阅读说明：本技术 选择性激光烧结和系统中使用热塑性聚氨酯的方法以及其制品 (Methods of using thermoplastic polyurethanes in selective laser sintering and systems, and articles thereof ) 是由 J·J·小翁托西克 G·韦尔米尼彻 E·W·阿尔特 A·普莱泽斯 于 2015-01-16 设计创作，主要内容包括：本发明涉及固体自由成形制造的系统和方法,特别是选择性激光烧结,以及使用其制造的各种制品,其中该系统和方法利用某些特别适合这种加工的热塑性聚氨酯。实用的热塑性聚氨酯衍生自(a)多异氰酸酯组分,(b)多元醇组分,和(C)任选的增链剂组分；其中所述产生的热塑性聚氨酯的熔融焓为至少5.5J/g,Tc(结晶温度)高于70℃,Δ(Tm:Tc)为20-75度,其中Δ(Tm:Tc)为Tm(熔融温度)与Tc之差。(The present invention relates to systems and methods for solid freeform fabrication, particularly selective laser sintering, and various articles of manufacture made using the same, wherein the systems and methods utilize certain thermoplastic polyurethanes that are particularly suited for such processing. Useful thermoplastic polyurethanes are derived from (a) a polyisocyanate component, (b) a polyol component, and (C) an optional chain extender component; wherein the resulting thermoplastic polyurethane has a melting enthalpy of at least 5.5J/g, a Tc (crystallization temperature) above 70 ℃, a Delta (Tm: Tc) of 20 to 75 degrees, wherein Delta (Tm: Tc) is the difference between Tm (melting temperature) and Tc.)

1. A system for fabricating a three-dimensional object, comprising a solid freeform fabrication apparatus that selectively fuses layers of powder;

wherein the powder comprises a thermoplastic polyurethane derived from (a) a polyisocyanate component, (b) a polyol component, and (C) an optional chain extender component;

wherein the powder has an average particle size of less than 200 microns;

wherein the resulting thermoplastic polyurethane has a melting enthalpy of at least 5.5J/g;

wherein the Tc of the resulting thermoplastic polyurethane is at least 70 ℃; and

wherein the resulting thermoplastic polyurethane has a Delta (Tm: Tc) of from 20 to 75 degrees.

2. A method of manufacturing a three-dimensional object, comprising the steps of: (I) operating a system for producing a three-dimensional object from a powder;

wherein the system comprises a solid freeform fabrication apparatus that selectively fuses layers of powder; so as to shape the three-dimensional object;

wherein the powder comprises a thermoplastic polyurethane derived from (a) a polyisocyanate component, (b) a polyol component, and (C) an optional chain extender component;

wherein the powder has an average particle size of less than 200 microns;

wherein the resulting thermoplastic polyurethane has a melting enthalpy of at least 5.5J/g;

wherein the Tc of the resulting thermoplastic polyurethane is at least 70 ℃; and

wherein the resulting thermoplastic polyurethane has a Delta (Tm: Tc) of from 20 to 75 degrees.

3. An article of manufacture produced by a solid freeform fabrication apparatus that selectively fuses layers of powder;

wherein the powder comprises a thermoplastic polyurethane derived from (a) a polyisocyanate component, (b) a polyol component, and (C) an optional chain extender component;

wherein the powder has an average particle size of less than 200 microns;

wherein the resulting thermoplastic polyurethane has a melting enthalpy of at least 5.5J/g;

wherein the Tc of the resulting thermoplastic polyurethane is at least 70 ℃; and

wherein the resulting thermoplastic polyurethane has a Delta (Tm: Tc) of from 20 to 75 degrees.

4. The system or method or article of any of claims 1-3, wherein the solid freeform fabrication apparatus comprises: (a) an inner chamber having a target area where an addition process is performed; (b) means for depositing and leveling a layer of powder at the target area; and (c) means for fusing selected portions of the powder layer over the target area.

5. The system or method or article of any of claims 1-4, wherein the solid freeform fabrication apparatus comprises a selective laser sintering apparatus.

6. The system or method or article of any of claims 1-5, wherein the polyisocyanate component comprises an aromatic diisocyanate.

7. The system or method or article of any of claims 1-6, wherein the polyisocyanate component comprises 4,4' -methylenebis (phenyl isocyanate).

8. The system or method or article of any of claims 1-8, wherein the polyol component comprises a polyether polyol, a polyester polyol, a copolymer of a polyether polyol and a polyester polyol, or a combination thereof.

9. A system or method or article of any of claims 1-9 wherein the polyol component comprises poly (tetramethylene ether glycol), polycaprolactone, polyadipate, copolymers thereof, or combinations thereof.

10. The system or method or article of any of claims 1-9, wherein the chain extender comprises a linear alkylene glycol.

11. The system or method or article of any of claims 1-1, wherein the chain extender component comprises 1, 4-butanediol, 1, 12-dodecanediol, dipropylene glycol, or a combination thereof.

12. The system or method or article of any of claims 1-11, wherein the thermoplastic polyurethane further comprises one or more colorants, antioxidants (including phenols, phosphites, thioesters, and/or amines), antiozonants, stabilizers, inert fillers, lubricants, inhibitors, hydrolysis stabilizers, light stabilizers, hindered amine light stabilizers, benzotriazole ultraviolet light absorbers, heat stabilizers, discoloration prevention stabilizers, dyes, pigments, inorganic and organic fillers, reinforcing agents, or any combination thereof.

13. The article according to any one of claims 3-12, wherein the article comprises cooking and storage appliances, furniture, automotive parts, toys, sportswear, medical equipment, personalized medical articles, replicated medical implants, dental articles, disinfection containers, drapes, gowns, filters, hygiene articles, diapers, films, sheets, tubing, pipe, wire jacketing, cable jacketing, agricultural films, geomembranes, sports equipment, cast films, blown films, profiles, boat and ship parts, transfer cases, containers, packaging, laboratory appliances, office floor mats, instrument sample holders, liquid storage containers, packaging materials, medical tubing and valves, footwear parts, sheets, tapes, adhesives, wire coverings, cables, protective apparel, automotive parts, coatings, foam laminates, overmolding, automotive skins, Sunshades, canvasses, leather articles, roofing articles, steering wheels, powder coatings, powder slush molding, durable consumer goods, grips, handles, hoses, hose linings, pipes, pipe linings, casters, pulleys, computer components, belts, stitching, footwear components, conveyor or timing belts, gloves, fibers, fabrics, or garments.

14. A medical device manufactured by a solid freeform fabrication apparatus that selectively fuses layers of powder;

wherein the powder comprises a thermoplastic polyurethane derived from (a) a polyisocyanate component, (b) a polyol component, and (C) an optional chain extender component;

wherein the powder has an average particle size of less than 200 microns;

wherein the resulting thermoplastic polyurethane has a melting enthalpy of at least 5.5J/g;

wherein the Tc of the resulting thermoplastic polyurethane is at least 70 ℃; and

wherein the resulting thermoplastic polyurethane has a Delta (Tm: Tc) of from 20 to 75 degrees.

Technical Field

The present invention relates to solid freeform fabrication systems and methods, particularly selective laser sintering, and various articles made therewith, wherein the systems and methods employ certain thermoplastic polyurethanes that are particularly suited for such processing. Useful thermoplastic polyurethanes are derived from (a) a polyisocyanate component, (b) a polyol component, and (c) an optional chain extender component; wherein the resulting thermoplastic polyurethane has a melting enthalpy of at least 5.5J/g, a Tc (crystallization temperature) above 70 ℃, a Delta (Tm: Tc) of 20 to 75 degrees, wherein Delta (Tm: Tc) is the difference between Tm (melting temperature) and Tc.

Background

The present invention relates to solid freeform fabrication using certain thermoplastic polyurethanes, and more particularly to selective laser sintering.

Solid free form fabrication (SFF) is a technique that enables the fabrication of arbitrarily shaped structures directly from computer data via additional molding steps. The basic operation of any SFF system consists of slicing a three-dimensional computer model into thin cross-sections, converting the results into two-dimensional positional data and transmitting the data to control equipment to produce a three-dimensional structure in a layered stack.

Solid freeform fabrication involves many different processes associated with this fabrication process, including three-dimensional printing, electron beam melt forming, stereolithography, selective laser sintering, layered object fabrication, fused deposition modeling, and others.

For example, in a three-dimensional printing process, build material is dispensed through a dispensing head having a set of nozzles to form a deposited layer on a support structure. The layers may then be cured or solidified using suitable means, depending on the build material. The build material can include modeling material that forms the object, and support material that supports the object being built.

Solid freeform fabrication is commonly used in design-related fields for visualization, demonstration, and prototype fabrication. Thus, SFF facilitates rapid manufacturing of functional prototypes with minimal equipment and labor. Such rapid prototyping reduces the product development cycle and improves the design process by providing rapid and efficient feedback to the designer. SFF can also be used to quickly fabricate non-functional parts, for example, to evaluate various aspects of a design such as aesthetics, fit, and assembly. Furthermore, SFF techniques have proven useful in the medical field, where expected results are simulated prior to performing a procedure. It is recognized that many other fields may benefit from rapid prototyping techniques, including, but not limited to, the architectural, dental, and orthopedic fields, where visualization of specific designs and/or functions is beneficial.

There is an increasing interest in this form of manufacturing. Many materials have been considered for use in the systems and methods described above, however, thermoplastic polyurethanes have proven difficult to use in these systems and methods. This is due, at least in part, to the difficulty in processing the TPU to the proper particle size distribution and to ensure that the physical properties of the TPU are well suited for the selective laser sintering process. The low crystallization rate of TPU also makes it difficult to maintain tolerances as the melt stream is deposited onto the part being built. In addition, the wide melting temperature range of TPU materials can make viscosity control challenging, and many TPU materials can create smoke or off-gassing problems.

Because thermoplastic polyurethanes offer an attractive combination of properties and because a wide variety of articles are conventionally made, there is an increasing need to identify and/or develop thermoplastic polyurethanes suitable for solid freeform fabrication, particularly those suitable for selective laser sintering.

Disclosure of Invention

The disclosed technology provides a system for fabricating a three-dimensional object, including a solid freeform fabrication apparatus that selectively fuses layers of powder; wherein the powder comprises a thermoplastic polyurethane derived from (a) a polyisocyanate component, (b) a polyol component, and (c) an optional chain extender component; wherein the powder has an average particle size of less than 200 microns (or even less than 150 microns or less than 100 microns, in some embodiments, at least 50 microns or even at least 100 microns); wherein the resulting thermoplastic polyurethane has a melting enthalpy (as measured by DSC) of at least 5.5J/g (alternatively at least 10J/g or at least 15J/g, and in some embodiments less than 100J/g, 50J/g, or even less than 45J/g); wherein the Tc (crystallization temperature as measured by DSC) of the resulting thermoplastic polyurethane is at least in excess of 70 ℃ (even above 80 ℃ or above 90 ℃, in some embodiments less than 150 ℃, 140 ℃, or even less than 130 ℃); and wherein the resulting thermoplastic polyurethane has a Δ (Tm: Tc) (the difference between Tm and Tc of the thermoplastic polyurethane, both as measured by DSC) of 20 to 75 degrees (or the difference is at least 20 degrees, 30 degrees, 40 degrees, 50 degrees, even 58 degrees, and no more than 75 degrees, 71 degrees, even no more than 60 degrees).

The disclosed technology provides a method of fabricating a three-dimensional object, comprising the steps of: (I) operating a system for producing a three-dimensional object from a powder; wherein the system comprises a solid freeform fabrication apparatus that selectively fuses layers of powder; so as to form a three-dimensional object; wherein the powder comprises a thermoplastic polyurethane derived from (a) a polyisocyanate component, (b) a polyol component, and (c) an optional chain extender component; wherein the powder has an average particle size of less than 200 microns (or even less than 150 microns or less than 100 microns, in some embodiments, at least 50 microns or even at least 100 microns); wherein the resulting thermoplastic polyurethane has a melting enthalpy (determined by DSC) of at least 5.5J/g (or at least 10J/g or at least 15J/g, and in some embodiments less than 100J/g, 50J/g, or even less than 45J/g); wherein the Tc (crystallization temperature as determined by DSC) of the thermoplastic polyurethane produced is at least in excess of 70 ℃ (even above 80 ℃ or above 90 ℃, in some embodiments less than 150 ℃, 140 ℃, or even less than 130 ℃); and wherein the resulting thermoplastic polyurethane has a Δ (Tm: Tc) (the difference between Tm and Tc of the thermoplastic polyurethane, both as measured by DSC) of 20 to 75 degrees (or the difference is at least 20 degrees, 30 degrees, 40 degrees, 50 degrees, even 58 degrees, and no more than 75 degrees, 71 degrees, even no more than 60 degrees).

The disclosed technology provides an article of manufacture made by a solid freeform fabrication apparatus that selectively fuses layers of powder; wherein the powder has an average particle size of less than 200 microns (or even less than 150 microns or less than 100 microns, in some embodiments, at least 50 microns or even 100 microns); wherein the resulting thermoplastic polyurethane has a melting enthalpy (as measured by DSC) of at least 5.5J/g (or at least 10J/g or at least 15J/g, and in some embodiments less than 100J/g, 50J/g, or even less than 45J/g); wherein the Tc (crystallization temperature as measured by DSC) of the resulting thermoplastic polyurethane is at least in excess of 70 ℃ (even above 80 ℃ or above 90 ℃, in some embodiments less than 150 ℃, 140 ℃, or even less than 130 ℃); and wherein the resulting thermoplastic polyurethane has a Δ (Tm: Tc) (the difference between Tm and Tc of the thermoplastic polyurethane, both as measured by DSC) of 20 to 75 degrees (or the difference is at least 20 degrees, 30 degrees, 40 degrees, 50 degrees, even 58 degrees, and no more than 75 degrees, 71 degrees, even no more than 60 degrees).

The disclosed technology provides any of the systems, methods, and/or articles described herein, wherein the solid freeform fabrication apparatus comprises: (a) an inner chamber having a target area in which an addition process is performed; (b) means for depositing and leveling a layer of powder at the target area; and (c) means for fusing selected portions of the powder layer in the target area.

The presently disclosed technology provides any of the systems, methods, and/or articles described herein, wherein the solid freeform fabrication apparatus comprises a selective laser sintering apparatus.

The presently disclosed technology provides any of the systems, methods, and/or articles described herein, wherein the polyisocyanate component comprises an aromatic diisocyanate.

The disclosed technology provides any of the systems, methods, and/or articles described herein, wherein the polyisocyanate component comprises 4,4' -methylenebis (phenyl isocyanate).

The presently disclosed technology provides any of the systems, methods, and/or articles described herein, wherein the polyol component comprises a polyether polyol, a polyester polyol, a polyether and polyester polyol copolymer, or a combination thereof.

The presently disclosed technology provides any of the systems, methods, and/or articles described herein, wherein the polyol component comprises poly (tetramethylene ether glycol), polycaprolactone, polyadipate, copolymers thereof, or combinations thereof.

The presently disclosed technology provides any of the systems, methods, and/or articles described herein, wherein the chain extender component comprises a linear alkylene glycol.

The presently disclosed technology provides any of the systems, methods, and/or articles described herein, wherein the chain extender component comprises 1, 4-butanediol, 1, 12-dodecanediol, dipropylene glycol, or a combination thereof

The presently disclosed technology provides any of the systems, methods, and/or articles described herein, wherein the thermoplastic polyurethane further comprises one or more colorants, antioxidants (including phenols, phosphites, thioesters, and/or amines), antiozonants, stabilizers, inert fillers, lubricants, inhibitors, hydrolysis stabilizers, light stabilizers, hindered amine light stabilizers, benzotriazole-based ultraviolet light absorbers, heat stabilizers, discoloration prevention stabilizers, dyes, pigments, organic and inorganic fillers, reinforcing agents, or any combination thereof.

The presently disclosed technology provides any of the systems, methods, and/or articles described herein, wherein the articles include cooking and storage appliances, furniture, automotive parts, toys, athletic garments, medical devices, personalized medical articles, replicated medical implants, dental articles, disinfection containers, drapes, gowns, filters, hygiene articles, diapers, films, sheets, tubing, wire jacketing, cable jacketing, agricultural films, geomembranes, sporting equipment, cast films, blown films, profiles, boat and ship parts, tote boxes, containers, packaging, laboratory appliances, office floor mats, instrument sample holders, liquid storage containers, packaging materials, medical conduits and valves, footwear parts, sheets, tapes, carpets, adhesives, wire coverings, cables, protective apparel, automotive parts, coatings, foam laminates, overmolding articles, Automotive housings, sunshades, canvasses, leather articles, roofing articles, steering wheels, powder coatings, powder slush molding, durable consumer goods, grips, handles, hoses, hose linings, pipes, pipe linings, casters, pulleys, computer components, belts, stitching, footwear components, conveyor or timing belts, gloves, fibers, fabrics, or garments.

The presently disclosed technology provides any of the systems, methods, and/or articles described herein, wherein the Tm (melting temperature as determined by DSC) that yields the thermoplastic polyurethane is at least 120 ℃ (or even greater than 130 ℃, 140 ℃, 170 ℃, or 175 ℃ and in some embodiments, less than 200 ℃, 190 ℃, or even 180 ℃).

The presently disclosed technology provides any of the systems, methods, and/or articles described herein, wherein the weight average molecular weight Mw (determined by GPC) of the resulting thermoplastic polyurethane is less than 150,000 (or even less than 140,000, 120,000, or less than 100,000, in some embodiments greater than 30,000, 40,000, 50,000, 60,000, or even greater than 70,000).

The presently disclosed technology provides any of the systems, methods, and/or articles described herein, wherein the resulting thermoplastic polyurethane has a Mw/Mn ratio (where Mw is the weight average molecular weight and Mn is the number average molecular weight, both determined by GPC) of less than 2.7 (or even less than 2.6, less than 2.5, or less than 2.0, in some embodiments, at least 1.0, greater than 1.5, 1.7, or even greater than 1.8).

Detailed Description

Various preferred features and embodiments will now be described by way of non-limiting illustration.

The disclosed technology provides a solid freeform fabrication system for three-dimensional objects and/or articles. Methods of using such systems and articles of manufacture made using such systems and/or methods are also provided. The disclosed technology provides such systems, methods, and articles in which certain thermoplastic polyurethanes are used, more particularly thermoplastic polyurethanes derived from (a) a polyisocyanate component, (b) a polyol component, and (c) an optional chain extender component; wherein the powder has an average particle size of less than 200 microns (or even less than 150 microns or less than 100 microns, in some embodiments, at least 50 microns or even 100 microns); wherein the resulting thermoplastic polyurethane has a melting enthalpy (DSC) of at least 5.5J/g (alternatively at least 10J/g or at least 15J/g, and in some embodiments, less than 100J/g, 50J/g, or even less than 45J/g); wherein the Tc (crystallization temperature as determined by DSC) of the resulting thermoplastic polyurethane is at least above 70 ℃ (or even above 80 ℃ or above 90 ℃, in some embodiments below 150 ℃, 140 ℃, or even below 130 ℃); and wherein the resulting thermoplastic polyurethane has a Δ (Tm: Tc) (the difference between Tm and Tc of the thermoplastic polyurethane, both as determined by DSC) of from 20 to 75 degrees (or the difference is at least 20 degrees, 30 degrees, 40 degrees, 50 degrees, even 58 degrees, no more than 75 degrees, 71 degrees, even no more than 60 degrees). In some embodiments, the thermoplastic polyurethane also has (i) a Tm (melting point as determined by DSC) of at least 120 ℃ (even greater than 130 ℃, 140 ℃, 170 ℃, or 175 ℃, in some embodiments less than 200 ℃, 190 ℃, or even less than 180 ℃), (ii) a weight average molecular weight Mw (as determined by GPC) of less than 150,000 (even less than 120,000, or less than 100,000, in some embodiments greater than 30,000, 40,000, 50,000, 60,000, or even greater than 70,000), and/or (iii) a Mw/Mn value (Mw being the weight average molecular weight and Mn being the number average molecular weight, both as determined by GPC) of less than 2.7 (or even less than 2.6, less than 2.5, or less than 2.0, in some embodiments at least 1.0, greater than 1.5, 1.7, or even greater than 1.8).

Thermoplastic polyurethanes

The thermoplastic polyurethanes used in the art are derived from (a) a polyisocyanate component, (b) a polyol component, and (c) an optional chain extender component; wherein the resulting thermoplastic polyurethane meets the above parameters.

The TPU compositions described herein are made using (a) a polyisocyanate component. The polyisocyanate and/or polyisocyanate component includes one or more polyisocyanates. In some embodiments, the polyisocyanate component includes one or more diisocyanates.

In some embodiments, the polyisocyanate and/or polyisocyanate component includes an alpha, omega-alkylene diisocyanate having 5 to 20 carbon atoms.

Suitable polyisocyanates include aromatic diisocyanates, aliphatic diisocyanates, or combinations thereof. In some embodiments, the polyisocyanate component includes one or more aromatic diisocyanates. In some embodiments, the polyisocyanate component is substantially free, or even completely free, of aliphatic diisocyanates. In other embodiments, the polyisocyanate component includes one or more aliphatic diisocyanates. In some embodiments, the polyisocyanate component is substantially free, or even completely free, of aromatic diisocyanates.

Examples of useful diisocyanates include aromatic diisocyanates such as 4,4' -methylenebis (phenyl isocyanate) (MDI), m-Xylylene Diisocyanate (XDI), phenylene-1, 4-diisocyanate, naphthalene-1, 5-diisocyanate, and Toluene Diisocyanate (TDI); and aliphatic diisocyanates such as isophorone diisocyanate (IPDI), 1, 4-cyclohexyl diisocyanate (CHDI), decane-1, 10-diisocyanate, Lysine Diisocyanate (LDI), 1, 4-Butane Diisocyanate (BDI), isophorone diisocyanate (PDI), 3' -dimethyl-4, 4' -biphenylene diisocyanate (TODI), 1, 5-Naphthalene Diisocyanate (NDI), and dicyclohexylmethane-4, 4' -diisocyanate (H12 MDI). Mixtures of two or more polyisocyanates may be used. In some embodiments, the polyisocyanate is MDI and/or H12 MDI. In some embodiments, the polyisocyanate comprises MDI. In some embodiments, the polyisocyanate comprises H12 MDI.

In some embodiments, the thermoplastic polyurethane is prepared with a polyisocyanate component that includes H12 MDI. In some embodiments, the thermoplastic polyurethane is prepared with a polyisocyanate component consisting essentially of H12 MDI. In some embodiments, the thermoplastic polyurethane is prepared with a polyisocyanate component consisting of H12 MDI.

In some embodiments, the thermoplastic polyurethane is prepared using a polyisocyanate component that includes (or consists essentially of, or even consists of) H12MDI and at least one of MDI, TDI, HDI, IPDI, LDI, BDI, PDI, CHDI, TODI, and NDI.

In some embodiments, at least 50% by weight of the polyisocyanate used to make the TPU and/or TPU compositions described herein is cycloaliphatic diisocyanate. In some embodiments, the polyisocyanate comprises an alpha, omega-alkylene diisocyanate having 5 to 20 carbon atoms.

In some embodiments, the polyisocyanate used to make the TPU and/or TPU compositions described herein includes hexamethylene-1, 6-diisocyanate, 1, 12-dodecane diisocyanate, 2, 4-trimethyl-hexamethylene diisocyanate, 2,4, 4-trimethyl-hexamethylene diisocyanate, 2-methyl-1, 5-pentamethylene diisocyanate, or combinations thereof.

In some embodiments, the polyisocyanate component includes an aromatic diisocyanate. In some embodiments, the polyisocyanate component includes 4,4' -methylenebis (phenyl isocyanate).

The preparation of the TPU compositions described herein employ (b) a polyol component. The polyols include polyether polyols, polyester polyols, polycarbonate polyols, polysiloxane polyols, and combinations thereof.

Suitable polyols, which may also be described as hydroxyl terminated intermediates, if present, may include one or more hydroxyl terminated polyesters, one or more hydroxyl terminated polyethers, one or more hydroxyl terminated polycarbonates, one or more hydroxyl terminated polysiloxanes, or mixtures thereof.

Suitable hydroxyl terminated polyester intermediates include linear polyesters having a number average molecular weight (Mn) of from about 500 to about 10000, from about 700 to about 5000, or from about 700 to about 4000, and typically having an acid number of less than 1.3 or less than 0.5. The molecular weight is determined by measurement of the terminal functional group and is related to the number average molecular weight. The polyester intermediate may be produced by (1) an esterification reaction of one or more diols and one or more dicarboxylic acids or anhydrides or (2) by a transesterification reaction, i.e., a reaction of one or more diols and dicarboxylic acid esters. Generally the molar ratio of diol and acid is preferably much greater than 1, so that a linear chain with a predominant number of terminal hydroxyl groups is obtained. Suitable polyester intermediates also include various lactones such as polycaprolactone typically prepared from caprolactone and a difunctional initiator such as diethylene glycol. The dicarboxylic acids of the desired polyester may be aliphatic, cycloaliphatic, aromatic, or combinations thereof. Suitable dicarboxylic acids, which may be used alone or in admixture generally, have a total number of carbon atoms of from 4 to 15 and include: succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, dodecanedioic acid, isophthalic acid, terephthalic acid, cyclohexanedicarboxylic acid, and the like. Anhydrides of the above dicarboxylic acids such as phthalic anhydride, tetrahydrophthalic anhydride, and the like can also be used. Adipic acid is the preferred acid. The diol reacted to form the desired polyester intermediate may be aliphatic, aromatic, or combinations thereof, any of the diols including the chain extender portion described above, and have a total number of carbon atoms of from 2 to 20 or from 2 to 12. Suitable examples include ethylene glycol, 1, 2-propanediol, 1, 3-butanediol, 1, 4-butanediol, 1, 5-pentanediol, 1, 6-hexanediol, 2-dimethyl-1, 3-propanediol, 1, 4-cyclohexanedimethanol, decanediol, dodecamethylene glycol, and mixtures thereof.

The polyol component may also include one or more polycaprolactone polyester polyols. Polycaprolactone polyester polyols useful in the technology described herein include polyester diols derived from caprolactone monomers. The polycaprolactone polyester polyol is terminated by a primary hydroxyl group. Suitable polycaprolactone polyester polyols can be prepared from caprolactone and a difunctional initiator such as diethylene glycol, 1, 4-butanediol, or any of the other glycols and/or diols listed herein. In some embodiments, the polycaprolactone polyester polyol is a linear polyester diol derived from caprolactone monomers.

Useful examples include CAPA^TM2202A, a wire having a number average molecular weight (Mn) of 2000A linear polyester diol, and CAPA^TM2302A, a 3000 Mn linear polyester diol, both commercially available from Perstorp polymers. These materials can also be described as polymers of 2-oxepan and 1, 4-butanediol.

The polycaprolactone polyester polyol can be prepared from 2-oxepan and a diol, wherein the diol can be 1, 4-butanediol, diethylene glycol, monoethylene glycol, 1, 6-hexanediol, 2-dimethyl-1, 3-propanediol, or any combination thereof. In some embodiments, the diol used to prepare the polycaprolactone polyester polyol is linear. In some embodiments, the polycaprolactone polyester polyol is prepared from 1, 4-butanediol. In some embodiments, the polycaprolactone polyester polyol has a number average molecular weight of 500-.

Suitable hydroxyl terminated polyether intermediates include polyether polyols derived from diols or polyols having 2 to 15 carbon atoms, in some embodiments alkyl glycols or ethylene glycols reacted with ethers comprising alkylene oxides having 2 to 6 carbon atoms, typically ethylene oxide or propylene oxide or mixtures thereof. For example, the hydroxy-functional polyether can be prepared by first reacting propylene glycol with propylene oxide and then subsequently reacting with ethylene oxide. Primary hydroxyl groups derived from ethylene oxide are more reactive than secondary hydroxyl groups and are therefore preferred. Useful commercial polyether polyols include the ethylene oxide and ethylene glycol reaction product poly (ethylene glycol), propylene oxide and propylene glycol reaction product poly (propylene glycol), water and tetrahydrofuran reaction product poly (tetramethylene ether glycol), which may also be described as polytetrahydrofuran, commonly referred to as PTMEG. In some embodiments, the polyether intermediate comprises PTMEG. Suitable polyether polyols also include polyamide adducts of alkylene oxides and may include, for example, ethylenediamine adducts comprising the reaction product of ethylenediamine and propylene oxide, diethylenetriamine adducts comprising the reaction product of diethylenetriamine and propylene oxide, and similar polyamide type polyether polyols. Copolyethers may also be used in the compositions. Typical copolyethers include the reaction product of tetrahydrofuran with ethylene oxide or tetrahydrofuran with propylene oxide. TheseAre available from BASF under the trade name ofB-a block copolymer, and Poly

R-a random copolymer. The number average molecular weight (Mn) of the various polyether intermediates is generally determined by analysis of the terminal functional groups and has an average molecular weight of greater than about 700, such as from about 700 to about 10,000, from about 1,000 to about 5,000, or from about 1,000 to about 2,500. In some embodiments, the polyether intermediate comprises a blend of two or more different molecular weight polyethers, such as M_nIs 2,000 and M_nA PTMEG blend of 1,000.

Suitable hydroxyl terminated polycarbonates include those prepared by reacting a diol with a carbonate. U.S. Pat. No.4,131,731, which discloses hydroxyl terminated polycarbonates and their preparation, is incorporated herein by reference. Such polycarbonates are linear, have terminal hydroxyl groups, and are substantially free of other terminal groups. The basic raw materials are dihydric alcohol and carbonate. Suitable diols are selected from cycloaliphatic and aliphatic diols containing 4 to 40 carbon atoms, and or even 4 to 12 carbon atoms, and from polyoxyalkylene glycols containing 2 to 20 alkoxy groups per molecule, each alkoxy group containing 2 to 4 carbon atoms. Suitable diols include aliphatic diols having from 4 to 12 carbon atoms, such as 1, 4-butanediol, 1, 5-pentanediol, neopentyl glycol, 1, 6-hexanediol, 2, 4-trimethyl-1, 6-hexanediol, 1, 10-decanediol, hydrogenated dioleyl diol, 3-methyl-1, 5-pentanediol; and alicyclic diols such as 1, 3-cyclohexanediol, 1, 4-dimethylolcyclohexane, 1, 4-cyclohexanediol, 1, 3-dimethylolcyclohexane, 1, 4-methano-2-hydroxy-5-hydroxymethylcyclohexane and polyalkylene glycols. The diol used in the reaction may be a single diol or a mixture of diols depending on the desired properties of the finished product. The hydroxyl terminated polycarbonate intermediates are generally those known in the art and in the literature. Suitable carbonates are selected from alkylene carbonates comprising five to seven membered rings. Suitable carbonates for use herein include ethylene carbonate, trimethylene carbonate, tetramethylene carbonate, 1, 2-propylene carbonate, 1, 2-butylene carbonate, 2, 3-butylene carbonate, 1, 2-ethylene carbonate, 1, 3-pentylene carbonate, 1, 4-pentylene carbonate, 2, 3-pentylene carbonate, and 2, 4-pentylene carbonate. Also suitable here are dialkyl carbonates, cycloaliphatic carbonates and diaryl carbonates. The dialkyl carbonate may have 2 to 5 carbon atoms per alkyl group, and specific examples thereof are diethyl carbonate and dipropyl carbonate. Cycloaliphatic carbonates, particularly di-cycloaliphatic carbonates, may contain from 4 to 7 carbon atoms in each ring structure, and there may be one or two such structures. When one group is cycloaliphatic, the other may be alkyl or aryl. On the other hand, if one group is an aryl group, the other may be an alkyl or alicyclic group. Examples of suitable diaryl carbonates, which may contain 6 to 20 carbon atoms per aryl group, are diphenyl carbonate, ditolyl carbonate and dinaphthyl carbonate.

Suitable polysiloxane polyols include alpha-omega-hydroxy or amine or carboxylic acid or mercapto or epoxy terminated polysiloxanes. Examples include poly (dimethylsiloxane) terminated with hydroxyl or amine or carboxylic acid or mercapto or epoxy groups. In some embodiments, the polysiloxane polyol is a hydroxyl terminated polysiloxane. In some embodiments, the polysiloxane polyol has a number average molecular weight of 300-5,000, or 400-3,000.

Polysiloxane polyols can be obtained by introducing alcoholic hydroxyl groups onto the polysiloxane backbone by a dehydrogenation reaction between a polysiloxane hydride and an aliphatic polyol or polyoxyalkylene alcohol.

In some embodiments, the polysiloxane may be represented by one or more compounds having the formula:

wherein: r¹And R²Each is independently an alkyl group having 1 to 4 carbon atoms, a benzyl group, or a phenyl group; each E is OH or NHR³Wherein R is³Is hydrogen, alkyl of 1 to 6 carbon atoms, or cycloalkyl of 5 to 8 carbon atoms; a and b are each independently an integer of 2 to 8; c is an integer of 3 to 50. In the amino-containing polysiloxane, at least one E group is NHR³. In the hydroxyl-containing polysiloxanes, at least one E group is OH. In some embodiments, R¹And R²Are both methyl groups.

Suitable examples include alpha-omega-hydroxypropyl terminated poly (dimethylsiloxane) and alpha-omega-aminopropyl terminated poly (dimethylsiloxane), both of which are commercially available materials. Further examples include copolymers of poly (dimethylsiloxane) materials with poly (alkylene oxides).

The polyol component, if present, comprises a poly (ethylene glycol), a poly (tetramethylene ether glycol), a poly (propylene oxide), an ethylene oxide-capped poly (propylene glycol), a poly (butylene adipate), a poly (ethylene adipate), a poly (hexamethylene adipate), a poly (tetramethylene-co-hexamethylene adipate), a poly (3-methyl-1, 5-pentamethylene adipate), a polycaprolactone diol, a poly (hexamethylene carbonate) diol, a poly (pentamethylene carbonate) diol, a poly (trimethylene carbonate) diol, a dimer fatty acid-based polyester polyol, a vegetable oil-based polyol, or any combination thereof.

Examples of dimer fatty acids that may be used to prepare suitable polyester polyols include the priplast commercially available from Croda^TMPolyester diols/polyols and Oleon are commercially available

A polyester diol.

In some embodiments, the polyol component includes a polyether polyol, a polycarbonate polyol, a polycaprolactone polyol, or any combination thereof.

In some embodiments, the polyol component includes a polyether polyol. In some embodiments, the polyol component is substantially free or even completely free of polyester polyols. In some embodiments, the polyol component used to make the TPU is substantially free, or even completely free, of polysiloxane.

In some embodiments, the polyol component includes ethylene oxide, propylene oxide, butylene oxide, styrene oxide, poly (tetramethylene ether glycol), poly (propylene glycol), poly (ethylene glycol), copolymers of poly (ethylene glycol) and poly (propylene glycol), epichlorohydrin, and the like, or combinations thereof. In some embodiments, the polyol component includes poly (tetramethylene ether glycol).

In some embodiments, the polyol has a number average molecular weight of at least 900. In other embodiments, the polyol has a number average molecular weight of at least 900, 1,000, 1,500, 1,750 and/or a number average molecular weight of up to 5,000, 4,000, 3,000, 2,500, or even 2,000.

In some embodiments, the polyol component includes a polycaprolactone polyester polyether polyol, a polycaprolactone polyester polyether copolymer polyol, a polyester polyol, or any combination thereof.

In some embodiments, the polyol component comprises a polycaprolactone polyester polyether polyol, a poly (tetramethylene ether glycol), a polycaprolactone polyester poly (tetramethylene ether glycol) copolymer polyol, polybutylene adipate, polybutylene glycol-hexanediol adipate (an adipate made from 1, 4-butanediol and 1, 6-hexanediol), or any combination thereof. In some embodiments, the polyol component includes a polycaprolactone polyester poly (tetramethylene ether glycol) copolymer polyol.

The TPU compositions described herein are prepared using (c) a chain extender component. Chain extenders include diols, diamines, and combinations thereof.

Suitable chain extenders include relatively small polyols, such as lower aliphatic or short chain diols, having a carbon number of from 2 to 20, or from 2 to 12, or from 2 to 10. Suitable examples include ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, 1, 4-Butanediol (BDO), 1, 6-Hexanediol (HDO), 1, 3-butanediol, 1, 5-pentanediol, neopentyl glycol, 1, 4-Cyclohexanedimethanol (CHDM), 2-bis [4- (2-hydroxyethoxy) phenyl ] propane (HEPP), hexamethylene glycol, heptanediol, nonanediol, dodecanediol, 3-methyl-1, 5-pentanediol, ethylenediamine, butanediamine, hexanediamine, Hydroxyethylresorcinol (HER), and the like, and mixtures thereof. In some embodiments, the chain extender comprises BDO, HDO, 3-methyl-1, 5-pentanediol, or a combination thereof. In some embodiments, the chain extender comprises BDO. Other glycols, such as aromatic glycols, may be used, but in some embodiments, the TPUs described herein are substantially unused, or even completely unused, of such materials.

In some embodiments, the chain extender used to make the TPU is substantially free of, or even completely free of, 1, 6-hexanediol. In some embodiments, a cyclic chain extender is included for preparing TUPs. Suitable examples include CHDM, HEPP, HER, and combinations thereof. In some embodiments, the chain extender used to make the TPU includes an aromatic cyclic chain extender, such as HEPP, HER, or a combination thereof. In some embodiments, the chain extender used to prepare TUP includes an aliphatic cyclic chain extender, for example, CHDM. In some embodiments, the chain extender used to prepare the TUP is substantially free, or even completely free, of aromatic chain extenders, e.g., aromatic cyclic chain extenders. In some embodiments, the chain extender used to make the TPU is substantially free, or even completely free, of the polysiloxane.

In some embodiments, the chain extender component comprises 1, 4-butanediol, 2-ethyl-1, 3-hexanediol, 2, 4-trimethylpentane-1, 3-diol, 1, 6-hexanediol, 1, 4-cyclohexanedimethanol, 1, 3-propanediol, 3-methyl-1, 5-pentanediol or combinations thereof. In some embodiments, the chain extender component includes 1, 4-butanediol, 3-methyl-1, 5-pentanediol, or a combination thereof. In some embodiments, the chain extender component includes 1, 4-butanediol.

In some embodiments, the chain extender component comprises a linear alkylene glycol. In some embodiments, the chain extender component includes 1, 4-butanediol, dipropylene glycol, or a combination of both. In some embodiments, the chain extender component includes 1, 4-butanediol.

In some embodiments, the molar ratio of chain extender to polyol is greater than 1.5. In other embodiments, the molar ratio of chain extender to polyol is at least (or greater than) 1.5, 2.0, 3.5, 3.7, and even 3.8 and/or the molar ratio of chain extender to polyol can be raised to 5.0, or even 4.0.

The thermoplastic polyurethanes described herein may also be considered as Thermoplastic Polyurethane (TPU) compositions. In such embodiments, the composition may comprise one or more TPUs. These TPUs are prepared by a) the polyisocyanate components described above; b) the above polyol component; and c) the chain extender component described above, wherein the reaction can be carried out in the presence of a catalyst. At least one of the TPUs in the composition must meet the parameters described above that make it suitable for solid freeform fabrication, particularly fused deposition modeling.

The reaction can be carried out in a process without undue restriction both as regards batch and continuous processing. In some embodiments, the technology relates to batch processing of aliphatic TPUs. In some embodiments, the technology relates to the continuous processing of aliphatic TPUs.

The compositions include the TPU materials described above, and also include TPU compositions that include such TPU materials and one or more additional components. These additional components include other polymeric materials that may be blended with the TPU. These additional components include one or more additives that may be added to the TPU, or blends containing the TPU, to affect the properties of the composition.

The TPU described herein may also be blended with one or more other polymers. The polymers that can be blended with the TPU are not overly limited. In some embodiments, the composition comprises two or more of the TPU materials. In some embodiments, the composition includes at least one of the TPU) materials and at least one other polymer that is not one of the TPU materials.

Polymers useful in combination with the TPU materials also include more traditional TPU materials such as non-caprolactone polyester based TPU, polyether based TPU, or TPU containing both non-caprolactone polyester and polyether groups. Other suitable materials that may be blended with the TPU material include polycarbonate, polyolefins, styrene polymers, acrylic polymers, polyoxymethylene polymers, polyamides, polyphenylene oxide, polyphenylene sulfide, polyvinyl chloride, chlorinated polyvinyl chloride, polylactic acid, or combinations thereof.

For the blendingSuitable examples include (i) Polyolefins (PO), such as Polyethylene (PE), polypropylene (PP), polybutylene, Ethylene Propylene Rubber (EPR), Polyoxyethylene (POE), Cyclic Olefin Copolymers (COC), or combinations thereof, (ii) styrenes, such as Polystyrene (PS), acrylonitrile butadiene styrene copolymer (ABS), styrene acrylonitrile copolymer (SAN), styrene butadiene rubber (SBR or HIPS), poly α methylstyrene, styrene-maleic anhydride copolymer (SMA), styrene-butadiene copolymers (SBC), such as styrene-butadiene-styrene copolymer (SBS) and styrene-ethylene/butadiene-styrene copolymer (SEBS), styrene-ethylene/propylene-styrene copolymer (SEPS), styrene-butadiene latex (SBL), Ethylene Propylene Diene Monomer (EPDM) modified SAN and/or acrylic elastomers (e.g., PS-SBR copolymers), or combinations thereof, (iii) Thermoplastic Polyurethanes (TPU) other than the above, (iv) polyamides, such as Nylon^TMComprising polyamide 6,6(PA66), polyamide 1,1(PA11), polyamide 1,2(PA12), a Copolyamide (COPA), or a combination thereof; (v) acrylic polymers such as polymethacrylate, polymethylmethacrylate, methylmethacrylate styrene copolymer (MS), or combinations thereof; (vi) polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), or combinations thereof; (vii) polyoxymethylene, such as polyacetal; (viii) polyesters, such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), copolyesters, and/or polyester elastomers (COPE), including polyetherester block copolymers, such as glycol-modified polyethylene terephthalate (PETG), polylactic acid (PLA), polyglycolic acid (PGA), copolymers of PLA and PGA, or combinations thereof; (ix) polycarbonate (PC), polyphenylene sulfide (PPS), polyphenylene oxide (PPO), or combinations thereof; or a combination thereof.

In some embodiments, these blends include one or more additional polymeric materials selected from groups (i), (iii), (vii), (viii), or some combination thereof. In some embodiments, the blends include one or more additional polymeric materials selected from group (i). In some embodiments, these blends include one or more additional polymeric materials selected from group (iii). In some embodiments, these blends comprise one or more additional polymeric materials selected from group (vii). In some embodiments, these blends comprise one or more additional polymeric materials selected from group (viii).

Additional additives suitable for use in the TPU composition are not overly limited. Suitable additives include pigments, ultraviolet light stabilizers, ultraviolet light absorbers, antioxidants, lubricants, heat stabilizers, hydrolytic stabilizers, crosslinking activators, flame retardants, layered silicates, fillers, colorants, reinforcing agents, adhesion media, impact strength modifiers, antimicrobial agents, and any combination thereof.

In some embodiments, the additional component is a flame retardant. Suitable flame retardants are not overly limited and can include boron phosphate flame retardants, magnesium oxide, dipentaerythritol, Polytetrafluoroethylene (PTFE) polymers, or any combination thereof. In some embodiments, the flame retardant comprises a boron phosphate flame retardant, magnesium oxide, dipentaerythritol, or any combination thereof. An example of a suitable boron phosphate flame retardant is BUDIT326 commercially available from Budenheim USA, Inc. The flame retardant component, if present, comprises from 0% to 10%, and in other embodiments, from 0.5% to 10%, or from 1% to 10%, or from 0.5% or 1% to 5%, or from 0.5% to 3%, or even from 1% to 3% by weight of the entire TPU composition.

The TPU compositions described herein may also include additional additives, which may be referred to as stabilizers. The stabilizers may include antioxidants such as phenolic, phosphite, thioester, and amine antioxidants, light stabilizers such as hindered amine light stabilizers and benzothiazole ultraviolet light absorbers, and other processing stabilizers and combinations thereof. In one embodiment, the preferred stabilizers are Irganox 1010 from BASF and Naugard 445 from Chemtura. The stabilizer is used in an amount from about 0.1 to about 5 weight percent, in another embodiment from about 0.1 to about 3 weight percent, and in another embodiment from about 0.5 to about 1.5 weight percent of the TPU composition.

In addition, various conventional inorganic flame retardant components may be used in the TPU composition. Suitable inorganic flame retardants include any of those known to those skilled in the art, such as metal oxides, hydrates of metal oxides, metal carbonates, ammonium phosphate, ammonium polyphosphate, calcium carbonate, antimony oxide, clays, mineral clays including talc, kaolin, wollastonite, nanoclays, montmorillonite clays commonly known as nanoclays, and mixtures thereof. In one embodiment, the flame retardant package includes talc powder. The talc powder in the flame retardant package enhances the performance of high Limiting Oxygen Index (LOI). The inorganic flame retardant may be used in an amount of from 0 wt% to about 30 wt%, from about 0.1 wt% to 20 wt%, and in another embodiment, from about 0.5 wt% to about 15 wt%, based on the total weight of the TPU.

Other additives may also optionally be used in the TPU composition. Additives include colorants, antioxidants (including phenols, phosphites, thioesters, and/or amines), antiozonants, stabilizers, inert fillers, lubricants, inhibitors, hydrolysis stabilizers, light stabilizers, hindered amine light stabilizers, benzothiazole ultraviolet light absorbers, heat stabilizers, discoloration prevention stabilizers, dyes, pigments, organic and inorganic fillers, reinforcing agents, and combinations thereof.

All of the above additives may be used in amounts customary for such materials. The non-flame retardant additive may be used in an amount of from about 0 weight percent to about 30 weight percent, in one embodiment from about 0.1 weight percent to about 25 weight percent, and in another embodiment from about 0.1 weight percent to 20 weight percent, based on the total weight of the TPU composition.

These additional additives may be introduced into the reaction mixture components or reaction mixture to make the TPU resin, or after making the TPU resin. In another process, all of the materials may be mixed with the TPU resin and then melted, or may be introduced directly into the TPU resin melt.

The above TPU material can be prepared by a process comprising the step (I): reacting the following reactants: (a) the polyisocyanate component described above; b) the polyol component described above; and (c) the chain extender described above, wherein the reaction can be carried out in the presence of a catalyst, resulting in a thermoplastic polyurethane composition.

The method may further comprise step (II): mixing the TPU composition of step (I) with one or more blend components, including one or more additional TPU materials and/or polymers, including any of those described above.

The method may further comprise step (II): mixing the TPU composition of step (I) with one or more of the additional additives described above.

The method may further comprise the steps of: (II) mixing the TPU composition of step (I) with one or more blend components, including one or more additional TPU materials and/or polymers, including any of those described above, and/or the steps of: (III) mixing the TPU of step (I) with one or more of the above-mentioned additives.

While not wishing to be bound by theory, it is believed that any TPU meeting the requirements will be more suitable for free-form fabrication, particularly selective laser sintering, than any TPU that does not meet. While not wishing to be bound by theory, it is believed that the necessary parameters are: (i) a melting enthalpy (as determined by DSC) of at least 5.5J/g (or even at least 10J/g or at least 15J/g, and in some embodiments less than 100J/g, 50J/g, 40J/g, and even less than 20J/g), although it is noted that while not wishing to be bound by theory, higher melting enthalpies are considered more suitable for this application, and there may not be a true maximum melting enthalpy, but if one wants to limit the melting enthalpy due to practical considerations and/or the properties of the ready-made material, the maximum provided above can be used in some embodiments); (ii) tc (crystallization temperature as determined by DSC) is at least above 70 ℃ (or even above 80 ℃ or above 90 ℃, in some embodiments below 150 ℃, 140 ℃, or even 130 ℃); and (iii) Δ (Δ (Tm: Tc)) (the difference between Tm and Tc of the TPU, both as determined by DSC) is from 20 to 75 degrees (or the difference is at least 20 degrees, 30 degrees, 40 degrees, 50 degrees, even 58 degrees, not more than 75 degrees, 71 degrees, even 60 degrees). The physical properties of the TPU powder are also important, and it is believed that the average particle size of the powder should be less than 200 microns (or even less than 150 microns or less than 100 microns). The combination of these parameters is believed to make the TPU well suited for free-form manufacturing, particularly selective laser sintering.

Furthermore, at least in some embodiments, the following parameters are also considered important: the resulting thermoplastic polyurethane (i) has a Tm (melting point as determined by DSC) of at least 120 ℃ (even greater than 130 ℃, 140 ℃, 170 ℃ or 175 ℃, in some embodiments less than 200 ℃, 190 ℃, or even 180 ℃), (ii) has a weight average molecular weight Mw (as determined by GPC) of less than 150,000 (even less than 120,000, or less than 100,000, in some embodiments greater than 30,000, 40,000, 50,000, 60,000, or even more than 70,000), and/or (iii) has a Mw/Mn ratio (where Mw is the weight average molecular weight and Mn is the number average molecular weight, both as determined by GPC) of less than 2.7 (even less than 2.6, less than 2.5, or less than 2.0, and in some embodiments, at least 1.0, greater than 1.5, 1.7, or even more than 1.8.

System and method

Solid freeform fabrication systems, particularly selective laser sintering systems and methods for using them in the described techniques, are not overly limited. Notably, the technology provides certain thermoplastic polyurethanes that are more suitable than others for solid freeform systems, particularly selective laser sintering systems, and the relative benefits of the technology are key. It is noteworthy that some solid freeform fabrication systems, including some selective laser sintering systems, may be more suitable for processing certain materials, including thermoplastic polyurethanes, due to their equipment configuration, process parameters, and the like. However, the technical focus described herein is not on the details of the solid freeform fabrication system, including some of the details of the selective laser sintering system, but rather highlights the provision of certain thermoplastic polyurethanes that are generally more suitable for solid freeform fabrication systems, and in particular selective laser sintering systems in general.

Selective laser sintering is an example of a freeform fabrication technique that includes the processes shown in the system provided by 3D Systems, inc, in which articles are produced in a layered fashion from laser-meltable powders. In some embodiments, selective laser sintering involves the use of powders that are laid down in thin layers and then melted, or sintered by directing laser energy at those portions of the powder that correspond to the cross-section of the article. Conventional selective laser sintering Systems, such as the Vanguard system available from 3D Systems, perform laser beam positioning via galvanometer driven laser beam deflection mirrors. The control of the deflection of the laser beam, in combination with the modulation of the laser itself, directs the laser energy at those locations in the layer of meltable powder that correspond to the cross-section of the article to be formed. The computer-based control system can be programmed with boundary information that is required to indicate a plurality of cross-sections of the part to be produced. The laser may be scanned across the powder in a raster fashion, with modulation of the laser being effected in conjunction therewith, or the laser may be directed in a vector fashion. In some applications, the article cross-section is shaped in a powder layer by fusing the powder in a vector fashion along the outline of the cross-section, either before or after a vector scan that "fills" the area within the vector drawn outline. In any case, after selective fusing of a given layer of powder, additional layers of powder are then laid down and repeated, with the fused portions of the following layers fusing the fused portions of the preceding layers (as appropriate for the article) until the article is completed.

Patents that may be found to describe the selective laser sintering technique in detail are U.S. patent No.4,863,538, U.S. patent No.5,132,143, and U.S. patent No.4,944,817, all assigned to the committee of the university of texas system, and U.S. patent No.4,247,508 to householder, all of which are incorporated herein by reference.

Selective laser sintering techniques allow the direct fabrication of high resolution and dimensional accuracy articles from a variety of materials, including polystyrene, some nylons, other plastics, and composite materials such as polymer coated metals and ceramics. Polystyrene parts can be used to produce tools by the well-known "lost wax" process. Alternatively, selective laser sintering may be used to directly fabricate molds, based on the CAD database of the object to be formed in the fabrication mold, in which case the computer operation will "invert" the CAD database of the object to be formed to directly form the negative mold from the powder. Using the disclosed technology, the TPU materials can now be used continuously as well in selective laser sintering technology.

In some embodiments, the laser sintering system employs a dual piston-cylinder feed system, which includes counter-rotating drums, and infrared sensors or pyrometers that measure the thermal conditions of the process chamber and the powder bed.

In some embodiments, the thermoplastic polyurethane used in the technology is in the form of a powder, which has the following characteristics: the d50 particle size distribution is 20-100 microns, preferably 30-70 microns, and satisfies the following equation: (d90-d10)/d50 is 0.85-1.2; the sphericity coefficient is from 0.8 to 1, preferably from 0.85 to 1; and the intra-granular porosity is lower than 0.05ml/g, preferably lower than 0.02 ml/g. As used herein, powder refers to a collection of powder particles.

The particle size distribution of the object can be obtained by laser diffraction measurements on a Malvern particle sizer with a wet module. The numbers used in this document refer to d10, d50, and d 90. The d10 mesh is the size where 10% of the particles are smaller and 90% are larger. The d50 mesh is the size where 50% of the particles are smaller and 50% are larger. The d90 mesh is the size where 90% of the particles are smaller and 10% are larger.

The sphericity index may be measured as follows: to quantify the sphericity of the object, image analysis is employed in the following manner. The characteristic wavelengths of the small and large diameters of each object were measured for at least 100 objects. For each object, the sphericity index is defined as the ratio of the minor diameter to the major diameter. For a perfect sphere, the ratio is 1. For particles with variable morphology, this ratio is lower and tends towards 1 when approaching perfect sphericity. For 100 collected subjects, the sphericity index is calculated from the diameter ratio, and then the average sphericity index is calculated. To do this, in a known manner, a sample of the particles is dispersed on a glass slide placed under an optical microscope and the characteristic length is continuously recorded.

The internal porosity of the particles can be measured as follows: the porous structure of the object was determined by mercury intrusion using an Autopore IV instrument from Micromeritics. The method is based on the intrusion of mercury into the inter-particle and intra-particle pore networks. This intrusion is controlled by increasing the pressure. The powder of the invention may have an intra-particle porosity of less than 0.05ml/g and a pore size of 0.01 to 1 micron.

The flowability of the powder can be measured by shearing a sample using a ring shear tester (sold by d. The powder can be pre-sheared with a vertical stress corresponding to a mass of 4.3 kg on a 81 square centimeter area unit. The flowability of powders is a technical concept and is also well known to the person skilled in the art; further details can be found, inter alia, in the literature: "Standard shear test methods for solid particles using Jenike shear units" is published in "The institute of chemical Engineers",1989(ISBN: 0852952325).

The packing density can be measured as follows: the powder was poured into a 250 ml glass measuring cylinder weighed beforehand. And leveling the top of the measuring cylinder. The weighed measuring cylinder is placed on a volume meter, and the scale of the measuring cylinder corresponding to the horizontal plane of the powder bed is read after the measuring cylinder is knocked 2048. The test conforms to the test described in the 1997 edition of the european pharmacopoeia.

The powders of the invention can be obtained in various ways known to those skilled in the art, depending on the materials used. Mention may be made in particular, for example, of two documents EP1797141 and WO 2007/115977.

In some embodiments, the materials used in the presently disclosed technology are free of polyamides and related materials, including but not limited to nylon 6, nylon 6-6, nylon 11, nylon 12, nylon 4-6, nylon 6-10, nylon 6-12, nylon 12-12, nylon 6-36; semi-aromatic polyamides, such as polyphthalamides obtained from terephthalic or isophthalic acid, such as the polyamides sold under the trade name AMODE, and copolymers and alloys thereof.

In some embodiments, the powder may have (i) an intra-particle porosity of less than 0.05ml/g, or less than 0.02ml/g, particularly for particles having a pore size of 0.01 or more nanometers; (ii) sphericity index from 0.8 to 1, and from 0.85 to 1, or even from 0.9 to 1; (iii) the fluidity is between 30 and 60; and/or (iv) an apparent density of 500-700g/L and a packing density of 550-800 g/L.

Selective melt production of layers is a method of manufacturing an article that includes depositing layers of material in powder form, selectively melting a portion or area of a layer, depositing a new layer of powder, and re-melting a portion of the layer, and continuing in this manner until the desired object is obtained. The selectivity of the portion of the layer to be melted is obtained, for example, by using absorbers, inhibitors, barrier films, or by focused energy input, such as a laser or electromagnetic beam. Sintering by means of additive layers, in particular by means of laser sintering rapid prototyping techniques, is preferred. Rapid prototyping is a process for obtaining parts of complex shape, without tools and without machining, from only a three-dimensional image of the article to be produced, by superimposing layers of powder by sintering using a laser. General information on rapid prototyping by laser sintering is provided in U.S. Pat. No.6,136,948 and in WO96/06881 and US20040138363 applications.

The machine for carrying out these methods may include a build chamber above the production piston, two powder-fed pistons around its left and right sides, a laser, and a powder-laying tool, such as a roller. The chamber is typically maintained at a constant temperature to avoid deformation.

Other production methods by powder layer addition are also suitable, such as those described in WO 01/38061 and EP 1015214. Both methods use infrared heating to melt the powder. The first way to obtain selectivity of the molten part is by using inhibitors and the second way is by using shielding. A further method is described in the application DE 10311438. In this process, the energy for melting the polymer is supplied by a microwave generator, optionally by using a susceptor. The disclosed technology also provides for the use of the thermoplastic polyurethanes in the systems and methods, as well as articles made therefrom.

Article of manufacture

The systems and methods described herein can utilize the thermoplastic polyurethanes described herein to produce various objects and/or articles. Objects and/or articles produced by the disclosed techniques are not overly limited.

In some embodiments, the objects and/or articles include cooking and storage appliances, furniture, automotive parts, toys, sportswear, medical equipment, personalized medical articles, replicated medical implants, dental articles, disinfection containers, drapes, gowns, filters, hygiene articles, diapers, films, sheets, tubing, pipe, wire jacketing, cable jacketing, agricultural film, geomembranes, sports equipment, cast film, blown film, profiles, boat and marine parts, tote, containers, packaging, laboratory appliances, office floor mats, instrument sample holders, liquid storage containers, packaging materials, medical conduits and valves, footwear parts, sheets, tapes, carpets, adhesives, wire coverings, cables, protective apparel, automotive parts, coatings, foam laminates, overmolded articles, automotive skins, sunshades, canvass, medical devices, films, sheets, tubing, wire jacketing, electrical wiring, and tubing, and/or other articles, Leather articles, roofing articles, steering wheels, powder coatings, powder slush molding, durable consumer goods, grips, handles, hoses, hose linings, pipes, pipe linings, casters, pulleys, computer components, belts, sewing, components of footwear, conveyor belts or synchronous belts, gloves, fibers, fabrics, or garments.

Additional articles that may be used with the present invention include jewelry, custom-made held milkshakes, and/or collectibles, including but not limited to coins, medallions, photo frames and rims, spectacle frames, keys, cups, mug, miniature models and models, wrist bands, actions of personalized characters, and the like.

As with all additive production, such techniques are of particular value in producing articles that may be part of rapid prototyping and new product development, as part of the fabrication of custom and/or disposable parts, or similar applications where mass production of articles in large quantities is unnecessary and/or impractical.

More generally, the compositions of the present invention, including any blends thereof, may be used in a variety of applications, including transparent articles such as cooking and storage vessels, and in other articles such as automotive parts, sterilizable medical devices, fibers, fabrics, nonwovens, oriented films, and other such articles. The compositions are useful in automotive parts such as bumpers and the like, grilles, trim parts, fenders and dashboards, exterior door and hood components, spoilers, windshields, hubcaps, rearview mirror housings, body panels, side protective trim, and other interior and exterior components associated with automobiles, trucks, boats, and other vehicles.

Other useful articles and articles that can be formed from the compositions of the present invention include: laboratory vessels such as roller bottles, medium bottles for growth of culture, instrument sample windows; liquid storage containers such as bags, bags and bottles for intravenous blood and transfusion; packaging material, packaging material for any medical device and single dose pharmaceutical or other blister or blister packaging, and packaging material for packaging and containing food products preserved by irradiation. Other useful items include medical tubing and valves for any medical device, including infusion bags, catheters and respiratory therapies, and including packaging materials for packaging medical devices or trays of irradiated food and packaging storage liquids, particularly water, milk or fruit juices, containers including single-serve and bulk storage containers, and delivery facilities such as tubing, hoses, tubing, and the like, including liners and jackets therefor. In some embodiments, the inventive article is a fire hose comprising a liner made from the TPU composition. In some embodiments, the lining is a layer applied to a jacket of a fire hose lining.

More useful uses and articles include: an automotive article includes an airbag cover, an automotive interior surface; biomedical devices include implantable devices, pacemaker leads, artificial hearts, heart valves, stent sleeves, artificial tendons, arteries and veins, implants containing pharmaceutically active agents, medical bags, medical tubing, drug delivery devices such as vaginal rings, and bioabsorbable implants; footwear related articles include uppers and soles, where the sole includes an insole, midsole and outsole, adhesive systems connecting any of the components, other footwear components include adhesives and fabric coatings, cleats, membranes, air bags, capsules or fluid bladders, inflated or inflatable inserts, laminate inserts, cushioning devices, microsphere-made soles, high-heeled shoes, embedded sole wheels, inflatable tongues, woven and non-woven fabrics, odor and moisture absorbing pads, pressurized ankle collars, eyelets and laces, orthoses or inserts, gel pads, elastic pads, barrier films and fabrics, and artificial leather; golf ball related articles that enclose 2 and 3 golf balls include a cover and a core.

Of particular importance are personalized medical articles, such as orthoses, implants, bones, blood vessels, dental items, etc., which are customized to the patient. For example, portions of bone and/or implants may be prepared using the systems and methods described above, with implants designed for a particular patient.

The amounts of the chemical components recited, excluding any solvents or diluent oils, may be generally present in commercially available materials, i.e., they are based on the active chemical, unless otherwise specified. However, unless otherwise indicated, each chemical or composition referred to herein should be construed as being a commercial grade material which may contain isomers, by-products, derivatives and other materials which are normally understood to be present in the commercial grade.

It is well known that some of the above materials may interact in the final formulation, such that the components of the final formulation may differ from those initially added. For example, metal ions (e.g., in flame retardants) can migrate to other acidic or anionic sites of other molecules. Products formed thereby, including products formed using compositions of the technology described herein for their intended use, may not be readily described in a well understood manner. However, all such variations and reaction products are included within the scope of the technology described herein; the technology described herein includes compositions prepared by incorporating the above ingredients.