Solid imaging method utilizing photohardenable compositions of self limiting thickness by phase separation

• US 4,942,060 A
• Filed: 04/21/1989
• Issued: 07/17/1990
• Est. Priority Date: 04/21/1989
• Status: Expired due to Term

• Current Assignee: DSM IP Assets BV (DSM-Firmenich AG)
• Original Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Inventors: Grossa, Mario
• Primary Examiner(s): SILVERMAN, STANLEY S
• Application Number:
  US07/341,611
• Time in Patent Office: 452 Days
• Field of Search: 427/54.1, 427/53.1, 427/407.1, 264/22, 264/25
• US Class Current: 427/553
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: G03F 7/0035 Multiple processes, e.g. applying a further resist layer on an already in a previously step, processed pattern or textured surface
• CPC Class Codes: G03F 7/0037 Production of three-dimensional images
• CPC Class Codes: G03F 7/027 Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds G03F7/075 takes precedence
• CPC Class Codes: G03F 7/091 characterised by antireflection means or light filtering or absorbing means, e.g. anti-halation, contrast enhancement
• CPC Class Codes: Y10S 430/148 Light sensitive titanium compound containing

Abstract

An integral three-dimensional object is formed from a photohardenable liquid composition containing latent deflecting matter which is soluble in the liquid but separates into a separate phase upon photohardening.

Claims

1. A method for accurately fabricating an integral three dimensional object from successive layers of a photohardenable liquid composition comprising the steps of:

(a) forming a layer of a photohardenable liquid;

(b) photohardening at least a portion of the layer of photohardenable liquid by exposure to actinic radiation;

(c) introducing a new layer of photohardenable liquid onto the layer previously exposed to actinic radiation; and

(d) photohardening at least a portion of the new liquid layer be exposure to actinic radiation, with the requirement that the photohardenable composition comprises an ethylenically unsaturated monomer, a photoinitiator, and a latent radiation deflecting matter, the latent radiation deflecting matter being in solution within the composition, and separating into separate domains upon photohardening the composition by subjecting it to the actinic radiation, the separate domains comprising a gas,, liquid, solid or mixtures thereof wherein at least a majority of the domains are smaller than the depth of photohardening and larger than one-half of the wavelength of the actinic radiation, the separate domains having a first index of refraction and the rest of the photohardened composition having a second index of refraction, and wherein the absolute value of the difference between the first index of refraction and the second index of refraction is greater than 0.01.

2. The method of claim 1, wherein steps (c) and (d) are successively repeated.

3. The method of claim 2, wherein the actinic radiation is in the form of a beam.

4. The method of claim 2, wherein the separate phase is a gas.

5. The method of claim 2, wherein the separate phase is a liquid.

6. The method of claim 2, wherein the separate phase is a solid.

7. The method of claim 3, wherein the beam is a light beam.