Three-dimensional printed porous silicone matrix using leachable porogen

Patent metadata

Field	Value
Publication number	US-2023250303-A1
Application number	US-202318129716-A
Country	US
Kind code	A1
Filing date	Mar 31, 2023
Priority date	Feb 28, 2020
Publication date	Aug 10, 2023
Grant date	—

Abstract

The silicone-based ink for additive manufacturing includes a siloxane macromer, and a porogen mixture comprising a water-soluble porogen and a surfactant. The product of additive manufacturing with a silicone-based ink includes a three-dimensional printed structure including a plurality of continuous filaments arranged in a predefined pattern and a plurality of inter-filament pores defined by the predefined pattern of the continuous filaments. In addition, each continuous filament of the three-dimensional printed structure includes a silicone matrix having an open cell structure with a plurality of intra-filament pores, and the intra-filament pores form continuous channels through the silicone matrix.

First claim

What is claimed is:

1 . A silicone-based ink for additive manufacturing, the ink comprising:
a siloxane macromer; and a porogen mixture comprising a water-soluble porogen and a surfactant.

2 . The ink as recited in claim 1 , wherein the siloxane macromer includes a vinyl-terminated siloxane macromer.

3 . The ink as recited in claim 1 , wherein the water-soluble porogen includes glycerol.

4 . The ink as recited in claim 3 , wherein a concentration of the glycerol is in a range of about 35 weight% to about 50 weight% of a total weight of the ink.

5 . The ink as recited in claim 1 , wherein the surfactant includes polyvinyl pyrrolidone.

6 . The ink as recited in claim 5 , where in a concentration of the polyvinyl pyrrolidone is in a range of greater than 0 wt% to about 25 weight% of a total weight of the ink.

7 . The ink as recited in claim 1 , further comprising a curing agent.

8 . The ink as recited in claim 1 , comprising an untreated silica.

9 . The ink as recited in claim 1 , comprising a rheology modifying additive.

10 . The ink as recited in claim 1 , wherein the porogen mixture further comprises a plurality of porogen particles.

11 . The ink as recited in claim 10 , wherein the porogen particles are selected from the group consisting of: urea particles, sugar particles, polyethylene glycol, and a combination thereof.

12 . The ink as recited in claim 1 , wherein a concentration of the siloxane macromer is in a range of about 25 weight% to about 70 weight% of a total weight of ink.

13 . A product of additive manufacturing with a silicone-based ink, the product comprising:
a three-dimensional printed structure comprising:
a plurality of continuous filaments arranged in a predefined pattern, the continuous filaments each comprising a silicone matrix having an open cell structure with a plurality of intra-filament pores, wherein the intra-filament pores form continuous channels through the silicone matrix; and
a plurality of inter-filament pores, wherein the inter-filament pores are defined by the predefined pattern of the continuous filaments.

14 . The product as recited in claim 13 , wherein the silicone matrix includes vinyl terminated siloxane polymers.

15 . The product as recited in claim 13 , wherein the continuous filaments have an average diameter greater than about 100 microns.

16 . The product as recited in claim 13 , wherein the inter-filament pores are interconnected from a surface of the three-dimensional printed structure to a surface on an opposite side of the three-dimensional printed structure.

Assignees

• L Livermore Nat Security Llc

Inventors

• Nguyen Du
• Duoss Eric
• Lenhardt Jeremy
• Wilson Thomas S

Classifications

• C09D11/102 Primary

  containing macromolecular compounds obtained by reactions other than those only involving unsaturated carbon-to-carbon bonds · CPC title

• B29C64/118

  using filamentary material being melted, e.g. fused deposition modelling [FDM] · CPC title

• B29C64/379

  Handling of additively manufactured objects, e.g. using robots · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y40/20

  Post-treatment, e.g. curing, coating or polishing · CPC title