Stereolithography using vinyl ether based polymers

• US 5,506,087 A
• Filed: 04/20/1994
• Issued: 04/09/1996
• Est. Priority Date: 02/27/1991
• Status: Expired due to Term

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: Alliedsignal Inc. (Honeywell International Inc.)
• Inventors: Brautigam, Richard J., Lapin, Stephen C.
• Primary Examiner(s): CHAPMAN, MARK A
• Application Number:
  US08/231,353
• Time in Patent Office: 720 Days
• Field of Search: 430/269, 430/284, 522/170, 264/22
• US Class Current: 264/401
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: C08F 290/14 Polymers provided for in subclass C08G
• 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

Abstract

Polymer precursor formulations suitable for stereolithography may be prepared from compositions containing (a) a vinyl ether oligomer, and (b) mono and/or multifunctional vinyl ether monomers.

Claims

1. In a process for forming a three-dimensional object from a liquid polymer precursor comprising repeatedly exposing the surface of a bath of said precursor to a beam of actinic light to solidify successive layers of said precursor the improvement comprising employing as said liquid polymer precursor a mixture of

(a) at least one vinyl ether oligomer having the formula

View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36)

2. The process of claim 1 wherein for (a) R'"'"' and R" are hydrogen.

3. The process of claim 1 wherein for (a) R'"'"' is methyl and R" is hydrogen.

4. The process of claim 1 wherein for (b) R'"'"' and R" are hydrogen.

5. The process of claim 1 wherein for (b) R'"'"' is methyl and R" is hydrogen.

6. The process of claim 1 wherein the liquid polymer precursor comprises 20-85 wt. % of the vinyl ether oligomers of (a) and 15-80 wt. % of the multifunctional vinyl ether monomers of (b) and up to 40 wt. % is the monofunctional monomers of (b) plus about 0.1 to 5 wt. % of a cationic photoinitiator of (c).

7. The process of claim 1 wherein said vinyl ether oligomers of (a) are derived from a urethane obtained by reacting

(i) an hydroxyl terminated polyester having the formula ##STR6## where X and Y are divalent radicals each having a molecular weight of 28 to about 500 and selected from the group consisting of alkylene, arylene, aralkylene, and cycloalkylene radicals m has an average value of 1 to about 100;

and

(ii) a diisocyanate having the formula

space="preserve" listing-type="equation">OCN--Q--NCO

where Q is a divalent radical selected from the group consisting of alkylene, arylene, aralkylene, and cycloalkylene radicals

or a polyisocyanate having a functionality greater than 2;

and

(iii) a hydroxy monovinyl ether having the formula

space="preserve" listing-type="equation">R'"'"'CH═

CR"O--Z--OH

where

R'"'"' and R" are mono valent radicals selected from the group consisting of H and alkyl groups having 1-10 carbon atoms

Z is a divalent radical having a molecular weight of 28 to about 250 and selected from the group consisting of alkylene, cycloalkylene, or poly(alkylene ether) radicals.

8. The process of claim 1 wherein said vinyl ether oligomers of (a) are derived from a urethane obtained by reacting

(i) an hydroxyl terminated polyether having the formula

9. The process of claim 1 wherein said vinyl ether oligomers of (a) are derived from a polyester obtained by reacting

(a) a dicarboxylic acid having the formula ##STR7## where X and Y are divalent radicals having a molecular weight of about 28 to 500 and selected from the group consisting of alkylene, arylene, aralkylene, and cycloalkylene radicals

m has an average value of about 1 to 100;

(b) with a hydroxy monovinyl ether having the formula

space="preserve" listing-type="equation">R'"'"'CH═

CR"OZOH

where

R'"'"' and R" are monovalent radicals selected from the group consisting of H and alkyl groups having 1-10 carbon atoms

Z is a divalent radical having a molecular weight of about 28 to 250 and selected from the group consisting of alkylene, cycloalkylene, or polyalkylene ether radicals.

10. The process of claim 1 wherein said vinyl ether oligomers of (a) are derived from a polysiloxane defined as

11. The process of claim 1 wherein said vinyl ether oligomers of (a) are derived from a phenol defined as

12. The process of claim 11 wherein Z is ethylene and A'"'"' is 4,4'"'"'-isopropylidene diphenol.

13. The process of claim 1 wherein said vinyl ether oligomers of (a) are derived from a polyether by reacting at least one of the groups consisting of poly(ethylene oxy), poly (propylene oxy), or poly (butylene oxy) glycols, where m has an average value from about 2 to 50 with acetylene or a vinyl oxy alkyl halide.

14. The process of claim 1 wherein said vinyl ether monomers of (b) are derived from esters and having the formula ##STR8## where n is 1 to 4,

M₁ is a mono, di, tri, or tetra functional radical having a molecular weight of 15 to 180 and selected from the group consisting of alkylene, arylene, aralkylene and cycloalkylene radicals,

Z is a divalent radical having a molecular weight of 28 to 250 and selected from the group consisting of alkylene, cycloalkylene, or polyalkylene ether radicals,

R'"'"' and R" are monovalent radicals selected from the group consisting of H and alkyl groups having 1-10 carbon atoms.

15. The process of claim 14 where M₁ is a mono, di, tri, or tetra functional radical of benzene.

16. The process of claim 14 wherein Z is the α

,α

'"'"' diradical derived from 1,4-dimethylcyclohexane and M₁ is alkylene with 2 to 4 carbon atoms.

17. The process of claim 1 wherein said vinyl ether monomers of (b) are derived from ethers by reacting at least one of the group consisting of poly(ethyleneoxy), poly(propyleneoxy), or poly(butyleneoxy) glycols, where m has an average value from about 1 to about 5 with acetylene or a vinyl oxy alkyl halide.

18. The process of claim 1 wherein said vinyl ether monomers of (b) are derived from aliphatic hydrocarbons described by the formula

19. The process of claim 1 wherein said vinyl ether monomers of (b) are derived from aromatic hydrocarbons described by the formula

20. The process of claim 1 wherein A is derived from 4,4'"'"'-diphenylmethane diisocyanate.

21. The process of claim 1 wherein Z is at least one member of the group consisting of ethylene, butylene, and the α

,α

'"'"' diradical derived from 1,4-dimethylcyclohexane.

22. The process of claim 1 wherein n is 3 or more for said vinyl ether oligomers and/or monomers.

23. The process of claim 1 wherein said cationic photoinitiator is an onium salt of Group V, VI, and VII elements.

24. The process of claim 23 wherein said cationic photoinitiator is based on an iodonium or sulfonium salt.

25. The process of claim 24 wherein said cationic photoinitiator is a triaryl sulfonium salt of hexafluorophosphate or hexafluoroantimony.

26. The process of claim 24 wherein said cationic photoinitiator is ##STR9## and y is 1 to 18.

27. The process of claim 24 wherein said photoinitiator is ##STR10## and y is 1 to 18.

28. The process of claim 24 wherein said photoinitiator is at least one member of the group consisting of ##STR11##

29. The process of claim 26, 27, or 28 wherein X^- is hexafluorophosphate or hexafluoroantimony.

30. The process of claim 24 wherein the photoinitiator is activated by a photosensitizer.

31. The process of claim 1 wherein said actinic light is ultraviolet light produced by a helium/cadmium laser.

32. The process of claim 1 wherein said actinic light is ultraviolet light produced by an argon ion laser.

33. The process of claim 1 wherein said actinic light is visible light produced by an argon ion laser.

34. The process of claim 1 wherein said three-dimensional object is postcured.

35. The process of claim 34 wherein said postcuring is provided by heating.

36. The process of claim 34 wherein said postcuring is provided by ultraviolet or visible light.