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US 11,655,329 B2Granted
Delayed action catalysts for dual cure additive manufacturing resins
AssigneeCarbon, Inc.
InventorAndrew Gordon Wright
Life of this patent
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Abstract
Provided herein is a dual cure resin useful for the production of an object by additive manufacturing, comprising or consisting essentially of: (a) a photoinitiator; (b) not more than 5, 10 or 20 ppm of a polyurethane catalyst (e.g., tin, tertiary amine, bismuth, zinc, zirconium, or nickel catalysts); (c) a polyol; (d) free (i.e., unblocked) polyisocyanate; and (e) blocked polyisocyanate, the isocyanate groups of which are blocked by reaction with an amine (meth)acrylate blocking agent. Methods of making an object with the resin are also provided.
Claims16
A method of making an object, comprising:
- (a) providing a dual cure resin comprising:
- (i) a photoinitiator;
- (ii) not more than 20 ppm of a polyurethane catalyst;
- (iii) a polyol;
- (iv) free polyisocyanate;
- and
- (v) blocked polyisocyanate, the isocyanate groups of which are blocked by reaction with an amine (meth)acrylate blocking agent wherein the molar ratio of free polyisocyanate to blocked polyisocyanate in said dual cure resin is at least 1 to 1;
- (b) producing an intermediate object by light polymerization of said resin in an additive manufacturing process;
- (c) optionally cleaning said intermediate object;
- and then
- (d) heating said intermediate object, wherein said amine (meth)acrylate blocking agent is present in said resin as a blocking agent in an amount sufficient so that, upon forming the intermediate object from said resin by light polymerization in the additive manufacturing process and subsequent heating of said intermediate object, said blocked polyisocyanate de-blocks and produces free amine (meth)acrylate in an amount effective to catalyze the polymerization of at least said free polyisocyanate with said polyol, and produce said object.
8 more elements
Dependencies are inferred from the claim text.