine monomer, a polyamine prepolymer, or a combination thereof

3 . The composition of claim 2 , wherein,
the polyisocyanate monomer and/or the polyamine monomer has a molecular weight less than 600 Daltons; and the polyisocyanate prepolymer and/or the polyamine prepolymer has a molecular weight from 1,000 Daltons to 20,000 Daltons.

4 . The composition of claim 1 , wherein the first viscosity is within ±20% of the second viscosity; wherein the viscosity is measured using an Anton Paar MCR 301 or 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.

5 . The composition of claim 1 , wherein the composition comprises a polymeric rheology modifier.

6 . The composition of claim 5 , wherein the polymeric rheology modifier comprises a reactive polymeric rheology modifier.

7 . The composition of claim 5 , wherein the rheology modifier is selected from a polyethylene, a polyethylene/ethylene copolymer, a polypropylene/ethylene copolymer, or a combination of any of the foregoing.

8 . The composition of claim 5 , wherein the second component comprises from 1 wt % to 20 wt % of the polymeric rheology modifier, wherein wt % is based on the total weight of the second component.

9 . The composition of claim 7 , wherein the composition comprises from 0.1 wt % to 40 wt % of a filler, wherein wt % is based on the total weight of the composition.

10 . The composition of claim 9 , wherein the composition comprises an inorganic filler, an organic filler, a low-density filler, an electrically conductive filler, magnetic filler, or a combination of any of the foregoing.

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

12 . The object of claim 11 , wherein the object comprises a plurality of layers, wherein adjacent layers forming the object are covalently bonded.

13 . A method of reactive additive manufacturing using the composition of claim 1 , comprising:
providing the first component into a first pump; providing the second component into a second pump, wherein the second prepolymer is reactive with the first prepolymer; pumping the first component from the first pump, and the second component from the second pump through a mixer to provide a reactive composition; and depositing the reactive composition through a nozzle connected to the mixer.

14 . The method of claim 13 , wherein each of the first pump and the second pump independently comprises a syringe pump, a peristaltic pump, or a progressive cavity pump.

15 . The method of claim 13 , wherein the mixer comprises a static mixer, a dynamic mixer, or a combination thereof.

16 . The method of claim 13 , wherein depositing comprises extruding the reactive composition.

17 . The method of claim 16 , wherein pumping comprises extruding each of the first component and the second component into the mixer.

18 . The method of claim 16 , wherein,
the method comprises extruding the reactive composition to form an extrudate; and a cross-sectional profile of the extrudate is characterized by a variable ratio of the first component to the second component.

19 . The method of claim 18 , wherein the ratio refers to the mol % ratio of the coreactive components in the extrudate.

20 . The method of claim 18 , wherein the ratio refers to the equivalents ratio of the functional groups in the extrudate.

21 . The method of claim 18 , wherein the ratio refers to the wt % ratio of the coreactive components in the extrudate.

22 . The method of claim 18 , wherein a surface of the extrudate has an excess of one or more functional groups.

23 . The method of claim 13 , wherein depositing comprises depositing from a single nozzle.

24 . The method of claim 13 , wherein depositing comprises spraying.

25 . An object fabricated using the method of claim 13 .

Assignees

• Ppg Ind Ohio Inc

Inventors

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

Classifications

• C08K3/046

  Carbon nanorods, nanowires, nanoplatelets or nanofibres · CPC title

• C08G75/14

  Polysulfides · CPC title

• C09D175/04

  Polyurethanes · CPC title

• C08G75/045

  from mercapto compounds and unsaturated compounds · CPC title

• C08G59/66 Primary

  Mercaptans · CPC title