COPOLYMERS FOR 3D PRINTING

• US 20160311972A1
• Filed: 04/24/2015
• Published: 10/27/2016
• Est. Priority Date: 04/24/2015
• Status: Active Grant

• Current Assignee: Xerox Corporation (Xerox Holdings Corp.)
• Original Assignee: Xerox Corporation (Xerox Holdings Corp.)
• Inventors: SACRIPANTE, GUERINO G., ZHOU, KE, ABUKAR, TASNIM
• Granted Patent: US 9,738,752 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29K 2067/003 PET, i.e. poylethylene terephthalate
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: C08G 63/183 Terephthalic acids

Abstract

A copolymer for use in 3D printing includes about 1 to about 30 mole percent of a diacid monomer unit, a diol monomer unit, and a terephthalate monomer unit, the copolymer having a glass transition temperature (T_g) in a range from about 50° C. to about 95° C.

Claims

1. A copolymer for use in 3D printing comprising:

about 1 to about 45 mole percent of a diacid monomer unit;

a diol monomer unit; and

a terephthalate monomer unit;

wherein the copolymer has a glass transition temperature (T_g) in a range from about 50°

C. to about 95°

C.

2. The copolymer of claim 1, wherein the diacid monomer unit is an aliphatic diacid having 2 to 12 carbon atoms.

3. The copolymer of claim 1, wherein the diacid monomer unit is succinic acid.

4. The copolymer of claim 1, wherein the diol monomer unit an aliphatic diol having 2 to 6 carbon atoms.

5. The copolymer of claim 1, wherein the diol monomer unit is 1,4 butanediol.

6. The copolymer of claim 1, wherein the diol monomer unit is present in an amount in a range from about 5 to about 45 mole percent of the polymer.

7. The copolymer of claim 1, wherein the copolymer has a yield stress in a range from about 10 megapascals to about 100 megapascals.

8. The copolymer of claim 1, wherein the copolymer has a yield strain in a range from about 1% to about 10%.

9. The copolymer of claim 1, wherein the copolymer has a Young'"'"'s Modulus in a range from about 0.5 to about 5 gigapascals.

10. The copolymer of claim 1, wherein the copolymer has a breaking strain in a range from about 10% to about 100%.

11. The copolymer of claim 1, wherein the copolymer has a breaking stress in a range from about 10 megapascals to about 100 megapascals.

12. The copolymer of claim 1, wherein the copolymer is provided in a form suitable for incorporation in a 3D printing apparatus as a spooled filament or granules.

13. A method of making a copolymer comprising:

copolymerizing in the presence of a catalyst a mixture comprising;

a diacid monomer unit;

a diol monomer unit; and

a depolymerized polyethylene terephthalate;

wherein copolymerizing is conducted at a temperature in a range from about 150°

C. to about 220°

C.; and

removing any excess diol monomer unit under reduced pressure.

14. The method of claim 13, wherein the catalyst is tin-based.

15. The method of claim 13, wherein the diacid monomer unit is present in a range from about 10% mole percent to about 25 mole percent of the mixture.

16. The method of claim 13, wherein the diol monomer unit is present in a range from about 10 mole percent to about 40 mole percent of the mixture.

17. The method of claim 13, wherein the depolymerized polyethylene terephthalate is present in a range from about 45 mole percent to about 55 mole percent of the mixture.

18. The method of claim 13, wherein the depolymerized polyethylene terephthalate is derived from a recycled polyethylene terephthalate.

19. The method of claim 13, wherein the copolymer is formed into a spool for use in 3D printing.

20. A method of 3D printing comprising:

providing a copolymer for use in 3D printing comprising;

about 10 mole percent to about 30 mole percent of a diacid monomer unit;

about 10 mole percent to about 40 mole percent a diol monomer unit; and

about 45 mole percent to about 55 mole percent a terephthalate monomer unit;

extruding the copolymer to provide a filament; and

supplying the filament to a heated nozzle to apply the copolymer to a substrate to form 3D object on the substrate.