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US 2022/0325093 A1Published application
Dual cure additive manufacturing resins for production of flame retardant objects
AssigneeCarbon, Inc.
InventorsIkpreet Singh Grover, Matthew S. Menyo
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Abstract
The present invention concerns methods of forming a three-dimensional object, and polymerizable liquids such as dual cure resins useful for making a three-dimensional object by sterolithography, such as by continuous liquid interface production (CLIP), wherein the three-dimensional object is flame retardant.
Claims19
A polymer blend comprising a light polymerized first component and a heat polymerized second component produced by a method comprising:
- (a) providing a polymerizable liquid comprising a mixture of (i) a light polymerizable first component, (ii) a second solidifiable component that is different from said first component, wherein said second solidifiable component comprises a flame retardant group, said flame retardant group comprising a halogen group (such as bromine, e.g., in an amount of from 1, 2, or 5% to 15 or 20% by weight of the polymerizable liquid), and (iii) a flame retardant synergist, said flame retardant synergist comprising antimony pentoxide (e.g., in an amount of from 0.1, 0.5 or 1% to 3, 4, or 5% by weight of the polymerizable liquid);
- (b) producing a three-dimensional intermediate from said polymerizable liquid by stereolithography including irradiating said polymerizable liquid with light to form a solid polymer scaffold from said first component and containing said second solidifiable component carried in said scaffold in unsolidified and/or uncured form, said intermediate having the same shape as, or a shape to be imparted to, said three-dimensional object;
- optionally wherein said polymerizable liquid further comprises an organic diluent and where said irradiating is performed under conditions in which said organic diluent chemically reacts (e.g., degrades, isomerizes, cross-reacts, and/or polymerizes (e.g., with a light polymerizable component), etc.) by an amount sufficient to increase the strength of said intermediate;
- (c) optionally washing said intermediate, and
- (d) concurrently with or subsequent to said producing step (b), further curing said second solidifiable component in said three-dimensional intermediate to form said three-dimensional object,
- wherein samples of the polymer blend that are configured for testing according to UL 94 and have a thickness of 2 millimeters achieve a UL 94 V-0, V-1, or V-2 rating (e.g., achieves a UL 94 V-0 rating).
3 more elements
A dual cure resin useful for making a three-dimensional object by stereolithography, comprising:
- (a) light-polymerizable monomers and/or prepolymers that can participate in forming an intermediate object by stereolithography such as CLIP (e.g., included in an amount of from 1, 5, or 10 percent by weight to 50, 60, or 80 percent by weight);
- (b) heat-polymerizable monomers and/or prepolymers (e.g., included in an amount of from 5 or 10 percent by weight to 50 or 60 percent by weight);
- (c) a hardener (e.g., a compound having amine, thiol, vinyl ether, maleimide, or allyl reactive end groups) (e.g., included in an amount of at least 1, 5, or 10 percent by weight, up to 40 or 50 percent by weight), or a chain extender (e.g., a dihydric phenolic compound) (e.g., in an amount of from 5 or 10 to 20, 25 or 30 percent by weight) (and optionally further comprising a chain extender catalyst (e.g., an onium salt such as a phosphonium salt, e.g., in an amount of from 0.01, 0.05 or 0.1 to 2, 5 or 10 percent by weight));
- (d) a flame retardant synergist, said flame retardant synergist comprising antimony pentoxide (e.g., in an amount of from 0.1, 0.5 or 1% to 3, 4, or 5% by weight of the polymerizable liquid);
- and
- (e) optionally, an organic diluent in a viscosity-reducing effective amount, optionally but preferably wherein said diluent solubilizes or dissolves said hardener in said resin,
- wherein one or both of said:
- (a) heat-polymerizable monomers and/or prepolymers, and said (c) hardener or chain extender, comprises a flame retardant group, said flame retardant group comprising a halogen group (such as bromine, e.g., in an amount of from 1, 2, or 5% to 15 or 20% by weight of the resin).
5 more elements
Dependencies are inferred from the claim text.