Metathesis polymerization binders for additive manufacturing

Patent metadata

Field	Value
Publication number	US-2023364860-A1
Application number	US-202318315021-A
Country	US
Kind code	A1
Filing date	May 10, 2023
Priority date	May 11, 2022
Publication date	Nov 16, 2023
Grant date	—

Abstract

Techniques are provided for fabricating parts via additive manufacturing by causing a component of a build material powder to contact a binder composition to thereby perform a metathesis chain-growth polymerization reaction (e.g., an olefin metathesis polymerization reaction such as ring-opening metathesis polymerization).

First claim

What is claimed is:

1 . A method of additive manufacturing comprising:
forming one or more parts by performing, a plurality of times:
depositing a layer of build material powder, wherein particles of the build material powder are coated with a catalyst; and
depositing a binder composition on at least a portion of the layer of build material powder, the binder composition comprising a precursor material comprising a monomer and/or a polymer, the monomer and/or polymer comprising an unsaturated carbon-carbon bond, thereby causing the monomer and/or polymer of the precursor material to undergo a metathesis chain-growth polymerization reaction catalyzed by the catalyst.

2 . The method of claim 1 , wherein the precursor material comprises a monomer comprising an unsaturated carbon-carbon bond.

3 . The method of claim 2 , wherein the monomer comprises dicyclopentadiene.

4 . The method of claim 1 , wherein the monomer and/or polymer comprises two or more unsaturated carbon-carbon bonds.

5 . The method of claim 1 , wherein the monomer and/or polymer comprises a bicyclic ring.

6 . The method of claim 1 , wherein the metathesis chain-growth polymerization reaction comprises a ring-opening olefin metathesis polymerization reaction.

7 . The method of claim 6 , wherein the catalyst comprises a metal center.

8 . The method of claim 7 , wherein the metal center is a transition metal.

9 . The method of claim 7 , wherein the catalyst comprises a Grubbs catalyst.

10 . The method of claim 1 , wherein the monomer and/or polymer are a first monomer and/or first polymer, and wherein the precursor material further comprises a second monomer and/or a second polymer comprising an unsaturated carbon-carbon bond, wherein the first monomer and/or first polymer is different than the second monomer and/or second polymer.

11 . The method of claim 10 , wherein the first monomer and/or first polymer comprises dicyclopentadiene and the second monomer and/or the second polymer comprises cyclooctene.

12 . The method of claim 1 , further comprising curing the deposited build material powder and the deposited binder composition, wherein the curing causes or accelerates the polymerization reaction.

13 . The method of claim 12 , wherein the curing comprises heating the deposited build material powder and the deposited binder composition.

14 . The method of claim 1 , wherein the precursor material comprises the monomer and/or the polymer in an amount greater than or equal to 80 wt %.

15 . The method of claim 1 , wherein the catalyst that coats the build material powder is part of a coating on the build material powder, and the catalyst is present in the coating on the build material powder in an amount of greater than or equal to 0.1 wt % by weight of the coating.

16 . The method of claim 1 , wherein the binder composition further comprises a solvent and/or a surfactant.

17 . The method of claim 1 , wherein the build material powder comprises a metal powder.

18 . A method of additive manufacturing comprising:
forming one or more parts by performing, a plurality of times:
depositing a layer of build material powder, wherein particles of the build material powder are coated with a precursor material comprising a monomer and/or a polymer, the monomer and/or polymer comprising an unsaturated carbon-carbon bond; and
depositing a binder composition on at least a portion of the layer of build material powder, the binder composition comprising a catalyst, thereby causing the monomer and/or polymer of the precursor material to undergo a metathesis chain-growth polymerization reaction catalyzed by the catalyst.

19 . A method of additive manufacturing comprising:
forming one or more parts by performing, a plurality of times:
depositing a layer of build material powder, wherein particles of the build material powder are coated with a latent catalyst and a precursor material comprising a monomer and/or a polymer, the monomer and/or polymer comprising an unsaturated carbon-carbon bond; and
depositing a binder composition on at least a portion of the layer of build material powder, the binder composition comprising an activator, thereby causing the monomer and/or polymer of the precursor material to undergo a metathesis chain-growth polymerization reaction catalyzed by the catalyst upon activation by the activator.

20 . A method of additive manufacturing comprising:
forming one or more parts by performing, a plurality of times:
depositing a layer of build material powder, wherein particles of the build material powder are coated with an activator; and
depositing a binder composition on at least a portion of the layer of build material powder, the binder composition comprising a latent catalyst and a precursor material comprising a monomer and/or a polymer, the monomer and/or polymer comprising an unsaturated carbon-carbon bond, thereby causing the monomer and/or polymer of the precursor material to undergo a metathesis chain-growth polymerization reaction catalyzed by the catalyst upon activation by the activator.

Assignees

• Desktop Metal Inc

Inventors

• Creran Brian
• Nick Robert J
• Barbati Alexander C
• Lund Benjamin Robert

Classifications

• B29C64/165 Primary

  using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber · CPC title

• B22F10/14

  by jetting of binder onto a bed of metal powder · CPC title

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B29K2105/0002

  monomers or prepolymers · CPC title