3D PRINTERS AND PHOTOCURABLE POLYMER AND RESIN BASED FEEDSTOCKS FOR 3D PRINTERS
This disclosure relates in general to three dimensional (“3D”) printers having a configuration that prepares a three-dimensional object by using a feedstock comprising carbon containing photocurable formulations and methods for the preparation of such feedstocks. This disclosure further relates to electrically conducting 3D polymer composites prepared by using such carbon containing photocurable formulations.
1 . A carbon containing photocurable formulation comprising:
a carbon;
a photocurable resin; and
a photoinitiator;
wherein the carbon containing photocurable formulation, when cured, yields a polymer composite with an electrical resistivity lower than or equivalent to 100 ohmcm.
2 . The carbon containing photocurable formulation of claim 1 , wherein the carbon containing photocurable formulation, when cured, yields a polymer composite with an electrical resistivity lower than or equivalent to 10 ohmcm.
3 . The carbon containing photocurable formulation of claim 1 , wherein the carbon containing photocurable formulation, when cured, yields a polymer composite with an electrical resistivity lower than or equivalent to 1 ohmcm.
4 . The carbon containing photocurable formulation of claim 1 , wherein the carbon containing photocurable formulation, when cured, yields a polymer composite with an electrical resistivity lower than or equivalent to 0.1 ohmcm.
5 . The carbon containing photocurable formulation of claim 1 , wherein the carbon containing photocurable formulation comprises a nanocarbon, a pyrolytic carbon, a graphite, an activated carbon, an amorphous carbon, a carbon fiber, or a combination thereof.
6 . The carbon containing photocurable formulation of claim 1 , wherein the carbon comprises a nanocarbon.
7 . The carbon containing photocurable formulation of claim 1 , wherein the carbon comprises a non-agglomerated nanocarbon.
8 . The carbon containing photocurable formulation of claim 1 , wherein the carbon comprises a nanocarbon and wherein the nanocarbon comprises a carbon nanotube, a graphene, a fullerene, or a combination thereof.
9 . The carbon containing photocurable formulation of claim 1 , wherein the carbon comprises a carbon nanotube; and wherein the carbon nanotube comprises a single-wall carbon nanotube, a double-wall carbon nanotube, a multi-wall carbon nanotube, or a combination thereof.
10 . The carbon containing photocurable formulation of claim 1 , wherein the carbon comprises a nanocarbon, and wherein the nanocarbon comprises a graphene; and wherein the graphene comprises a single layer graphene, a double layer graphene, a multilayer graphene, a graphene strip, or a combination thereof.
11 . The carbon containing photocurable formulation of claim 1 , wherein the carbon comprises a fullerene; and wherein the fullerene comprises a C 60 , a C 70 , a C 76 , a C 78 , a C 84 , or a combination thereof.
12 . The carbon containing photocurable formulation of claim 1 , wherein the photocurable resin comprises a monomer, oligomer, or a polymer of an acrylate, a methacrylate, an epoxy, a urethane, an ester, a silicone, a styrene, or a combination thereof.
13 . The carbon containing photocurable formulation of claim 1 , wherein the carbon containing photocurable formulation has a viscosity; and wherein the viscosity of the carbon containing photocurable formulation is in the range of 1 millipascalsecond to 1,000 millipascalsecond at about 25° C.
14 . The carbon containing photocurable formulation of claim 1 , wherein the carbon containing photocurable formulation has a viscosity; and wherein the viscosity of the carbon containing photocurable formulation is in the range of 10 millipascalsecond to 300 millipascalsecond at about 25° C.
15 . The carbon containing photocurable formulation of claim 1 , wherein the carbon containing photocurable formulation has a viscosity; and wherein the viscosity of the carbon containing photocurable formulation is in the range of 50 millipascalsecond to 150 millipascalsecond at about 25° C.
16 . The carbon containing photocurable formulation of claim 1 , wherein the carbon comprises a carbon nanotube; and wherein the carbon nanotube comprises a single-wall carbon nanotube, a double-wall carbon nanotube, a multi-wall carbon nanotube, or a combination thereof; wherein the carbon containing photocurable formulation, when cured, yields a polymer composite with an electrical resistivity lower than or equivalent to 1 ohmcm.
17 . A method of preparation of a carbon containing photocurable formulation, comprising:
processing a conditioned photocurable mixture at a high shear rate and thereby preparing a carbon containing photocurable formulation;
wherein the conditioned photocurable mixture is prepared by a method comprising processing a photocurable mixture at a low shear rate;
wherein the photocurable mixture comprises a carbon, a photocurable resin, and a photoinitiator;
wherein the high shear rate is equivalent to or higher than 200,000 s −1 ; and
wherein the low shear rate is lower than 200,000 s −1 .
18 . The preparation method of claim 17 , wherein the conditioned photocurable mixture is substantially free of any dispersing agent.
19 . The preparation method of claim 17 , wherein the carbon is substantially free of functional groups that can facilitate dispersion of the carbon compound in the mixture.
20 . The preparation method of claim 17 , wherein the high shear rate is equivalent to or higher than 500,000 s −1 .
21 . The preparation method of claim 17 , wherein the high shear rate is equivalent to or higher than 1,000,000 s −1 .
22 . The preparation method of claim 17 , wherein the high shear rate is equivalent to or higher than 10,000,000 s −1 .
23 . The preparation method of claim 17 , wherein the carbon comprises a nanocarbon, a pyrolytic carbon, a graphite, an activated carbon, an amorphous carbon, a carbon fiber, or a combination thereof.
24 . The preparation method of claim 17 , wherein the carbon comprises a nanocarbon; and wherein the nanocarbon comprises a carbon nanotube, a graphene, a fullerene, or a combination thereof.
25 . The preparation method of claim 17 , wherein the carbon comprises a carbon nanotube; and wherein the carbon nanotube comprises a single-wall carbon nanotube, a double-wall carbon nanotube, a multi-wall carbon nanotube, or a combination thereof.
26 . The preparation method of claim 17 , wherein the carbon comprises a graphene; and wherein the graphene comprises a single layer graphene, a double layer graphene, a multilayer graphene, a graphene strip, or a combination thereof.
27 . The preparation method of claim 17 , wherein the carbon comprises a fullerene; and wherein the fullerene comprises a C 60 , a C 70 , a C 76 , a C 78 , a C 84 , or a combination thereof.
28 . The preparation method of claim 17 , wherein the photocurable resin comprises a monomer, oligomer or a polymer of an acrylate, a methacrylate, an epoxy, a urethane, an ester, a silicone, a vinyl alcohol, a vinyl acetate, an alkene, a glycerol, a glycol, a ketone, or a combination thereof.
29 . The preparation method of claim 17 , wherein carbon containing photocurable formulation has a viscosity; and wherein the viscosity of the carbon containing photocurable formulation is in the range of 1 millipascalsecond to 1,000 millipascalsecond at about 25° C.
30 . The preparation method of claim 17 , wherein carbon containing photocurable formulation has a viscosity; and wherein the viscosity of the carbon containing photocurable formulation is in the range of 10 millipascalsecond to 300 millipascalsecond at about 25° C.
31 . The preparation method of claim 17 , wherein carbon containing photocurable formulation has a viscosity; and wherein the viscosity of the carbon containing photocurable formulation is in the range of 50 millipascalsecond to 150 millipascalsecond at about 25° C.
32 . The preparation method of claim 17 , wherein the carbon containing photocurable formulation, when cured, yields a polymer composite with an electrical resistivity lower than or equivalent to 100 ohmcm.
33 . The preparation method of claim 17 , wherein the carbon containing photocurable formulation, when cured, yields a polymer composite with an electrical resistivity lower than or equivalent to 10 ohmcm.
34 . The preparation method of claim 17 , wherein the carbon containing photocurable formulation, when cured, yields a polymer composite with an electrical resistivity lower than or equivalent to 1 ohmcm.
35 . The preparation method of claim 17 , wherein the carbon containing photocurable formulation, when cured, yields a polymer composite with an electrical resistivity lower than or equivalent to 0.1 ohmcm.
36 . The preparation method of claim 17 , wherein the carbon comprises a carbon nanotube, and wherein the carbon nanotube comprises a single-wall carbon nanotube, a double-wall carbon nanotube, a multi-wall carbon nanotube, or a combination thereof; and wherein the carbon containing photocurable formulation, when cured, yields a polymer composite with an electrical resistivity lower than or equivalent to 1 ohmcm.