Photocurable compositions for articles having stable tensile properties

1. A process for producing a three-dimensional article in sequential cross-sectional layers in accordance with a model of the article, the process comprising the steps of:

(1) forming a first layer of a photocurable composition comprising (a) a cationically curable compound; (b) an acrylate-containing compound; (c) a hydroxyl-containing compound; (d) a cationic photoinitiator; and (e) a free radical photoinitiator wherein said composition has less than 0.54 equivalents of cationically curable groups, less than 0.10 equivalents of acrylate groups and between less than 0.10 to about 0.03 equivalents of hydroxyl groups per 100 grams of said composition;

(2) exposing said first layer to actinic radiation in a pattern corresponding to a respective cross-sectional layer of the model sufficient to harden the first layer in the imaged area;

(3) forming a second layer of said composition above the hardened first layer;

(4) exposing said second layer to actinic radiation in a pattern corresponding to a respective cross-sectional layer of the model sufficient to harden the second layer in the imaged area; and

(5) repeating steps (3)-(4) to form successive layers as desired to form said thee-dimensional article.

2. A three-dimensional article produced by the process of claim 1 .

3. A process for bonding two or more digital versatile disc (DVD) layers together, the process comprising the steps of:

(1) combining the components of a photocurable composition comprising (a) a cationically curable compound; (b) an acrylate-containing compound; (c) a hydroxyl-containing compound; (d) a cationic photoinitiator; and (e) a free radical photoinitiator wherein said composition has less than 0.54 equivalents of cationically curable groups, less than 0.10 equivalents of acrylate groups and between less than 0.10 to about 0.03 equivalents of hydroxyl groups per 100 grams of said composition;

(2) applying the mixture to form a bonding layer positioned between two DVD layers to be bonded together;

(3) curing the photocurable composition with actinic radiation; and

(4) optionally pressing together the two DVD layers having the cured bonding layer between them.

4. The process of claim 3 , wherein the photocurable composition is cured with UV radiation at a dose of about 0.02-1.0 J/cm 2 .

5. The process of claim 3 , wherein the photocurable composition is cured with UV radiation at a dose of about 0.4 J/cm 2 .

6. A digital versatile disc produced by the process of claim 3 .

7. A process for forming a thee-dimensional article in sequential cross-sectional layers in accordance with a model of the article, the process comprising the steps of: jet depositing droplets of a photocurable composition comprising (a) a cationically curable compound; (b) an acrylate-containing compound; (c) a hydroxyl-containing compound; (d) a cationic photoinitiator; and (e) a free radical photoinitiator wherein said composition has less than 0.54 equivalents of cationically curable groups, less than 0.10 equivalents of acrylate groups and between less than 0.10 to about 0.03 equivalents of hydroxyl groups onto a substrate in a pattern corresponding to a respective cross-sectional layer of the model so that adjacent droplets merge together; repeating these steps to form successive layers; and applying actinic radiation to cure the photocurable composition, pixel-by-pixel, line-by-line, layer-by-layer, after several layers have been formed and/or after all desired layers have been formed.

8. A thee-dimensional article produced by the process of claim 7 .

9. A process for forming a three-dimensional article in sequential cross-sectional layers in accordance with a model of the article, the process comprising the steps of: defining a layer of powder material onto a substrate; jet depositing a photocurable composition comprising (a) a cationically curable compound; (b) an acrylate-containing compound; (c) a hydroxyl-containing compound; (d) a cationic photoinitiator; and (e) a free radical photoinitiator wherein said composition has less than 0.54 equivalents of cationically curable groups, less than 0.10 equivalents of acrylate groups and between less than 0.10 to about 0.03 equivalents of hydroxyl groups per 100 grams of said composition onto the powder layer in a pattern corresponding to a respective cross-sectional layer of the model; repeating these steps to form successive layers; and applying actinic radiation to cure the photocurable composition, pixel-by-pixel, line-by-line, layer-by-layer, after several layers have been formed and/or after all desired layers have been formed.

10. A three-dimensional article produced by the process of claim 9 .

11. The process of claim 9 characterized in that the powder comprises a reactive component that reacts with the photocurable composition, or is facilitated by the photocurable composition to react with itself.

12. The process of claim 9 , wherein the powder is comprised of the photocurable composition.

13. A process for producing a coated optical glass fiber, the process comprising the steps of: applying a photocurable composition comprising (a) a cationically curable compound; (b) an acrylate-containing compound; (c) a hydroxyl-containing compound; (d) a cationic photoinitiator; and (e) a free radical photoinitiator wherein said composition has less than 0.54 equivalents of cationically curable groups, less than 0.10 equivalents of acrylate groups and between less than 0.10 to about 0.03 equivalents of hydroxyl groups per 100 grams of said composition to optical glass fiber; and curing the photocurable composition with actinic radiation.

14. A coated optical glass fiber produced by the process of claim 13 .

15. A process for sealing a light emitting diode, the process comprising the steps of: applying a photocurable composition comprising (a) a cationically curable compound; (b) an acrylate-containing compound; (c) a hydroxyl-containing compound; (d) a cationic photoinitiator; and (e) a free radical photoinitiator wherein said composition has less than 0.54 equivalents of cationically curable groups, less than 0.10 equivalents of acrylate groups and between less than 0.10 to about 0.03 equivalents of hydroxyl groups per 100 grains of said composition between a P-type semiconductor and an N-type semiconductor; and curing the photocurable composition with actinic radiation.

16. A sealed light emitting diode produced by the process of claim 15 .