Patent Description:
3D printing involves a process of generating a three-dimensional object from a digital file. 3D printing has a great freedom in creating a shape of an object, and is almost not limited by the complexity of the shape. The development trend of 3D printing is toward fast speed, high precision, low cost, and wide application. So far, 3D printing has evolved from model making to batch production and manufacture of final consumer goods. A photosensitive resin mainly includes an oligomer, a diluent, and a photoinitiator, and is solidified under the action of ultraviolet light. This principle is widely used in the light-curing 3D printing technology such as stereolithography (SLA) and digital light processing (DLP).

The patent application <CIT> filed by Carbon3D Inc. discloses a continuous liquid interphase printing (CLIP), using oxygen gas as a polymerization inhibitor to form a dead zone where no polymerization occurs, on the basis of DLP printing technology. Compared to the traditional 3D printing, the continuous liquid interphase printing has increased the printing speed by <NUM> times, becoming a revolutionary 3D printing technology and having been widely used in the polymer material processing. Carbon 3D Inc. also discloses a multiple solidifiable photosensitive resin material, which is a high performance 3D printing material obtained by curing a blocked polyurethane under the ultraviolet light and then unblocking and rearranging the polyurethane by heating. However, the unblocking temperature of the blocked polyurethane is relatively high, reaching <NUM>, which causes a waste of energy and generates a lot of pollutants such as waste gases in the post-processing.

The continuous 3D printing, which is fundamentally different from the traditional light-curing 3D printing technology, abolishes the concept of layers and creates shapes rapidly through continuous irradiation of light. SLA and DLP both perform the printing in a layer-by-layer manner with a layer thickness of <NUM> to <NUM>. In the light-curing 3D printing, the liquid photosensitive resin irradiated by the ultraviolet light is transformed into the solid. The penetration depth (Dp) and the critical exposure (Ec) of the photosensitive resin have great impacts on success rate, precision, and surface quality of the 3D printing. If the penetration depth (Dp) is larger than the thickness of the layer of photosensitive resin, an excess part will be generated due to the overexposure, causing the low precision and the poor surface roughness of the product formed by the light curing. If the penetration depth (Dp) is smaller than the thickness of the layer, one layer cannot be well bonded to another layer, causing the failure of printing. At present, for the ordinary DLP and SLA photosensitive resins, the penetration depth (Dp) and the critical exposure (Ec) thereof can be regulated by regulating a ratio of the initiator to the pigment paste, to achieve a relatively good surface quality. However, for the 3D printing with continuous irradiation, the ultraviolet light irradiates continuously, and thus it is difficult to precisely regulate the penetration depth (Dp) and the critical exposure (Ec) via the pigment paste and the initiator.

In addition, the patent application publication <CIT> filed by Carbon3D Inc. discloses a method for forming a three-dimensional object comprised of polyurethane, polyurea, or copolymer thereof, including steps of: (a) providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; (b) filling the build region with a polymerizable liquid; (c) irradiating the build region with light through the optically transparent member to form a solid blocked polymer scaffold and advancing the carrier away from the build surface to form a three-dimensional intermediate having the same shape as, or a shape to be imparted to, the three-dimensional object, with the intermediate containing the chain extender; and then (d) heating or microwave irradiating the three-dimensional intermediate sufficiently to form from the three-dimensional intermediate the three-dimensional object comprised of polyurethane, polyurea, or copolymer thereof.

An object of the present invention is to provide a dual-cure phase-separation type photosensitive resin composition for continuous 3D printing with high precision as defined in claim <NUM>. Aspects, embodiments, examples, and implementations of the present disclosure that do not fall within the scope of the appended claims do not form part of the invention and are merely provided for illustrative purposes. In order to achieve the above object, the following technical solution is provided in the present invention. A dual-cure phase-separation type photosensitive resin composition for continuous 3D printing with high precision includes an acrylate having a cross-linkable double bond, a polyurethane prepolymer, a chain extender, and a photoinitiator. Wherein the polyurethane prepolymer is a polyurethane prepolymer having an isocyanate active group (-NCO). The polyurethane prepolymer having the isocyanate active group (-NCO) is produced by a reaction between an isocyanate and a polyether polyol with a molecular weight larger than or equal to <NUM> under heating and catalytic action.

In one of preferred embodiments, the photosensitive resin composition includes <NUM> to <NUM> parts by weight of the acrylate having the cross-linkable double bond, <NUM> to <NUM> parts by weight of the polyurethane prepolymer, <NUM> to <NUM> parts by weight of the chain extender, and <NUM> to <NUM> parts by weight of the photoinitiator with respect to <NUM> parts by weight of the photosensitive resin composition.

In one of preferred embodiments, the polyurethane prepolymer having the isocyanate active group (-NCO) is produced by the reaction between the isocyanate and the polyether polyol with a molecular weight of <NUM> to <NUM> under heating and catalytic action. In this preferred embodiment, more preferably, the polyurethane prepolymer having the isocyanate active group (-NCO) is produced by the reaction between the isocyanate and the polyether polyol with a molecular weight of <NUM> under heating and catalytic action.

In one of preferred embodiments, the polyurethane prepolymer having the isocyanate active group (-NCO) is produced by the reaction between the isocyanate and the polyether polyol with an average functionality of <NUM> to <NUM> under heating and catalytic action.

In one of preferred embodiments, the photosensitive resin composition satisfies the following condition: phase separation and whitening phenomenon occur in the photosensitive resin composition during the change of the photosensitive resin composition from liquid to solid. In a preferred embodiment, the acrylate having the cross-linkable double bond is selected from an acrylate monomer having one or more double bonds capable of participating in free radical reaction, an acrylate prepolymer having one or more double bonds capable of participating in free radical reaction, and a combination thereof. More preferably, the acrylate monomer having one or more double bonds capable of participating in free radical reaction is selected from a monofunctional acrylate monomer with a functionality equal to <NUM>, a multi-functional acrylate monomer with a functionality larger than <NUM>, and a combination thereof. Or more preferably, the acrylate prepolymer having one or more double bonds capable of participating in free radical reaction is selected from polyurethane acrylate, epoxy acrylate, polyester acrylate, and combinations thereof.

In one of preferred embodiments, an amount of the isocyanate active group (-NCO) in the polyurethane prepolymer is <NUM> to <NUM> percent by weight. Or more preferably, the isocyanate used in the reaction under heating is selected from at least one or a combination of toluene diisocynate (TDI), methylene diphenyl diisocyanate (MDI), hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), dicyclohexylmethane-<NUM>,<NUM>'-diisocyanate (HMDI), xylylene diisocynate (XDI), tetramethyl-m-xylylene diisocyanate (TMXDI), methylcyclohexane diisocyanate (HTDI), <NUM>,<NUM>-phenylene diisocyanate (PPDI), norbornane diisocyanate (NBDI), and <NUM>,<NUM>-cyclohexane diisocyanate (CHDI). Preferably, the polyether polyol is produced by addition polymerization of an initiator, ethylene oxide (EO), propylene oxide (PO), butylene oxide (BO) in the presence of a catalyst, wherein the initiator is a compound containing an active hydrogen group. The catalyst is an organobismuth catalyst, an organotin catalyst, or a combination thereof for the synthesis of polyurethane.

In one of preferred embodiments, the polyurethane prepolymer is synthesized by using the following method: (<NUM>) dehydrating the polyether polyol by vacuuming, wherein the vacuuming satisfies the condition: the temperature is <NUM> to <NUM>, and the vacuum degree is -<NUM> to -<NUM> MPa; (<NUM>) adding weighed isocyanate and <NUM> to <NUM> parts by weight of the catalyst, and then reacting at <NUM> to <NUM> for <NUM> to <NUM> hours.

In one of preferred embodiments, the chain extender is a polyol, a polyamine, or an alkylol amine, with a functionality of <NUM> to <NUM> and a molecular weight smaller than <NUM>.

In one of preferred embodiments, the chain extender is selected from at least one or combinations of ethylene glycol, propylene glycol, <NUM>,<NUM>-butanediol, diethylene glycol, glycerol, trimethylolpropane, <NUM>,<NUM>-cyclohexanediol, dimethylene benzenediol, hydroquinone di-β-hydroxyethyl ether, resorcinol hydroxy ether, diethyl toluene diamine, <NUM>,<NUM>-dimethyl thio-toluene diamine, ethanol amine, diethanol amine, triethanol amine, triisopropanol amine, and N,N'-bis(<NUM>-hydroxypropy) aniline.

In one of preferred embodiments, the photoinitiator is selected from at least one or combinations of <NUM>,<NUM>,<NUM>-trimethylbenzoyl ethylphosphinate, <NUM>,<NUM>,<NUM>-(trimethylbenzoyl)-diphenyl phosphine oxide (TPO), <NUM>-methyl-<NUM>-[<NUM>- methylthiophenyl]-<NUM>-morpholinyl-<NUM>-propanone, <NUM>-isopropylthioxanthone (<NUM>, <NUM> isomer mixture), ethyl <NUM>-dimethylamino benzoate, <NUM>-hydroxy-cyclohexyl-phenyl ketone, <NUM>-hydroxy-<NUM>-methyl-<NUM>-pheny-<NUM>-propanone, benzoin dimethyl ether, o-benzoyl benzomethoxycarbonyl, <NUM>-chlorobenzophenone, and <NUM>-phenylbenzophenone.

In one of preferred embodiments, the photosensitive resin composition includes <NUM> to <NUM> parts by weight of the acrylate having the cross-linkable double bond, <NUM> parts by weight of the polyurethane prepolymer, <NUM> to <NUM> parts by weight of the chain extender, <NUM> to <NUM> parts by weight of the photoinitiator, <NUM> to <NUM> part by weight of a pigment, and <NUM> to <NUM> parts by weight of an additive with respect to <NUM> parts by weight of the photosensitive resin composition, wherein the pigment is a pigment paste curable under UV. The additive includes an antioxidant, a light stabilizer, and a filler.

The advantages of the technical solution of the present invention will be described in detail in the following embodiments in combination with the examples.

The present invention will be further illustrated below by means of the specific embodiments. The following examples are the specific embodiments of the present invention.

According to an embodiment of a dual-cure phase-separation type photosensitive resin composition for continuous 3D printing with high precision, the photosensitive resin composition includes: (i) an acrylate having a cross-linkable double bond; (ii) a polyurethane prepolymer; (iii) a chain extender; and (vi) a photoinitiator.

With respect to <NUM> parts by weight of the photosensitive resin composition, weight proportions of respective components are as follows: <NUM> to <NUM> parts by weight of the acrylate having the cross-linkable double bond, <NUM> to <NUM> parts by weight of the polyurethane prepolymer, <NUM> to <NUM> parts by weight of the chain extender, and <NUM> to <NUM> parts by weight of the photoinitiator. Preferably, the acrylate having the cross-linkable double bond takes <NUM> to <NUM> parts by weight, the polyurethane prepolymer takes <NUM> to <NUM> parts by weight, the chain extender takes <NUM> to <NUM> parts by weight, and the photoinitiator takes <NUM> to <NUM> parts by weight.

The polyurethane prepolymer can be a polyurethane prepolymer having an isocyanate active group (-NCO). The polyurethane prepolymer having the isocyanate active group (-NCO) can be produced by a reaction between an isocyanate and a polyether polyol with a molecular weight larger than or equal to <NUM> under heating and catalytic action.

In a preferred embodiment, the polyurethane prepolymer having the isocyanate active group (-NCO) is produced by the reaction between the isocyanate and the polyether polyol with a molecular weight of <NUM> to <NUM> under heating and catalytic action. More preferably, the polyurethane prepolymer having the isocyanate active group (-NCO) is produced by the reaction between the isocyanate and the polyether polyol with a molecular weight of <NUM> under heating and catalytic action.

In a preferred embodiment, preferably, the polyurethane prepolymer having the isocyanate active group (-NCO) is produced by the reaction between the isocyanate and the polyether polyol with an average functionality of <NUM> to <NUM> under heating and catalytic action.

In a preferred embodiment, the photosensitive resin composition satisfies the following condition: obvious phase separation and obvious whitening phenomenon occur in the photosensitive resin composition during the change of the photosensitive resin composition from liquid to solid.

The components mentioned above will be described in detail in combination with the embodiments as follows.

The suitable acrylate monomers having one or more double bonds capable of participating in free radical reaction are available from various commercial sources, for example, including but not limited to SR295, SR444, DPHA, SR351, SR494, SR454, SR506, CD590, SR420, SR217, SR531, SR285, SR9003, SR306, SR508, SR259, SR268, SR231, SR206, SR595, SR205, SR239, SR214, SR252, SR297F NS, SR348, SR601, SR540, SR541, SR602, SR480, SR834, SR603, SR210, CD406, SR610, SR399, SR502, SR415, SR9020, SR368, SR350, SR9035, SR355, SR339, SR340, CD495B, SR203, SR421, SR423, SR789, SR504, SR833, SR349, SR238 from Sartomer; for example, including but not limited to EM210, EM2103, EM2108, EM211, EM212, EM21, EM2191, EM315, EM35, EM70, EM75, EM90, EM2202, EM221, EM2211, EM222, EM2222, EM223, EM2243, EM215, EM218, EM219, EM2241, EM225, EM2251, EM226, EM2261, EM2288, EM229, EM2265, EM227, EM2280, EM320, EM324, EM326, EM3260, EM3261, EM3265, EM328, EM329, EM39, EM2308, EM231, EM235, EM2380, EM2383, EM2384, EM2385, EM2386, EM2381, EM2382, EM2387, EM331, EM3380, EM241, EM2411, EM242, EM2421, EM243, EM265, etc. from Eternal Chemical; or can be made by known methods.

The acrylate prepolymer having one or more double bonds preferably capable of participating in free radical reaction is polyurethane acrylate, epoxy acrylate, polyester acrylate.

The suitable polyurethane acrylates, epoxy acrylates, and polyester acrylates are available from various commercial sources, for example, including but not limited to CN1964, CN8010, CN110, CN989, CN8887, CN980, CN7001, CN1963, CN9893, CN8888, CN8881, CN2282, CN978, CN2261, CN9001, CN2283, CN2254, CN2204, CN983, CN790, CN8004, CN159, CN153, CN117, CN981, CN2302, CN2303, CN2203, CN996, CN991, CN2262, CN9782, CN115, CN131, CN146, CN959, CN120, CN104, CN964, etc., from Sartomer; for example, including but not limited to Etercure 611A-<NUM>, 611B-<NUM>, <NUM>-<NUM>, 6121F-<NUM>, 6122F-<NUM>, 6130B-<NUM>, <NUM>-<NUM>, <NUM>, 6134B-<NUM>, 6136B-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, 6143A-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, 6147B-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, 621A-<NUM>, 621F-<NUM>, 6214X-<NUM>, <NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, 622A-<NUM>, <NUM>-<NUM>, 624A-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>, <NUM>, <NUM>, etc., from Eternal Chemical; or can be made by known methods.

(ii) The amount of the isocyanate active group (-NCO) in the polyurethane prepolymer is preferably <NUM> to <NUM> percent by weight with respect to the total weight of the polyurethane prepolymer.

The isocyanate includes but is not limited to one or more of toluene diisocynate (TDI), methylene diphenyl diisocyanate (MDI), hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), dicyclohexylmethane-<NUM>,<NUM>'-diisocyanate (HMDI), xylylene diisocynate (XDI), tetramethyl-m-xylylene diisocyanate (TMXDI), methylcyclohexane diisocyanate (HTDI), <NUM>,<NUM>-phenylene diisocyanate (PPDI), norbornane diisocyanate (NBDI), and <NUM>,<NUM>-cyclohexane diisocyanate (CHDI). The polyether polyol is produced by addition polymerization between an initiator (a compound containing an active hydrogen group) and ethylene oxide (EO), propylene oxide (PO), butylene oxide (BO), and the like in the presence of a catalyst.

In a preferred embodiment, the polyurethane prepolymer is synthesized by using the following method: (<NUM>) dehydrating the polyether polyol by vacuuming at <NUM> for <NUM> with a vacuum degree of -<NUM> to -<NUM> MPa; (<NUM>) adding weighed isocyanate and <NUM> to <NUM> parts by weight of the catalyst, and then reacting at <NUM> for <NUM> to <NUM>.

The polyether polyols are available from various commercial sources, for example, including but not limited to, Pluracol <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, 410R, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> from BASF; for example, including but not limited to VORANOL™ 2000LM, 1000LM, <NUM>, <NUM>, <NUM>, <NUM>-037N, <NUM>-034N, 3000LM, 3003LM, 3003N, 3010N, <NUM>, 4000LM, <NUM>, <NUM>, <NUM>, <NUM>, 8000LM, CP1421, CP6001, CP6055 from Dow Chemistry; and DL-<NUM>, DL-<NUM>, DL-1000D, DL-2000D, DL-3000D, DL-4000D from Dongda; or can be made by known methods.

In another preferred embodiment, the photosensitive resin composition further includes a pigment and an additive. With respect to <NUM> parts by weight of the photosensitive resin composition, the photosensitive resin composition further includes: (v) <NUM> to <NUM> parts by weight of the pigment; and (vi) <NUM> to <NUM> parts by weight of the additive. Preferably, the pigment is a pigment paste curable under UV. The pigment includes but is not limited to SYMULER FAST YELLOW <NUM>, 4400T, <NUM>, <NUM>, <NUM>, SYMULER FAST Orange V, SYMULER FAST OrangeK, SYMULER Red <NUM>, 3013P, <NUM>, <NUM>, <NUM>, etc. The additive includes an antioxidant, a light stabilizer, a filler, etc..

The present invention will be described in more detail with reference to the preparation examples as follows. However, the preparation examples are exemplary embodiments and the present invention is not limited thereto.

Preparation Example <NUM> A dual-cure phase-separation type photosensitive resin composition for continuous 3D printing with high precision is prepared from the following materials: <NUM>% of SR306 (purchased from Sartomer Company), <NUM>% of dicyclohexylmethane-<NUM>,<NUM>'-diisocyanate (HMDI), <NUM>% of polyether polyol VORANOL4000LM (purchased from Dow Chemical Company), <NUM>% of organotin catalyst T12, <NUM>% of chain extender <NUM>, <NUM>-butanediol, and <NUM>% of photoinitiator TPO, wherein all of the percentages are weight percentages.

The preparation method includes two steps: (<NUM>) preparing the prepolymer: <NUM>% of polyether polyol VORANOL4000LM is vacuum dried at <NUM> for <NUM> with a vacuum degree of -<NUM> MPa, then the temperature is lowered to <NUM>, and then <NUM>% of dicyclohexylmethane-<NUM>,<NUM>'-diisocyanate (HMDI) and <NUM>% of organotin catalyst T12 are added to carry out a reaction which is terminated after <NUM>. A measurement is performed according to the fourth part, "the measurement of the content of the isocyanate radical", of "aromatic isocyanate for producing polyurethane plastic" of GB/T <NUM>-<NUM> Standard; (<NUM>) preparing the dual-cure photosensitive resin: <NUM>% of SR306, <NUM>% of chain extender <NUM>, <NUM>-butanediol, and <NUM>% of photoinitiator TPO are added into the prepolymer prepared in the step (<NUM>) and stirred for <NUM> to <NUM> until being completely dissolved.

The prepared photosensitive resin composition is cured and formed into a <NUM> of membrane under the irradiation of ultraviolet light. The irradiation conditions are as follows. The wavelength is <NUM> of. The intensity of the ultraviolet light is 20mw/cm<NUM>. The irradiation time is <NUM>. Then the reaction is continued at <NUM> for <NUM>. The transmittance of the membrane formed by the photosensitive resin is measured according to the measurement method of the transmittance and the haze of the transparent plastic recorded in GB/T <NUM>-<NUM>.

The Comparative Examples <NUM>-<NUM> and Examples <NUM>-<NUM> adopt the same or similar preparation methods as the Example <NUM>. The materials used in the Comparative Examples <NUM>-<NUM> and Examples <NUM>-<NUM> and the measurement results are shown in Table <NUM>. In rows numbered <NUM>-<NUM> in Table <NUM>, the product models of the materials are shown in the upper sub-rows and the weight percentages are shown in the lower sub-rows.

The results of Examples <NUM>-<NUM> indicates that as compared to Example <NUM>, when the molecular weight of the polyether polyol is also <NUM> and the additive such as the titanium white powder or the light stabilizer is added, the transmittance of the photosensitive resin composition is further decreased, which results a higher precision of the printed product.

Claim 1:
A dual-cure phase-separation type photosensitive resin composition for continuous 3D printing with high precision, characterized in that the photosensitive resin composition comprises: an acrylate having a cross-linkable double bond; a polyurethane prepolymer; a chain extender; and a photoinitiator; wherein the polyurethane prepolymer is a polyurethane prepolymer having an isocyanate active group, and the polyurethane prepolymer having the isocyanate active group is produced by a reaction between an isocyanate and a polyether polyol with a molecular weight larger than or equal to <NUM> under heating and catalytic action.