Methods for the preparation of three-dimensional bodies
First Claim
1. A method for preparing a three-dimensional green body comprisingpassing a first liquid composition having a viscosity of at least about 10 poise and comprising thermally-polymerizable components through a dispensing head and onto a base in a predetermined pattern to form a layer of the first liquid composition on the base,passing a second liquid composition through a dispensing head and onto the previously-formed layer of the first liquid composition in a predetermined pattern to provide a multi-layered intermediate,heating the multi-layered intermediate to cause the thermally-polymerizable components in the first and second liquid compositions to polymerize,wherein the first and second liquid compositions are the same or different.
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Abstract
The present invention generally relates compositions and methods for the preparation of three-dimensional bodies e.g., green bodies, ceramic-loaded green bodies, and polymer matrix composites by the controlled, sequential deposition of layers of material upon one another The method for preparing a green body comprises depositing a liquid composition having a viscosity of at least about 10 poise and comprising thermally-polymerizable components onto a base in a predetermined pattern to form a layer of the liquid composition on the base. Subsequently, at least one further layer of the liquid composition is deposited on a previously-formed layer in a predetermined pattern to form a multi-layered intermediate and, then, the multi-layered intermediate is heated to cause the thermally-polymerizable components to polymerize, providing the three-dimensional green body. Another method of the present invention provides a method for reinforcing a green body with fibers. More than simply reinforcing the body, however, this particular aspect of the present invention allows the alignment of reinforcing fibers in the body to be controlled. A further aspect of the present invention is the discovery of a novel composition which may be used to provide a three-dimensional polymer matrix composite using free-formation methods. This composition comprises at least one urethane acrylate oligomer, at least one vinyl monomer, and has a viscosity of at least 10 poise.
134 Citations
27 Claims
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1. A method for preparing a three-dimensional green body comprising
passing a first liquid composition having a viscosity of at least about 10 poise and comprising thermally-polymerizable components through a dispensing head and onto a base in a predetermined pattern to form a layer of the first liquid composition on the base, passing a second liquid composition through a dispensing head and onto the previously-formed layer of the first liquid composition in a predetermined pattern to provide a multi-layered intermediate, heating the multi-layered intermediate to cause the thermally-polymerizable components in the first and second liquid compositions to polymerize, wherein the first and second liquid compositions are the same or different.
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21. A method for preparing a fiber-reinforced three-dimensional body comprising
passing a first fiber-laden suspension having a viscosity of at least about 10 poise and comprising fibers and thermally-polymerizable components through a flow passage of a nozzle, the flow passage being configured so that the fibers are oriented substantially parallel to each other and substantially in the direction of the first fiber-laden suspension movement relative to the nozzle as the first fiber-laden suspension passes through the flow passage, depositing the first fiber-laden suspension after it has passed through the flow passage onto a base in a predetermined pattern to provide a layer of the first fiber-laden suspension on the base, simultaneously with the deposition of the first fiber-laden suspension onto the base, moving the nozzle and base relative to one another so that the fibers in the deposited layer of the first fiber-laden suspension are aligned substantially parallel to the direction of relative movement of the nozzle, and heating the layer to cause the thermally-polymerizable components of the deposited layer of the first fiber-laden suspension to polymerize.
Specification