US20120259031A1 - Led curable liquid resin compositions for additive fabrication - Google Patents

Led curable liquid resin compositions for additive fabrication Download PDF

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Publication number
US20120259031A1
US20120259031A1 US13/515,629 US201013515629A US2012259031A1 US 20120259031 A1 US20120259031 A1 US 20120259031A1 US 201013515629 A US201013515629 A US 201013515629A US 2012259031 A1 US2012259031 A1 US 2012259031A1
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United States
Prior art keywords
photocurable resin
resin composition
salts
sulfonium
phenyl
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Abandoned
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US13/515,629
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English (en)
Inventor
Ken Dake
Jigeng Xu
Timothy Bishop
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DSM IP Assets BV
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DSM IP Assets BV
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Publication date
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Priority to US13/515,629 priority Critical patent/US20120259031A1/en
Publication of US20120259031A1 publication Critical patent/US20120259031A1/en
Assigned to DSM ASSETS B.V. reassignment DSM ASSETS B.V. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DAKE, KEN
Assigned to DSM IP ASSETS B.V. reassignment DSM IP ASSETS B.V. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: XU, JIGENG, BISHOP, TIMOTHY EDWARD, DAKE, KEN
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/245—Platforms or substrates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
    • B29C64/129—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
    • B29C64/135—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B29C64/268—Arrangements for irradiation using laser beams; using electron beams [EB]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B29C64/277—Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/0011—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for shaping plates or sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/20—Post-treatment, e.g. curing, coating or polishing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
    • G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
    • G03F7/0037—Production of three-dimensional images
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
    • G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
    • G03F7/004—Photosensitive materials
    • G03F7/0045—Photosensitive materials with organic non-macromolecular light-sensitive compounds not otherwise provided for, e.g. dissolution inhibitors
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
    • G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
    • G03F7/004—Photosensitive materials
    • G03F7/027—Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
    • G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
    • G03F7/004—Photosensitive materials
    • G03F7/027—Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds
    • G03F7/028—Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds with photosensitivity-increasing substances, e.g. photoinitiators
    • G03F7/029—Inorganic compounds; Onium compounds; Organic compounds having hetero atoms other than oxygen, nitrogen or sulfur
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
    • G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
    • G03F7/004—Photosensitive materials
    • G03F7/038—Macromolecular compounds which are rendered insoluble or differentially wettable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C2033/0005—Moulds or cores; Details thereof or accessories therefor with transparent parts, e.g. permitting visual inspection of the interior of the cavity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0827—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using UV radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0838—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using laser
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31511—Of epoxy ether
    • Y10T428/31515—As intermediate layer

Definitions

  • the present invention relates to photocurable resin compositions used in additive fabrication applications.
  • Additive fabrication processes for producing three dimensional articles are known in the field.
  • Additive fabrication processes utilize computer-aided design (CAD) data of an object to build three-dimensional parts layer-by-layer. These three-dimensional parts may be formed from liquid resins, powders, or other materials.
  • CAD computer-aided design
  • SL stereolithography
  • CAD data of an object wherein the data is transformed into thin cross-sections of a three-dimensional object.
  • the data is loaded into a computer which controls a laser beam that traces the pattern of a cross section through a liquid radiation curable resin composition contained in a vat, solidifying a thin layer of the resin corresponding to the cross section.
  • the solidified layer is recoated with resin and the laser beam traces another cross section to harden another layer of resin on top of the previous layer.
  • the process is repeated layer by layer until the three-dimensional object is completed.
  • the three-dimensional object is, in general, not fully cured and therefore may be subjected to post-curing, if required.
  • An example of an SL process is described in U.S. Pat. No. 4,575,330.
  • lasers used in stereolithography There are several types of lasers used in stereolithography, ranging from 193 nm to 355 nm in wavelength.
  • the use of bulky and expensive gas lasers to cure liquid radiation curable resins is well known.
  • the delivery of laser energy in a stereolithography system can be Continuous Wave (CW) or Q-switched pulses.
  • CW lasers provide continuous laser energy and can be used in a high speed scanning process.
  • their output power is limited which reduces the amount of curing that occurs during object creation. As a result the finished object will need additional post process curing.
  • excess heat could be generated at the point of irradiation which may be detrimental to the resin.
  • the use of a laser requires scanning point by point on the resin which can be time-consuming.
  • LEDs Light emitting diodes
  • LEDs are semiconductor devices which utilize the phenomenon of electroluminescence to generate light.
  • LEDs consist of a semiconducting material doped with impurities to create a p-n junction capable of emitting light as positive holes join with negative electrons when voltage is applied.
  • the wavelength of emitted light is determined by the materials used in the active region of the semiconductor.
  • Typical materials used in semiconductors of LEDs include, for example, elements from Groups 13 (III) and 15 (V) of the periodic table. These semiconductors are referred to as III-V semiconductors and include, for example, GaAs, GaP, GaAsP, AlGaAs, InGaAsP, AlGaInP, and InGaN semiconductors.
  • Other examples of semiconductors used in LEDs include compounds from Group 14 (IV-IV semiconductor) and Group 12-16 (II-V1). The choice of materials is based on multiple factors including desired wavelength of emission, performance parameters, and cost.
  • LEDs used gallium arsenide (GaAs) to emit infrared (IR) radiation and low intensity red light. Advances in materials science have led to the development of LEDs capable of emitting light with higher intensity and shorter wavelengths, including other colors of visible light and UV light. It is possible to create LEDs that emit light across a wide wavelength spectrum, for example, from a low of about 100 nm to a high of about 900 nm. Typically, LED UV light sources currently emit light at wavelengths between 300 and 475 nm, with 365 nm, 390 nm, and 395 nm being common peak spectral outputs. See textbook,“Light-Emitting Diodes” by E. Fred Schubert, 2′′ Edition, ⁇ E. Fred Schubert 2006, published by Cambridge University Press.
  • LED lamps for commercial curing applications. For example, Phoseon Technology, Summit UV, Honle UV America, Inc., IST Metz GmbH, Jenton International Ltd., Lumos Solutions Ltd., Solid UV Inc., Seoul Optodevice Co., Ltd., Spectronics Corporation, Luminus Devices Inc., and Clearstone Technologies, are some of the manufacturers offering LED lamps for curing ink-jet printing compositions, PVC floor coating compositions, metal coating compositions, plastic coating composition, and adhesive compositions.
  • LED curing devices are used in dental work.
  • An example of such a device is the ELIPARTM FreeLight 2 LED curing light from 3M ESPE. This device emits light in the visible region with a peak irradiance at 460 nm. LED equipment is also being tested for use in the ink-jet printing, including, for example, by IST Metz.
  • U.S. Pat. No. 7,211,368 reportedly discloses a liquid stereolithography resin comprising a first urethane acrylate oligomer, a first acrylate monomer, a polymerization modifier, a second urethane acrylate oligomer different from the first urethane acrylate oligomer, and a stabilizer.
  • the first urethane acrylate oligomer is an aliphatic polyester urethane diacrylate oligomer
  • the first acrylate monomer is ethoxylated (3) trimethylolpropane acrylate
  • the polymerization modifier is selected from the group consisting of isobornyl acrylate, ethoxylated (5) pentaerythritol tetraacrylate, an aliphatic urethane acrylate, tris-(2-hydroxyethyl)isocyanurate triacrylate, and mixtures thereof.
  • the resin includes 5-35 weight % of an aliphatic polyester urethane diacrylate oligomer and 0.5-25 weight % ethoxylated (3) trimethylolpropane acrylate, wherein the resin includes 15-45 weight % ethoxylated (5) pentaerythritol tetraacrylate.
  • the '368 patent indicates that a laser is used to cure the resin. Further, the '368 patent fails to disclose the use of an acid generating photoinitiator, such as a cationic photoinitiator.
  • U.S. Pat. No. 6,927,018 and U.S. Patent Application Publication No. 2005/0227186 purportedly provide a method, article of manufacture and system for fabricating an article using photo-activatable building material.
  • the method according to the '018 patent and the '186 publication includes the steps of applying a layer of the photo-activatable building material to a preselected surface, scanning the layer using a plurality of light-emitting centers to photo-activate the layer of photo-activatable building material in accordance with a predetermined photo-initiation process to obtain polymerization of the building material.
  • Scanning is accomplished at a predetermined distance using a predetermined light intensity, and repeating the steps of applying the layer.
  • Each layer is applied to an immediately previous layer, and the layer is scanned with the plurality of light-emitting centers to polymerize the building material until the article is fabricated.
  • UV LEDs and laser diodes as suitable light-emitting centers, they fail to disclose detailed information on photo-activatable building material suitable for LED cure.
  • U.S. Pat. No. 7,270,528 purportedly discloses a flash curing system for solid freeform fabrication which generates a plurality of radiation emitting pulses that forms a planar flash.
  • the planar flash initiates curing of a curable material dispensed by a solid freeform fabrication apparatus.
  • the '528 patent while mentioning UV light-emitting diodes (LED) lamps in the specification, sets forth examples where a flash lamp is used to cure the resin composition.
  • the resin composition illustrated in the '528 patent does contain a cationically curable monomer or a cationic photoinitiator.
  • U.S. Patent Application Publication No. 2008/0231731 or 2008/0169589 or European Patent Application No. EP 1950032 purportedly discloses a solid imaging apparatus that includes a replaceable cartridge containing a source of build material and an extendable and retractable flexible transport film for transporting the build material layer-by-layer from the cartridge to the surface of a build in an image plane. If desired, the apparatus can produce a fully reacted build. A high intensity UV source is said to cure the build between layers.
  • the above publications state that the solid imaging radiation that is used to cure the build material can be “any actinic radiation which causes a photocurable liquid to react to produce a solid, whether a visible or UV source or other source,”
  • International Patent Publication No. WO 2008/118263 is directed to a system for building a three-dimensional object based on build data representing the three-dimensional object, wherein the system includes an extrusion head that deposits a radiation-curable material in consecutive layers at a high deposition rate. The radiation-curable material of each of the consecutive layers is cooled to a self-supporting state.
  • the system is said to include a radiation source that selectively exposes portions of the consecutive layers to radiation at a high resolution in accordance with the build data.
  • the exposure head includes a linear array of high resolution, UV light-emitting diodes (LEDs).
  • LEDs UV light-emitting diodes
  • P71-1464 CUREBARTM and P150-3072 PRINTHEADTM are described as examples of suitable UV-radiation sources for the exposure head.
  • the '263 publication fails to describe exemplary photocurable formulations suitable for curing by LED light in an additive fabrication process.
  • the invention in this PCT patent application relates to the use of LED curing in structural applications, in particular in applications for the lining or relining of objects, and to objects containing a cured resin composition obtained by LED curing.
  • This invention provides a simple, environmentally safe and readily controllable method for (re)lining pipes, tanks and vessels, especially for such pipes and equipment having a large diameter, in particular more than 15 cm.
  • the specification does not describe LED radiation curable photocurable resins.
  • U.S. Patent Application Publication No. 2007/0205528 reportedly discloses an optical molding process wherein the radiation source used is a non-coherent source of radiation.
  • the '528 publication indicates that the photocurable compositions are formulated so as to enable the production of three-dimensional articles having better performance when irradiated with conventional (non-coherent) UV rather than with Laser UV, and states that the photocurable compositions disclosed are more appropriate for UV non-coherent irradiation than for Laser UV.
  • the exposure system uses irradiation from non-coherent light sources, e.g., a xenon fusion lamp, or light emitting diode bars
  • the exemplified exposure was reportedly carried out according to the method of WO 00/21735, which is said to describe an apparatus and a method wherein the photosensitive material is exposed to a light source illuminating a cross-section of a material by at least two modulator arrangements of individually controllable light modulators.
  • U.S. Patent Application Publication No. 2009/0267269A or WO 2009/132245 reportedly discloses a continuous-wave (CW) ultraviolet (UV) curing system for solid freeform fabrication (SFF), wherein the curing system is configured to provide an exposure of UV radiation for one or more layers of UV-curable material. It is reported that one or more UV exposures may initiate curing of a curable material in the layer dispensed by a solid freeform fabrication apparatus. According to the '269 or '245 publication, one approach to provide the single or multiple UV exposures is the use of one or more UV LEDs, which generate UV radiation without generating any substantial amounts of infrared (IR) radiation at the same time.
  • IR infrared
  • the invention provides a photocurable resin composition for additive fabrication comprising a polymerizable component that is polymerizable by free-radical polymerization, by cationic polymerization, or by both free-radical polymerization and cationic polymerization, and a photoinitiating system capable of initiating the free-radical polymerization, cationic polymerization, or both free-radical polymerization and cationic polymerization.
  • the invention also provides a three-dimensional article comprising a cured resin composition which is obtained by curing the photocurable resin composition for additive fabrication, and a method of curing the photocurable resin composition for additive fabrication.
  • the ratio by weight of cationic photoinitiator to free-radical photoinitiator is less than about 4.0.
  • the ratio by weight of cationic polymerizable component to free-radical polymerizable component is less than about 7.0.
  • greater than at least 30 wt % of the ingredients in the photocurable resin composition for additive fabrication are bio-based, rather than petroleum based.
  • the invention provides a photocurable resin composition for additive fabrication comprising a polymerizable component that is polymerizable by free-radical polymerization, by cationic polymerization, or by both free-radical polymerization and cationic polymerization, and a photoinitiating system capable of initiating the free-radical polymerization, cationic polymerization, or both free-radical polymerization and cationic polymerization; wherein the photocurable resin composition for additive fabrication is a liquid at about 25° C., and is capable of curing to provide a solid upon irradiation with light emitted from a light emitting diode (LED), wherein the light has a wavelength of from about 100 nm to about 900 nm; and wherein the liquid photocurable resin composition for additive fabrication has a Critical Exposure (Ec) and a Depth of Penetration (Dp) as measured on a layer of the resin composition for additive fabrication as the composition is curing upon exposure to LED light, wherein
  • the invention provides a three-dimensional article comprising a cured photocurable resin, wherein the cured photocurable resin is obtained by curing a photocurable resin composition for additive fabrication by irradiating it with light emitted from a light emitting diode (LED) light having a wavelength from about 100 nm to about 900 nm;
  • the photocurable resin composition for additive fabrication comprising: a polymerizable component that is polymerizable by free-radical polymerization, cationic polymerization, or both free-radical polymerization and cationic polymerization, and a photoinitiating system capable of initiating the free-radical polymerization, cationic polymerization, or both free-radical polymerization and cationic polymerization;
  • the photocurable resin composition is a liquid at about 25° C., and is capable of curing to provide a solid upon irradiation with light emitted from a light emitting diode (LED), wherein the light has a
  • the invention provides a process for making a three-dimensional article comprising the steps of: forming and selectively curing a layer of a photocurable resin composition by irradiation with a light emitting diode (LED) light having a wavelength from about 100 nm to about 900 nm, the photocurable resin composition comprising: a polymerizable component that is polymerizable by free-radical polymerization, cationic polymerization, or both free-radical polymerization and cationic polymerization, and a photoinitiating system capable of initiating the free-radical polymerization, cationic polymerization, or both free-radical polymerization and cationic polymerization; wherein the photocurable resin composition is a liquid at about 25° C., and is capable of curing to provide a solid upon exposure to a light emitting diode (LED) light having a wavelength of from about 100 nm to about 900 nm, and wherein the liquid photocurable resin
  • the present invention provides a LED photocurable resin composition for additive fabrication comprising a polymerizable component that is polymerizable by at least one of a free-radically initiated polymerization and a cationically initiated polymerization, and a photoinitiating system capable of initiating the polymerization of a free-radically polymerizable component and/or the cationically polymerizable component.
  • the photocurable resin composition for additive fabrication of the invention is characterized by one or more advantages, for example, rapid cure and improved mechanical properties of the resulting cured resin and the three-dimensional article.
  • the photocurable resin composition is a liquid at about 25° C., and is capable of curing to provide a solid upon irradiation with light emitted from a light emitting diode (LED), wherein the light has a wavelength of from about 100 nm to about 900 nm.
  • LED light emitting diode
  • the wavelength of the light can be in the UV or visible region or higher into the infrared region.
  • UVA, UVB, and UVC are possible, which are characterized by the wavelength of from about 320 to about 400 nm, from about 280 to about 320 nm, and from about 100 to about 280 nm, respectively.
  • the photocurable resin composition for additive fabrication is highly photosensitive. For example, it has a Critical Exposure (Ec) and a Depth of Penetration (Dp) as measured on a layer of the photocurable resin composition as the composition is curing, wherein Ec is from about 0.01 seconds to about 6.0 seconds and Dp is about 1 ⁇ 4 to about 4 times the thickness of the layer.
  • the wavelength of the LED light is 365 nm.
  • Ec is about 0.01 seconds to about 1, 2, 3, 4, 5, or 6 seconds. In embodiments, Dp is about 1 ⁇ 4 to about 2 times the thickness of the layer. In an embodiment, Ec is from about 0.01 seconds to about 2.0 seconds.
  • the photosensitivity of the liquid formulations was determined by using a technique similar to the so-called WINDOWPANESTM technique, a technique known to those skilled in the art of stereolithography.
  • WINDOWPANESTM technique a technique known to those skilled in the art of stereolithography.
  • single-layer test specimens are produced by using different amounts of exposure energies to cure the liquid formulation to solid, and the solid resin layer thicknesses obtained are measured.
  • the resulting layer thickness is plotted on a graph against the natural logarithm of the irradiation energy used to provide a “working curve.”
  • the slope of this curve is termed Dp (given in mm or mils).
  • Ec The energy value at which the curve passes through the x-axis is termed Ec (and is the energy at which gelling of the material just takes place; P. Jacobs, Rapid Prototyping and Manufacturing, Soc.
  • the exposure time in seconds
  • the exposure energy in mW/cm 2
  • Dp is from about 1 to about 8 mils, more particularly from about 1 to about 7 mils, and in embodiments, from about 1 mil to about 7 mils or from about 2 to about 5 mils, even more particularly from about 2 mils to about 4 mils.
  • Embodiments of the invention include photocurable resin compositions which display advantageous mechanical properties such as storage modulus as it is curing.
  • the photocurable resin composition as it is curing has a storage shear modulus (G′) value greater than 1.0 ⁇ 10 5 Pa, e.g., from about 5.0 ⁇ 10 5 Pa to about 1.0 ⁇ 10 6 Pa or to about 1.0 ⁇ 10 7 Pa, when measured on a Real Time-Dynamic Mechanical Analyzer (RT-DMA) with an 8 mm plate and a sample gap of 0.10 mm at 3.9 seconds from the beginning of light exposure of 44-50 mW/cm 2 light intensity for 1.0 second.
  • the G′ value is from about 6.0 ⁇ 10 5 Pa to about 9.0 ⁇ 10 5 Pa, and in some other embodiments, the G′ value is from about 7.0 ⁇ 10 5 Pato about 8.0 ⁇ 10 5 Pa.
  • the photocurable resin composition for additive fabrication includes at least one free-radical polymerizable component and at least one cationic polymerizable component.
  • the photocurable resin composition for additive fabrication of the invention comprises at least one free-radical polymerizable component, that is, a component which undergoes polymerization initiated by free radicals.
  • the free-radical polymerizable components are monomers, oligomers, and/or polymers; they are monofunctional or polyfunctional materials, i.e., have 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 20, 30, 40, 50, 100, or more functional groups that can polymerize by free radical initiation, may contain aliphatic, aromatic, cycloaliphatic, arylaliphatic, heterocyclic moiety(ies), or any combination thereof.
  • polyfunctional materials include dendritic polymers such as dendrimers, linear dendritic polymers, dendrigraft polymers, hyperbranched polymers, star branched polymers, and hypergraft polymers; see US 2009/0093564 A1.
  • the dendritic polymers may contain one type of polymerizable functional group or different types of polymerizable functional groups, for example, acrylates and methacrylate functions.
  • free-radical polymerizable components include acrylates and methacrylates such as isobornyl (meth)acrylate, bornyl (meth)acrylate, tricyclodecanyl (meth)acrylate, dicyclopentanyl (meth)acrylate, dicyclopentenyl (meth)acrylate, cyclohexyl (meth)acrylate, benzyl (meth)acrylate, 4-butylcyclohexyl (meth)acrylate, acryloyl morpholine, (meth)acrylic acid, 2-hydroxyethyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate, 2-hydroxybutyl (meth)acrylate, methyl (meth)acrylate, ethyl (meth)acrylate, propyl (meth)acrylate, isopropyl (meth)acrylate, butyl (meth)acrylate, amyl (meth)acrylate, isobutyl (meth)acrylate,
  • polyfunctional free-radical polymerizable components include those with (meth)acryloyl groups such as trimethylolpropane tri(meth)acrylate, pentaerythritol (meth)acrylate, ethylene glycol di(meth)acrylate, bisphenol A diglycidyl ether di(meth)acrylate, dicyclopentadiene dimethanol di(meth)acrylate, [2-[1,1-dimethyl-2-[(1-oxoallyl)oxy]ethyl]-5-ethyl-1,3-dioxan-5-yl]methyl acrylate; 3,9-bis(1,1-dimethyl-2-hydroxyethyl)-2,4,8,10-tetraoxaspiro[5.5]undecane di(meth)acrylate; dipentaerythritol monohydroxypenta(meth)acrylate, propoxylated trimethylolpropane tri(meth)acrylate, propoxylated neopen
  • the polyfunctional (meth)acrylates of the polyfunctional component may include all methacryloyl groups, all acryloyl groups, or any combination of methacryloyl and acryloyl groups.
  • the free-radical polymerizable component is selected from the group consisting of bisphenol A diglycidyl ether di(meth)acrylate, ethoxylated or propoxylated bisphenol A or bisphenol F di(meth)acrylate, dicyclopentadiene dimethanol di(meth)acrylate, [2-[1,1-dimethyl-2-[(1-oxoallyl)oxy]ethyl]-5-ethyl-1,3-dioxan-5-yl]methyl acrylate, dipentaerythritol monohydroxypenta(meth)acrylate, dipentaerythritol hexa(meth)crylate, propoxylated trimethylolpropane tri(meth)acrylate,
  • the free-radical polymerizable component is selected from the group consisting of bisphenol A diglycidyl ether diacrylate, dicyclopentadiene dimethanol diacrylate, [2-[1,1-dimethyl-2-[(1-oxoallyl)oxy]ethyl]-5-ethyl-1,3-dioxan-5-yl]methyl acrylate, dipentaerythritol monohydroxypentaacrylate, propoxylated trimethylolpropane triacrylate, and propoxylated neopentyl glycol diacrylate, and any combination thereof.
  • the photocurable resin compositions for additive fabrication of the invention include one or more of bisphenol A diglycidyl ether di(meth)acrylate, dicyclopentadiene dimethanol di(meth)acrylate, dipentaerythritol monohydroxypenta(meth)acrylate, propoxylated trimethylolpropane tri(meth)acrylate, and/or propoxylated neopentyl glycol di(meth)acrylate, and more specifically one or more of bisphenol A diglycidyl ether diacrylate, dicyclopentadiene dimethanol diacrylate, dipentaerythritol monohydroxypentaacrylate, propoxylated trimethylolpropane triacrylate, and/or propoxylated neopentyl glycol diacrylate.
  • the photocurable resin composition for additive fabrication can include any suitable amount of the free-radical polymerizable component, for example, in certain embodiments, in an amount up to about 95% by weight of the composition, in certain embodiments, up to about 50% by weight of the composition, and in further embodiments from about 5% to about 25% by weight of the composition.
  • the photocurable resin compositions for additive fabrication of the invention comprise at least one cationically polymerizable component, that is, a component which undergoes polymerization initiated by cations or in the presence of acid generators.
  • the cationically polymerizable components may be monomers, oligomers, and/or polymers, and may contain aliphatic, aromatic, cycloaliphatic, arylaliphatic, heterocyclic moiety(ies), and any combination thereof.
  • Suitable cyclic ether compounds can comprise cyclic ether groups as side groups or groups that form part of an alicyclic or heterocyclic ring system.
  • the cationic polymerizable component is selected from the group consisting of cyclic ether compounds, cyclic acetal compounds, cyclic thioethers compounds, spiro-orthoester compounds, cyclic lactone compounds, and vinyl ether compounds, and any combination thereof.
  • cationically polymerizable components include cyclic ether compounds such as epoxy compounds and oxetanes, cyclic lactone compounds, cyclic acetal compounds, cyclic thioether compounds, Spiro orthoester compounds, and vinylether compounds.
  • cationically polymerizable components include bisphenol A diglycidyl ether, bisphenol F diglycidyl ether, bisphenol S diglycidyl ether, brominated bisphenol A diglycidyl ether, brominated bisphenol F diglycidyl ether, brominated bisphenol S diglycidyl ether, epoxy novolac resins, hydrogenated bisphenol A diglycidyl ether, hydrogenated bisphenol F diglycidyl ether, hydrogenated bisphenol S diglycidyl ether, 3,4-epoxycyclohexylmethyl-3′,4′-epoxycyclohexanecarboxylate, 2-(3,4-epoxycyclohexyl-5,5-spiro-3,4-epoxy)-cyclohexane-1,4-dioxane, bis(3,4-epoxycyclohexylmethyl)adipate, vinylcyclohexene oxide, 4-vinylepoxycyclohexane
  • dendritic polymers may contain one type of polymerizable functional group or different types of polymerizable functional groups, for example, epoxy and oxetane functions.
  • the cationic polymerizable component is at least one selected from the group consisting of a cycloaliphatic epoxy and an oxetane.
  • the cationic polymerizable component is an oxetane, for example, an oxetane containing 2 or more than 2 oxetane groups.
  • the cationic polymerizable component is a cycloaliphatic epoxy, for example, a cycloaliphatic epoxy with 2 or more than 2 epoxy groups.
  • the epoxide is 3,4-epoxycyclohexylmethyl-3′,4-epoxycyclohexanecarboxylate (available as CELLOXIDETM 2021 P from Daicel Chemical, or as CYRACURETM UVR-6105 from Dow Chemical), hydrogenated bisphenol A-epichlorohydrin based epoxy resin (available as EPONEXTM 1510 from Hexion), 1,4-cyclohexanedimethanol diglycidyl ether (available as HELOXYTM 107 from Hexion), a mixture of dicyclohexyl diepoxide and nanosilica (available as NANOPDXTM), and any combination thereof.
  • CELLOXIDETM 2021 P from Daicel Chemical
  • CYRACURETM UVR-6105 from Dow Chemical
  • EPONEXTM 1510 from Hexion
  • 1,4-cyclohexanedimethanol diglycidyl ether available as HELOXYTM 107 from Hexion
  • the above-mentioned cationically polymerizable compounds can be used singly or in combination of two or more thereof.
  • the photocurable resin composition for additive fabrication can include any suitable amount of the cationic polymerizable component, for example, in certain embodiments, in an amount up to about 95% by weight of the composition, and in certain embodiments, up to about 50% by weight of the composition. In further embodiments the amount of the cationic polymerizable component is from about 5% to about 70% by weight of the composition. In further embodiments from about 5% to about 25% by weight of the composition
  • the polymerizable component of the photocurable resin composition for additive fabrication is polymerizable by both free-radical polymerization and cationic polymerization.
  • a polymerizable component is a vinyloxy compound, for example, one selected from the group consisting of bis(4-vinyloxybutyl)isophthalate, tris(4-vinyloxybutyl) trimellitate, and combinations thereof.
  • Other examples of such a polymerizable component include those that contain an acrylate and an epoxy group, or an acrylate and an oxetane group, on a same molecule.
  • the photocurable resin composition for additive fabrication of the present invention includes a photoinitiating system.
  • the photoinitiating system can be a free-radical photoinitiator or a cationic photoinitiator or a photoinitiator that contains both free-radical initiating function and cationic initiating function on the same molecule.
  • the photoinitiator is a compound that chemically changes due to the action of light or the synergy between the action of light and the electronic excitation of a sensitizing dye to produce at least one of a radical, an acid, and a base.
  • free radical photoinitiators are divided into those that form radicals by cleavage, known as “Norrish Type I” and those that form radicals by hydrogen abstraction, known as “Norrish type II”.
  • the Norrish type II photoinitiators require a hydrogen donor, which serves as the free radical source.
  • the Norrish type II photoinitiators are generally slower than Norrish type I photoinitiators which are based on the unimolecular formation of radicals.
  • Norrish type II photoinitiators possess better optical absorption properties in the near-UV spectroscopic region.
  • Photolysis of aromatic ketones such as benzophenone, thioxanthones, benzil, and quinones
  • hydrogen donors such as alcohols, amines, or thiols
  • the photopolymerization of vinyl monomers is usually initiated by the radicals produced from the hydrogen donor.
  • the ketyl radicals are usually not reactive toward vinyl monomers because of the steric hindrance and the delocalization of an unpaired electron.
  • the photocurable resin composition for additive fabrication includes at least one free radical photoinitiator, e.g., those selected from the group consisting of benzoylphosphine oxides, aryl ketones, benzophenones, hydroxylated ketones, 1-hydroxyphenyl ketones, ketals, metallocenes, and any combination thereof.
  • at least one free radical photoinitiator e.g., those selected from the group consisting of benzoylphosphine oxides, aryl ketones, benzophenones, hydroxylated ketones, 1-hydroxyphenyl ketones, ketals, metallocenes, and any combination thereof.
  • the photocurable resin composition for additive fabrication includes at least one free-radical photoinitiator selected from the group consisting of 2,4,6-trimethylbenzoyl diphenylphosphine oxide and 2,4,6-trimethylbenzoyl phenyl, ethoxy phosphine oxide, bis(2,4,6-trimethylbenzoyl)-phenylphosphineoxide, 2-methyl-1-[4-(methylthio)phenyl]-2-morpholinopropanone-1,2-benzyl-2-(dimethylamino)-1-[4-(4-morpholinyl)phenyl]-1-butanone, 2-dimethylamino-2-(4-methyl-benzyl)-1-(4-morpholin-4-yl-phenyl)-butan-1-one, 4-benzoyl-4′-methyl diphenyl sulphide, 4,4′-bis(diethylamino) benzophenone, and 4,4′-bis(N,N′-
  • suitable free-radical photoinitiators absorbing in this area include: benzoylphosphine oxides, such as, for example, 2,4,6-trimethylbenzoyl diphenylphosphine oxide (Lucirin TPO from BASF) and 2,4,6-trimethylbenzoyl phenyl, ethoxy phosphine oxide (Lucirin TPO-L from BASF), bis(2,4,6-trimethylbenzoyl)-phenylphosphineoxide (Irgacure 819 or BAPO from Ciba), 2-methyl-1-[4-(methylthio)phenyl]-2-morpholinopropanone-1 (Irgacure 907 from Ciba), 2-benzyl-2-(dimethylamino)-1-[4-(4-morpholinyl)phenyl
  • benzoylphosphine oxides such as, for example, 2,4,6-trimethylbenzoyl diphenylphosphine oxide (Lucirin
  • photosensitizers are useful in conjunction with photoinitiators in effecting cure with LED light sources emitting in this wavelength range.
  • suitable photosensitizers include: anthraquinones, such as 2-methylanthraquinone, 2-ethylanthraquinone, 2-tertbutylanthraquinone, 1-chloroanthraquinone, and 2-amylanthraquinone, thioxanthones and xanthones, such as isopropyl thioxanthone, 2-chlorothioxanthone, 2,4-diethylthioxanthone, and 1-chloro-4-propoxythioxanthone, methyl benzoyl formate (Darocur MBF from Ciba), methyl-2-benzoyl benzoate (Chivacure OMB from Chitec), 4-benzoyl-4′-methyl diphenyl sulphide (Chivacure BMS from Chitec), 4,
  • LED UV light sources it is possible for LED UV light sources to be designed to emit light at shorter wavelengths.
  • a photosensitizer is used when curing with LED light sources emitting at wavelengths from between about 100 and about 300 nm.
  • photosensitizers such as those previously listed are present in the formulation, other photoinitiators absorbing at shorter wavelengths can be used.
  • photoinitiators include: benzophenones, such as benzophenone, 4-methyl benzophenone, 2,4,6-trimethyl benzophenone, and dimethoxybenzophenone, and, 1-hydroxyphenyl ketones, such as 1-hydroxycyclohexyl phenyl ketone, phenyl (1-hydroxyisopropyl)ketone, 2-hydroxy-1-[4-(2-hroxyethoxy)phenyl]-2-methyl-1-propanone, and 4-isopropylphenyl(1-hydroxyisopropyl)ketone, benzil dimethyl ketal, and oligo-[2-hydroxy-2-methyl-1-[4-(1-methylvinyl)phenyl]propanone] (Esacure KIP 150 from Lambeth).
  • benzophenones such as benzophenone, 4-methyl benzophenone, 2,4,6-trimethyl benzophenone, and dimethoxybenzophenone
  • 1-hydroxyphenyl ketones such as 1-hydroxycycl
  • LED light sources can also be designed to emit visible light.
  • suitable free radical photoinitiators include: camphorquinone, 4,4′-bis(diethylamino)benzophenone (Chivacure EMK from Chitec), 4,4′-bis(N,N′-dimethylamino)benzophenone (Michler's ketone), bis(2,4,6-trimethylbenzoyl)-phenylphosphineoxide (Irgacure 819 or BAPO from Ciba), metallocenes such as bis(eta 5-2-4-cyclopentadien-1-yl) bis[2,6-difluoro-3-(1H-pyrrol-1-yl)phenyl]titanium (Irgacure 784 from Ciba), and the visible light photoinitiators from Spectra Group Limited, Inc.
  • H-Nu 470 H-Nu-535, H-Nu-635, H-Nu-Blue-640, and H-Nu-Blue-660. It is often desirable to employ a photosensitizer with a photoinitiator for LED light sources emitting between 475 nm and 900 nm.
  • the light emitted by the LED is UVA radiation, which is radiation with a wavelength between about 320 and about 400 nm. In one embodiment of the instant claimed invention, the light emitted by the LED is UVB radiation, which is radiation with a wavelength between about 280 and about 320 nm. In one embodiment of the instant claimed invention, the light emitted by the LED is UVC radiation, which is radiation with a wavelength between about 100 and about 280 nm.
  • the photocurable resin composition for additive fabrication can include any suitable amount of the free-radical photoinitiator, for example, in certain embodiments, in an amount up to about 15% by weight of the composition, in certain embodiments, up to about 10% by weight of the composition, and in further embodiments from about 1% to about 5% by weight of the composition.
  • the photocurable resin composition for additive fabrication includes a photoinitiating system that is a photoinitiator having both cationic initiating function and free radical initiating function.
  • the photocurable resin composition for additive fabrication includes a cationic photoinitiator.
  • the cationic photoinitiator generates photoacids upon irradiation of light. They generate Brönsted or Lewis acids upon irradiation.
  • Any suitable cationic photoinitiator can be used, for example, those selected from the group consisting of onium salts, halonium salts, iodosyl salts, selenium salts, sulfonium salts, sulfoxonium salts, diazonium salts, metallocene salts, isoquinolinium salts, phosphonium salts, arsonium salts, tropylium salts, dialkylphenacylsulfonium salts, thiopyrilium salts, diaryl iodonium salts, triaryl sulfonium salts, sulfonium antimonate salts, ferrocenes, di(cyclopentadienyliron)arene salt compounds, and pyridinium salts, and any combination thereof.
  • onium salts halonium salts, iodosyl salts, selenium salts, sulfonium salts, sulfoxon
  • Onium salts e.g., iodonium salts, sulfonium salts and ferrocenes, have the advantage that they are thermally stable. Thus, any residual photoinitiator does not continue to cure after the removal of the irradiating light.
  • Cationic photoinitiators offer the advantage that they are not sensitive to oxygen present in the atmosphere.
  • the photocurable resin composition for additive fabrication of the invention includes at least one cationic photoinitiator, wherein the cationic photoinitiator is selected from the group consisting of aromatic diazonium salts, aromatic sulfonium salts, aromatic iodonium salts, metallocene based compounds, aromatic phosphonium salts and silanol aluminium complexes, and any combination thereof.
  • the cationic photoinitiator is selected from the group consisting of aromatic sulfonium salts, aromatic iodonium salts, and metallocene based compounds, and any combination thereof.
  • the cationic photoinitiator is selected from the group consisting of triarylsulfonium salts, diaryliodonium salts, and metallocene based compounds, and any combination thereof.
  • the cationic photoinitiator has an anion selected from the group consisting of BF 4 ⁇ , AsF 6 ⁇ , SbF 6 ⁇ , PF 6 ⁇ , B(C 6 F 5 ) 4 ⁇ , perfluoroalkylsulfonates, perfluoroalkylphosphates, and carborane anions.
  • the cationic photoinitiator has a cation selected from the group consisting of aromatic sulfonium salts, aromatic iodonium salts, and metallocene based compounds with at least an anion selected from the group consisting of SbF 6 ⁇ , PF 6 ⁇ , B(C 6 F 5 ) 4 ⁇ , perfluoroalkylsulfonates, perfluoroalkylphosphates, and (CH 6 B 11 Cl 6 ) ⁇ .
  • the cationic photoinitiator is an aromatic sulfonium salt based cationic photoinitiator selected from the group consisting of 4-(4-benzoylphenylthio)phenyldiphenylsulfonium hexafluoroantimonate, 4-(4-benzoylphenylthio)phenylbis(4-hydroxyethyloxyphenyl)sulfonium hexafluoroantimonate, 4-(4-benzoylphenylthio)phenylbis(4-fluorophenyl)sulfonium hexafluoroantimonate, 4-(4-benzoylphenylthio)phenylbis(4-chlorophenyl)sulfonium hexafluoroantimonate, 4-[4-(3-chlorobenzoyl)phenylthio]phenylbis(4-fluorophenyl)sulfonium hexafluor
  • the cationic photoinitiator is an aromatic iodonium salt based cationic photoinitiator selected from the group consisting of diphenyliodonium hexafluorophosphate, diphenyliodonium hexafluoroantimonate, diphenyliodonium tetrafluoroborate, diphenyliodonium tetrakis(pentafluorophenyl)borate, bis(dodecylphenyl)iodonium hexafluorophosphate, bis(dodecylphenyl)iodonium hexafluoroantimonate, bis(dodecylphenyl)iodonium tetrafluoroborate, bis(dodecylphenyl)iodonium tetrakis(pentafluorophenyl)borate, 4-methylphenyl-4-(1-methylethyl)phenyli
  • the cationic photoinitiator is selected from the group consisting of tetrakis(pentafluorophenyl)borate or hexafluoroantimonate salt of 4-(4-benzoylphenylthio)phenyldiphenylsulfonium, 4-(4-benzoylphenylthio)phenylbis(4-hydroxyethyloxyphenyl)sulfonium, 4-(4-benzoylphenylthio)phenylbis(4-fluorophenyl)sulfonium, 4-(4-benzoylphenylthio)phenylbis(4-chlorophenyl)sulfonium, 4-[4-(3-chlorobenzoyl)phenylthio]phenylbis(4-fluorophenyl)sulfonium, 4-[4-(2-chlorobenzoyl)phenylthio]phenylbis(4-fluoropheny
  • the photocurable resin composition for additive fabrication includes a cationic photoinitiator selected from the group consisting of triarylsulfonium SbF 6 ⁇ , triarylsulfonium borate, tris(4-(4-acetylphenyl)thiophenyl)sulfonium tetrakis(pentafluorophenyl)borate, diaryliodonium borate, iodonium [4-(1-methylethyl)phenyl](4-methylphenyl)-tetrakis(pentafluorophenyl)borate, and any combination thereof.
  • a normucleophilic anion serves as the counterion.
  • Examples of such anions include BF 4 ⁇ , AsF 6 ⁇ , SbF 6 ⁇ , PF 6 ⁇ , B(C 6 F 5 ) 4 ⁇ , perfluoroalkylsulfonates, perfluoroalkylphosphates, and carborane anions such as (CH 6 B 11 Cl 6 ) ⁇ .
  • Examples of cationic photoinitiators useful for curing at 300-475 nm, particularly at 365 nm UV light, without a sensitizer include 4-[4-(3-chlorobenzoyl)phenylthio]phenylbis(4-fluorophenyl)sulfonium hexafluoroantimonate, 4-[4-(3-chlorobenzoyl)phenylthio]phenylbis(4-fluorophenyl)sulfonium tetrakis(pentafluorophenyl)borate, and tris(4-(4-acetylphenyl)thiophenyl)sulfonium tetrakis(pentafluorophenyl)borate (GSID4480-1 also known as IRGACURE® PAG 290) from Ciba used in some of the example compositions.
  • the photocurable resin composition for additive fabrication it is desirable for the photocurable resin composition for additive fabrication to include a photosensitizer.
  • the term “photosensitizer” is used to refer to any substance that either increases the rate of photoinitiated polymerization or shifts the wavelength at which polymerization occurs; see textbook by G. Odian, Principles of Polymerization, 3 rd Ed., 1991, page 222.
  • Examples of photosensitizers include those selected from the group consisting of methanones, xanthenones, pyrenemethanols, anthracenes, pyrene, perylene, quinones, xanthones, thioxanthones, benzoyl esters, benzophenones, and any combination thereof.
  • photosensitizers include those selected from the group consisting of [4-[(4-methylphenyl)thio]phenyl]phenyl ⁇ methanone, isopropyl-9H-thioxanthen-9-one, 1-pyrenemethanol, 9-(hydroxymethyl)anthracene, 9,10-diethoxyanthracene, 9,10-dimethoxyanthracene, 9,10-dipropoxyanthracene, 9,10-dibutyloxyanthracene, 9-anthracenemethanol acetate, 2-ethyl-9,10-dimethoxyanthracene, 2-methyl-9,10-dimethoxyanthracene, 2-t-butyl-9,10-dimethoxyanthracene, 2-ethyl-9,10-diethoxyanthracene and 2-methyl-9,10-diethoxyanthracene, anthracene, anthraquinones, 2-methylanthraquinone
  • photosensitizers are useful in combination with photoinitiators in effecting cure with LED light sources emitting in the wavelength range of 300-475 nm.
  • suitable photosensitizers include: anthraquinones, such as 2-methylanthraquinone, 2-ethylanthraquinone, 2-tertbutylanthraquinone, 1-chloroanthraquinone, and 2-amylanthraquinone, thioxanthones and xanthones, such as isopropyl thioxanthone, 2-chlorothioxanthone, 2,4-diethylthioxanthone, and 1-chloro-4-propoxythioxanthone, methyl benzoyl formate (Darocur MBF from Ciba), methyl-2-benzoyl benzoate (Chivacure OMB from Chitec), 4-benzoyl-4′-methyl diphenyl sulphide (Chivacure
  • the photosensitizer is a fluorone, e.g., 5,7-diiodo-3-butoxy-6-fluorone, 5,7-diiodo-3-hydroxy-6-fluorone, 9-cyano-5,7-diiodo-3-hydroxy-6-fluorone, or a photosensitizer is
  • the photocurable resin composition for additive fabrication can include any suitable amount of the photosensitizer, for example, in certain embodiments, in an amount up to about 10% by weight of the composition, in certain embodiments, up to about 5% by weight of the composition, and in further embodiments from about 0.05% to about 2% by weight of the composition.
  • photoinitiators When photosensitizers are employed, other photoinitiators absorbing at shorter wavelengths can be used.
  • photoinitiators include: benzophenones, such as benzophenone, 4-methyl benzophenone, 2,4,6-trimethyl benzophenone, and dimethoxybenzophenone, and 1-hydroxyphenyl ketones, such as 1-hydroxycyclohexyl phenyl ketone, phenyl (1-hydroxyisopropyl)ketone, 2-hydroxy-1-[4-(2-hydroxyethoxy)phenyl]-2-methyl-1-propanone, and 4-isopropylphenyl(1-hydroxyisopropyl)ketone, benzil dimethyl ketal, and oligo-[2-hydroxy-2-methyl-1-[4-(1-methylvinyl)phenyl]propanone] (Esacure KIP 150 from Lamberti).
  • These photoinitiators when used in combination with a photosensitizer are suitable for use with LED
  • LED light sources that emit visible light are also known.
  • suitable photoinitiators include: camphorquinone, 4,4′-bis(diethylamino) benzophenone (Chivacure EMK from Chitec), 4,4′-bis(N,N′-dimethylamino)benzophenone (Michler's ketone), bis(2,4,6-trimethylbenzoyl)-phenylphosphineoxide (Irgacure 819 or BAPO from Ciba), metallocenes such as bis(eta 5-2-4-cyclopentadien-1-yl)bis[2,6-difluoro-3-(1H-pyrrol-1-yl)phenyl]titanium (Irgacure 784 from Ciba), and the visible light photoinitiators from Spectra Group Limited, Inc
  • a photosensitizer or co-initiator may be used to improve the activity of the cationic photoinitiator. It is for either increasing the rate of photoinitiated polymerization or shifting the wavelength at which polymerization occurs.
  • the sensitizer used in combination with the above-mentioned cationic photoinitiator is not particularly limited.
  • a variety of compounds can be used as photosensitizers, including heterocyclic and fused-ring aromatic hydrocarbons, organic dyes, and aromatic ketones. Examples of sensitizers include compounds disclosed by J. V. Crivello in Advances in Polymer Science, 62, 1 (1984), and by J. V. Crivello & K.
  • Dietliker “Photoinitiators for Cationic Polymerization” in Chemistry & technology of UV & EB formulation for coatings, inks & paints. Volume III, Photoinitiators for free radical and cationic polymerization. by K. Dietliker; [Ed. by P.K.T. Oldring], SITA Technology Ltd, London, 1991. Specific examples include polyaromatic hydrocarbons and their derivatives such as anthracene, pyrene, perylene and their derivatives, thioxanthones, ⁇ -hydroxyalkylphenones, 4-benzoyl-4′-methyldiphenyl sulfide, acridine orange, and benzoflavin.
  • cationic photoinitiators include, for example, onium salts with anions of weak nucleophilicity.
  • onium salts with anions of weak nucleophilicity examples are halonium salts, iodosyl salts or sulfonium salts, such as are described in published European patent application EP 153904 and WO 98/28663, sulfoxonium salts, such as described, for example, in published European patent applications EP 35969, 44274, 54509, and 164314, or diazonium salts, such as described, for example, in U.S. Pat. Nos. 3,708,296 and 5,002,856. All eight of these disclosures are hereby incorporated in their entirety by reference.
  • Other cationic photoinitiators are metallocene salts, such as described, for example, in published European applications EP 94914 and 94915, which are both hereby incorporated in their entirety by reference.
  • Suitable ferrocene type cationic photoinitiators include, for example, di(cyclopentadienyliron)arene salt compounds of formula (I) as disclosed in Chinese Patent No. CN 101190931:
  • anion MXn is selected from BF4, PF6, SbF6, AsF6, (C6F5) 4 B, C104, CF3SO3, FSO3, CH3SO3, C4F9SO3, and Ar is a fused ring or polycyclic arene.
  • illustrative ferrocene type cationic photoinitiators include, for example, ( ⁇ 6-Carbazole)( ⁇ 5-cyclopenta-dienyl) iron hexafluorophosphate salts, specifically [cyclopentadiene-Fe—N-butylcarbazole]hexafluoro-phosphate (C4-CFS PF6) and [cyclopentadiene-Fe—N-octyl-carbazole]hexafluorophosphate (C8-CFS PF6), bearing C4 and C8 alkyl chains, respectively, on the nitrogen atom (see Polymer Eng.
  • ( ⁇ 6-Carbazole)( ⁇ 5-cyclopenta-dienyl) iron hexafluorophosphate salts specifically [cyclopentadiene-Fe—N-butylcarbazole]hexafluoro-phosphate (C4-CFS PF6) and [cyclopentadiene-F
  • ferrocenium dication salts e.g., biphenyl bis[( ⁇ -cyclopentadienyl)iron]hexafluorophosphate ([bis(Cp-Fe)-biphenyl](PF6) 2 ) and straight cyclopentadien-iron-biphenyl hexafluorophosphate ([Cp-Fe-biphenyl]+PF6 ⁇ ) as disclosed in Chinese J. Chem.
  • alkoxy-substituted ferrocenium salts for example, [cyclopendadien-Fe-anisole]PF6, [cyclopendadien-Fe-anisole]BF4, [cyclopendadien-Fe-diphenylether]PF6, [cyclo-pendadien-Fe-diphenylether]BF4, and [cyclopendadien-Fe-diethoxy-benzene]PF6, as disclosed in Chinese J.
  • cyclopentadiene-iron-arene tetrafluoroborates for example, cyclopentadiene-iron-naphthalene tetrafluoroborate ([Cp-Fe-Naph] BF4) salt, as disclosed in Imaging Science J (2003), 51(4), 247-253; ferrocenyl tetrafluoroborate ([Cp-Fe-CP]BF4), as disclosed in Ganguang Kexue Yu Guang Huaxue (2003), 21(1), 46-52; [CpFe( ⁇ 6-tol)]BF4, as disclosed in Ganguang Kexue Yu Guang Huaxue (2002), 20(3), 177-184, Ferrocenium salts ( ⁇ 6- ⁇ -naphthoxybenzene) ( ⁇ 5-cyclopentadienyl)iron hexafluorophosphate (NOFC-1) and ( ⁇ 6-
  • Suitable onium type cationic photoinitiators include, for example, iodonium and sulfonium salts, as disclosed in Japanese Patent JP 2006151852.
  • Other illustrative onium type photoinitiators include, for example, onium salts such as, diaryliodonium salts, triarylsulfonium salts, aryl-diazonium salts, ferrocenium salts, diarylsulfoxonium salts, diaryl-iodoxonium salts, triaryl-sulfoxonium salts, dialkylphenacyl-sulfonium salts, dialkylhydroxy-phenylsulfonium salts, phenacyl-triarylphosphonium salts, and phenacyl salts of heterocyclic nitrogen-containing compounds, as disclosed in U.S.
  • BPEA Photoactive allyl ammonium salt
  • Illustrative iodonium type cationic photoinitiators include, for example, diaryliodonium salts having counterions like hexafluorophosphate and the like, such as, for example, (4-n-pentadecyloxy-phenyl)phenyliodonium hexafluoroantimonate, as disclosed in US2006041032; diphenyliodonium hexafluorophosphate, as disclosed in U.S. Pat. No.
  • diaryliodonium salts e.g., 4,4′-di-tert-butyldiphenyl-iodonium hexafluoroarsenate, as disclosed in J Polymr Sci, Polymr Chem Edition (1978), 16(10), 2441-2451;
  • Diaryliodonium salts containing complex metal halide anions such as diphenyliodonium fluoroborate, as disclosed in J Polymr Sci, Poly Sympos (1976), 56, 383-95; and any combination thereof.
  • Illustrative sulfonium type cationic photoinitiators include, for example, UVI 6992 (sulfonium salt) as disclosed in Japanese patent JP2007126612; compounds of the formula:
  • Suitable pyridinium type cationic photoinitiators include, for example, N-ethoxy 2-methylpyridinium hexafluorophosphate (EMP+PF6 ⁇ ), as disclosed in Turkish J of Chemistry (1993), 17(1), 44-49; Charge-transfer complexes of pyridinium salts and aromatic electron donors (hexamethyl-benzene and 1,2,4-trimethyoxy-benzene), as disclosed in Polymer (1994), 35(11), 2428-31; N,N′-diethoxy-4,4′-azobis(pyridinium)hexafluorophosphate (DEAP), as disclosed in Macromolecular Rapid Comm (2008), 29(11), 892-896; and any combination thereof.
  • EMP+PF6 ⁇ N-ethoxy 2-methylpyridinium hexafluorophosphate
  • EMP+PF6 ⁇ Charge-transfer complexes of pyridinium salts and aromatic electron donors (hexamethyl-benzene and 1,2,4
  • Suitable cationic photoinitiators include, for example, Acylgermane based photoinitiator in the presence of onium salts, e.g., benzoyltrimethylgermane (BTG) and onium salts, such as diphenyl-iodonium hexafluorophosphate (Ph2I+PF6 ⁇ ) or N-ethoxy-2-methyl-pyridinium hexafluorophosphate (EMP+PF6 ⁇ ), as disclosed in Macromolecules (2008), 41(18), 6714-6718; Di-Ph diselenide (DPDS), as disclosed in Macromolecular Symposia (2006), 240, 186-193; N-phenacyl-N,N-dimethyl-anilinium hexafluoroantimonate (PDA+SbF6 ⁇ ), as disclosed in Macromol Rapid Comm (2002), 23(9), 567-570; Synergistic blends of: diaryliodonium hexaflu
  • Suitable cationic photoinitiators include, for example, triarylsulfonium salts such as triarylsulfonium borates modified for absorbing long wavelength UV.
  • modified borates include, for example, SP-300 available from Denka, tris(4-(4-acetylphenyl)thiophenyl)sulfonium tetrakis(pentafluorophenyl)borate (GSID4480-1 or Irgacure PAG-290) available from Ciba/BASF, and those photoinitiators disclosed in WO1999028295; WO2004029037; WO2009057600; U.S. Pat. No. 6,368,769 WO2009047105; WO2009047151; WO2009047152; US 20090208872; and U.S. Pat. No. 7,611,817.
  • Preferred cationic photoinitiators include a mixture of: bis[4-diphenylsulfoniumphenyl]sulfide bishexafluoroantimonate; thiophenoxyphenylsulfonium hexafluoroantimonate (available as Chivacure 1176 from Chitec); tris(4-(4-acetylphenyl)thiophenyl)sulfonium tetrakis(pentafluorophenyl)borate (GSID4480-1 from Ciba/BASF), iodonium, [4-(1-methylethyl)phenyl](4-methylphenyl)-, tetrakis(pentafluorophenyl)borate (available as Rhodorsil 2074 from Rhodia), 4-[4-(2-chlorobenzoyl)phenylthio]phenylbis(4-fluorophenyl)sulfonium hexafluoroanti
  • the photocurable resin composition for additive fabrication can include any suitable amount of the cationic photoinitiator, for example, in certain embodiments, in an amount up to about 50% by weight of the composition, in certain embodiments, up to about 20% by weight of the composition, and in further embodiments from about 1% to about 10% by weight of the composition. In a further embodiment from about 0.4 wt % to about 6.5 wt % of the composition. In an embodiment, the above ranges are particularly suitable for use with epoxy monomers.
  • the photocurable resin composition for additive fabrication can further include a chain transfer agent, particularly a chain transfer agent for a cationic monomer.
  • the chain transfer agent has a functional group containing active hydrogen. Examples of the active hydrogen-containing functional group include an amino group, an amide group, a hydroxyl group, a sulfo group, and a thiol group.
  • the chain transfer agent terminates the propagation of one type of polymerization, i.e., either cationic polymerization or free-radical polymerization and initiates a different type of polymerization, i.e., either free-radical polymerization or cationic polymerization.
  • chain transfer to a different monomer is a preferred mechanism.
  • chain transfer tends to produce branched molecules or crosslinked molecules.
  • chain transfer offers a way of controlling the molecular weight distribution, crosslink density, thermal properties, and/or mechanical properties of the cured resin composition.
  • the chain transfer agent for a cationic polymerizable component is a hydroxyl-containing compound, such as a compound containing 2 or more than 2 hydroxyl-groups.
  • the chain transfer agent is selected from the group consisting of a polyether polyol, polyester polyol, polycarbonate polyol, ethoxylated or propoxylated aliphatic or aromatic compounds having hydroxyl groups, dendritic polyols, hyperbranched polyols.
  • An example of a polyether polyol is a polyether polyol comprising an alkoxy ether group of the formula [(CH 2 ) n O] m , wherein n can be 1 to 6 and m can be 1 to 100.
  • a particular example of a chain transfer agent is polytetrahydrofuran such as TERATHANETM.
  • the photocurable resin composition for additive fabrication can include any suitable amount of the chain transfer agent, for example, in certain embodiments, in an amount up to about 50% by weight of the composition, in certain embodiments, up to about 30% by weight of the composition, and in certain other embodiments from about 10% to about 20% by weight of the composition.
  • the photocurable resin composition for additive fabrication of the invention can further include one or more additives selected from the group consisting of bubble breakers, antioxidants, surfactants, acid scavengers, pigments, dyes, thickneners, flame retardants, silane coupling agents, ultraviolet absorbers, resin particles, core-shell particle impact modifiers, soluble polymers and block polymers, organic, inorganic, or organic-inorganic hybrid fillers of sizes ranging from about 8 nanometers to about 50 microns.
  • additives selected from the group consisting of bubble breakers, antioxidants, surfactants, acid scavengers, pigments, dyes, thickneners, flame retardants, silane coupling agents, ultraviolet absorbers, resin particles, core-shell particle impact modifiers, soluble polymers and block polymers, organic, inorganic, or organic-inorganic hybrid fillers of sizes ranging from about 8 nanometers to about 50 microns.
  • Stabilizers are often added to the compositions in order to prevent a viscosity build-up, for instance a viscosity build-up during usage in a solid imaging process.
  • Preferred stabilizers include those described in U.S. Pat. No. 5,665,792, the entire disclosure of which is hereby incorporated by reference.
  • Such stabilizers are usually hydrocarbon carboxylic acid salts of group IA and IIA metals. Most preferred examples of these salts are sodium bicarbonate, potassium bicarbonate, and rubidium carbonate. Rubidium carbonate is preferred for formulations of this invention with recommended amounts varying between 0.0015 to 0.005% by weight of composition.
  • Alternative stabilizers include polyvinylpyrrolidones and polyacrylonitriles.
  • additives include dyes, pigments, fillers (e.g. silica particles—preferably cylindrical or spherical silica particles—, talc, glass powder, alumina, alumina hydrate, magnesium oxide, magnesium hydroxide, barium sulfate, calcium sulfate, calcium carbonate, magnesium carbonate, silicate mineral, diatomaceous earth, silica sand, silica powder, titanium oxide, aluminum powder, bronze powder, zinc powder, copper powder, lead powder, gold powder, silver dust, glass fiber, titanic acid potassium whisker, carbon whisker, sapphire whisker, beryllia whisker, boron carbide whisker, silicon carbide whisker, silicon nitride whisker, glass beads, hollow glass beads, metaloxides and potassium titanate whisker), antioxidants, wetting agents, photosensitizers for the free-radical photoinitiator, chain transfer agents, leveling agents, defoamers, surfactants and the like.
  • fillers e.g. si
  • the photocurable resin composition for additive fabrication contains the polymerizable components such that the desired photosensitivity is obtained by choosing an appropriate ratio of the initiators and/or polymerizable components.
  • the ratio of the components and of the initiators affect the photosensitivity, speed of curing, degree of curing, crosslink density, thermal properties (e.g., T g ), and/or mechanical properties (e.g., tensile strength, storage modulus, loss modulus) of the photocurable resin composition for additive fabrication or of the cured article.
  • the ratio by weight of cationic photoinitiator to free-radical photoinitiator is less than about 4.0, preferably from about 0.1 to about 2.0, and more preferably from about 0.2 to about 1.0.
  • the photocurable resin composition for additive fabrication has a ratio by weight of cationic polymerizable component to free-radical polymerizable component (CPC/RPC) is less than about 7.0, or less than about 5.0, e.g., from about 0.5 to about 2.0, and more preferably from about 1.0 to about 1.5.
  • CPC/RPC ratio by weight of cationic polymerizable component to free-radical polymerizable component
  • the photocurable resin composition for additive fabrication is free or substantially free of antimony-containing initiator (less than 1.5% by weight).
  • the present invention further provides a three-dimensional article comprising a cured photocurable resin composition for additive fabrication, wherein the cured photocurable resin composition for additive fabrication is obtained by curing a photocurable resin composition for additive fabrication by irradiating it with light emitted from a light emitting diode (LED) light having a wavelength from about 100 nm to about 900 nm.
  • LED light emitting diode
  • the present invention further provides a process for making a three-dimensional article comprising the steps of forming and selectively curing a layer of a photocurable resin composition for additive fabrication by irradiation with a light emitting diode (LED) light having a wavelength from about 100 nm to about 900 nm, the photocurable resin composition and repeating the steps of forming and selectively curing a layer of the photocurable resin composition a plurality of times to obtain the three-dimensional article.
  • LED light emitting diode
  • the term “renewable resource material” is defined as a starting material that is not derived from petroleum but as a starting material derived from a plant including the fruits, nuts and/or seeds of plants. These plant derived materials are environmentally friendly and biologically based materials. Thus, these starting materials are also frequently called “bio-based” materials or “natural oil” materials.
  • biobased products are products determined by the U.S. Secretary of Agriculture to be “commercial or industrial goods (other than food or feed) composed in whole or in significant part of biological products, forestry materials, or renewable domestic agricultural materials, including plant, animal or marine materials.
  • Biobased content may be determined by testing to ASTM Method D6866-10, STANDARD TEST METHODS FOR DETERMINING THE BIOBASED CONTENT OF SOLID, LIQUID, AND GASEOUS SAMPLES USING RADIOCARBON ANALYSIS. This method, similar to radiocarbon dating, compares how much of a decaying carbon isotope remains in a sample to how much would be in the same sample if it were made of entirely recently grown materials. The percentage is called the product's biobased content.
  • bio-based raw materials can be found in polyols and other ingredients.
  • the photocurable resin compositions for additive fabrication comprise at least 30 wt % of bio-based ingredients, rather than petroleum based ingredients. In other embodiments, the photocurable resin compositions for additive fabrication comprise at least 40 wt % of bio-based ingredients, rather than petroleum based ingredients.
  • Tables 1A-1D describe the various components of the photocurable resin compositions for additive fabrication illustrated in Tables 2-7.
  • This Example illustrates some of the properties of the photocurable resin composition for additive fabrication embodiments set forth in Examples 1-56.
  • Tables 8-26 set forth the Dp, Ec, and E3-E5 values and Table 27 sets forth the CPI/RPI and CPC/RPC values.
  • the photosensitivity of the compositions are evaluated by measuring Critical Energy (Ec) values, Depth of Penetration (Dp) values, and Storage Shear Modulus (G′) upon exposure to curing light.
  • Ec Critical Energy
  • Dp Depth of Penetration
  • G′ Storage Shear Modulus
  • the photo cure speed test using 365 nm LED light is used to measure values for Ec and Dp.
  • a single UV LED “bare bulb” (Model No. NCSUO33A; Nichia Corporation, Japan) having a peak wavelength of 365 nm is used as the LED light source in a light curing apparatus, wherein the single LED light is bottom-mounted on a flat surface inside a 30° C. chamber and positioned in an upward-looking arrangement and pointing vertically.
  • the LED light is powered by a 3.30 V/0.050
  • a DC output from a Programmable Power Supply (Model No. PSS-3203; GW Instek).
  • a 10-mil sheet of polyester film (Melinex #515, Polybase Mylar D, 0.010 gauge) is placed at a distance of 12 mm above from the bottom of the LED light bulb.
  • a drop of the liquid resin is placed on the polyester film over the center of the LED light.
  • the resin is exposed to the LED light through the polyester film for a specific time interval. The process is repeated with fresh resin for 2, 4, 6, 8, 10 second exposure times or up to 12, 16, or 20 seconds for slow curing resin formulations.
  • the exposure energy mJ/cm 2
  • the exposure time in seconds
  • the tensile properties (tensile strength, percent elongation at break, and modulus) of cured samples of the photocurable resin compositions for additive fabrication are tested on films, where applicable, using a universal testing instrument, Instron Model 4201 equipped with a suitable personal computer and Instron software to yield values of tensile strength, percent elongation at break, and elastic modulus.
  • the tensile test is performed on the Instron with a crosshead speed of 1.00 inch/min and a crosshead jaw separation of 2.00 inches in a 50% relative humidity room at room temperature.
  • Samples are prepared for testing by curing the liquid resin composition applied on Mylar (0.01 gauge) with a 5 mil square draw bar, and cured on an unfiltered Fusion D bulb (600W) in nitrogen with an exposure of 300 mJ/cm 2 .
  • the cured film samples were cut within 1 hour of cure to have 0.5 ⁇ 4′′ strips and conditioned in a 50% relative humidity room at RT for 24 hours before the tensile test was performed.
  • Tensile test data was not performed for Examples 1-5, 13-27, 31-36, and 45-56.
  • RT-DMA Real Time Dynamic Mechanical Analysis
  • G′ storage shear modulus
  • RT-DMA is carried out under ambient lab conditions (20-23° C. and 25-35% RH), on compositions undergoing curing using a StressTech Rheometer (Reologicia Instruments AB, Sweden) with an 8 mm plate, a gap of 0.1 mm or 0.05 mm, as specified in the Tables 15-23, and modified to include a mercury lamp light source (OMNICURE Series 2000 available from EXFO), fitted with a 365 nm interference filter (also available from EXFO) placed in the light path and a liquid-filled light guide for conveying light from the source to the rheometer.
  • the 365 nm interference filter produces the spectral output shown in FIG. 1 .
  • the samples are evaluated under the following parameters: 10 s of equilibrium time; frequency of 10 Hz; 44-50 mW/cm2 light intensity (as specified in the Tables 15-23) by the IL 1400 radiometer with XRL140B detector (International Light, Newburyport, Mass.); 1.0 s exposure that starts at 2.1 seconds from the beginning of data collection; FFT smoothing of curves; G′ taken at 2.5, 2.7, 3, 4, and 6 s from the beginning of data collection by using the accompanying software for data analysis.
  • FIG. 2 shows a schematic of the RT-DMA apparatus.
  • the photocurable resin composition (1) is placed on a plane (2).
  • the amount of liquid resin used should be approximately the amount indicated in the figure.
  • the plane is a quartz plate that is sold with the StressTech Rheometer.
  • the 8 mm plate (3) is positioned with a 0.1 mm gap (4) between the plate and the plane. The gap is set via the software accompanying the StressTech Rheometer.
  • Light (5) is provided though the plane (2).
  • G′ data was not measured for Examples 45-56.
  • Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Example 7 Example 8 Example 9 Dp (mil) 3.53 2.72 2.73 2.62 2.78 2.79 2.95 2.91 2.78 Ec (s) 1.13 1.27 0.94 0.81 0.97 0.77 0.70 0.71 1.00 E3 (s) 2.64 3.81 2.83 2.53 2.85 2.27 1.93 2.00 2.95 E4 (s) 3.50 5.50 4.08 3.71 4.09 3.25 2.71 2.82 4.24 E5 (s) 4.65 7.95 5.88 5.43 5.85 4.65 3.80 3.98 6.07
  • Example 43 Example 44 Example 45 Example 46 Example 47 Example 48 Example 49 Example 50 Dp (mil) 4.05 3.38 2.83 2.89 4.15 3.01 9.04 2.80 Ec (s) 0.77 0.59 0.88 0.91 1.39 1.19 2.00 1.19 E3 (s) 1.62 1.44 2.53 2.57 2.86 3.24 2.79 3.47 E4 (s) 2.08 1.94 3.59 3.63 3.63 4.52 3.12 4.96 E5 (s) 2.66 2.61 5.12 5.13 4.62 6.30 3.48 7.08
  • Example 12 Elastic Modulus (MPa) 1403 1023 666 537 1030 2262 1892 Elongation at Break (%) 5.8 10.9 19.5 14.6 7.9 2.9 2.2
  • This comparative example illustrates the results obtained when curing a typical laser curable resin with LED light.
  • a solid state laser emitting at 354.7 nm is used, with 1 mil scan spacing, 65 mW/cm 2 power, and 58 kHz frequency, for obtaining the Ec and Dp values from the “working curve” by using WINDOWPANESTM technique.
  • the LED is a single UV LED “bare bulb” (Model No. NCSUO33A; Nichia Corporation, Japan) having a peak wavelength of 365 nm and is used as the LED light source in a light curing apparatus, wherein the single LED light is bottom-mounted on a flat surface inside a 30° C. chamber and positioned in an upward-looking arrangement and pointing vertically.
  • the LED light is powered by a 3.30 V/0.050
  • a DC output from a Programmable Power Supply (Model No. PSS-3203; GW Instek).
  • Comparative Example 1 The composition of Comparative Example 1 is shown in Table 28. Ec and Dp data, as determined using the previously mentioned methods, when cured with both laser light and LED light is shown in Table 29.

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