IP Library › Granted Patent US 12,410,329
Granted Patent B2
US 12,410,329 · App. 17/440,091 · Granted Sep 9, 2025

Radiation-curable, nonradiation-curable copolymer system for additive manufacturing

Inventor: Eric Bukovsky (Livermore, CA)
Assignee: Lawrence Livermore National Security, LLC
C09D11/101B29C64/106B33Y70/00C08G18/10C08G18/672C09D11/102B33Y10/00
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Quick Facts
Patent No.
US 12,410,329
App. No.
17/440,091
Granted
Sep 9, 2025
Kind
B2
Abstract

According to one aspect of an inventive concept, an ink includes a nonradiation-curable pre-polymer having at least two nonradiation-curable components per molecule of the nonradiation-curable pre-polymer, a radiation-curable component, a polymer having at least one reactive hydrogen component, and a photoinitiator. A concentration of the nonradiation-curable pre-polymer having at least two nonradiation-curable components is in a range of greater than 0 weight % to less than 99 weight % of a total weight of the ink.

Claims (35)

1. An ink, comprising

a nonradiation-curable pre-polymer having at least one molecule that comprises two nonradiation-curable components and a radiation-curable component;

a polymer having at least one reactive hydrogen component; and

a photoinitiator,

wherein a concentration of the nonradiation-curable pre-polymer having at least two nonradiation-curable components is in a range of greater than 0 weight % to less than 99 weight % of a total weight of the ink.

2. An ink as recited in claim 1 , wherein the nonradiation-curable pre-polymer comprises the at least two nonradiation-curable components linked by a linker.

3. An ink as recited in claim 2 , wherein the nonradiation-curable pre-polymer comprises the radiation-curable component coupled to the linker.

4. An ink as recited in claim 1 , wherein the radiation-curable component is selected from the group consisting of: an acrylate, a thiol-ene, an epoxy, a vinyl, and a combination thereof.

5. An ink as recited in claim 1 , wherein a concentration of the radiation-curable component is in a range of greater than 0 weight % to less than 99 weight % of a total weight of the ink.

6. An ink as recited in claim 1 , wherein at least one of the at least two nonradiation-curable components of the nonradiation-curable pre-polymer include an isocyanate component.

7. An ink as recited in claim 6 , wherein the polymer having at least one reactive hydrogen component is a polyamine, wherein the at least one reactive hydrogen component is an amine component, wherein the isocyanate component and amine component are configured to form a urea linkage.

8. An ink as recited in claim 6 , the polymer having at least one reactive hydrogen component is a polyol, wherein the at least one reactive hydrogen component is an alcohol component, wherein the isocyanate component and the alcohol component are configured to form a urethane linkage.

9. An ink as recited in claim 8 , wherein a ratio of the alcohol component to the isocyanate component in the ink is at least 1:1.

10. An ink as recited in claim 8 , wherein the alcohol component includes a diol component.

11. An ink as recited in claim 8 , wherein the alcohol component includes both a diol component and a polyalcohol component having the chemical formula R(OH) n , wherein n>1.

12. An ink as recited in claim 11 , wherein a ratio of the diol component to the polyalcohol component is greater than about 1:1.

13. An ink as recited in claim 1 , wherein a concentration of the photoinitiator is greater than 0.1 weight % of a total weight of the ink.

14. An ink as recited in claim 1 , comprising a solid.

15. An ink as recited in claim 14 , wherein a concentration of the solid is less than 75 volume % of a total volume of the ink.

16. An ink as recited in claim 14 wherein the solid is a porogen.

17. An ink as recited in claim 16 , wherein the solid is solvable, wherein the solid is configured to be removed post-processing.

18. An ink as recited in claim 17 , wherein the solvable solid includes sodium chloride particles.

19. An ink as recited in claim 14 , wherein the solid includes a reinforcing material.

20. An ink as recited in claim 19 , wherein the solid includes material selected from the group consisting of: nanoclay, fumed silica, graphene, carbon fiber, fiber glass, and carbon nanotubes.

21. An ink as recited in claim 14 , wherein the solid includes an inorganic material.

22. An ink as recited in claim 21 , wherein the inorganic material is selected from the group consisting of: metal oxide, metal, and inorganic composites.

23. An ink as recited in claim 14 , wherein the solid includes a reactive material.

24. An ink as recited in claim 23 , wherein the reactive material is selected from the group consisting of: an explosive, a propellent, and a thermite.

25. A method of forming a three-dimensional product, the method comprising:

extruding an ink from a nozzle to form a printed three-dimensional product, the ink comprising:

a nonradiation-curable pre-polymer having at least two nonradiation-curable components per molecule of the nonradiation-curable pre-polymer,

a radiation-curable component,

a polymer having at least one reactive hydrogen component, and

a photoinitiator; and

directing an ultraviolet (UV) light toward the nozzle for irradiating the extruded ink to form a three-dimensional product having a plurality of continuous filaments arranged in a geometric pattern, the filaments comprising the radiation-cured component.

Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Oct 18, 2021
From: BUKOVSKY, ERIC
To: LAWRENCE LIVERMORE NATIONAL SECURITY, LLC
Reel/Frame 057841/0170 →
CONFIRMATORY LICENSE Recorded Oct 7, 2021
From: LAWRENCE LIVERMORE NATIONAL SECURITY, LLC.
To: U.S. DEPARTMENT OF ENERGY
Reel/Frame 057748/0775 →
Continuity (1)
Related Publication 20220186053A1 · Jun 16, 2022
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