Three-Dimensional Printing Processes Using 1,1-Di-Activated Vinyl Compounds

Abstract

A process for producing an article by three-dimensional printing includes applying a 1,1-di-activated vinyl compound-containing liquid binder over a predetermined area of a layer of solid particles. The liquid binder infiltrates gaps between the solid particles to form a first cross-sectional layer of an article, and the 1,1-di-activated vinyl compound reacts to solidify the liquid binder and bind the solid particles in the first cross-sectional layer of the article. Also provided is an article produced by the three-dimensional printing process, set forth herein.

1 - 25 . (canceled) 
     
     
         26 . A three-dimensional article comprising:
 a plurality of cross-sectional layers bonded together, each cross-sectional layer comprising:
 a solid binder comprising a reaction product of a 1,1-di-activated vinyl compound, or a multifunctional form thereof, or a combination thereof; and 
 a plurality of solid particles in the solid binder, wherein the solid particles comprise an activator compound chemically and/or physically absorbed onto surfaces of the solid particles. 
   
     
     
         27 . The three-dimensional article of  claim 26 , wherein the solid binder comprises a polymerization reaction product of the 1,1-di-activated vinyl compound, or multifunctional form thereof, or combination thereof. 
     
     
         28 . The three-dimensional article of  claim 27 , wherein the solid particles comprise inorganic particles. 
     
     
         29 . The three-dimensional article of  claim 28 , wherein the solid particles comprise titanium dioxide, zirconium dioxide, zinc oxide, magnesium oxide, an iron oxide, a chromium oxide, silicon dioxide, an aluminum oxide, a metal, an alloy, or a glass, or a combination of any thereof. 
     
     
         30 . The three-dimensional article of  claim 29 , wherein the solid particles comprise glass particles. 
     
     
         31 . The three-dimensional article of  claim 29 , wherein the solid particles comprise silica. 
     
     
         32 . The three-dimensional article of  claim 26 , wherein the solid particles comprise organic particles. 
     
     
         33 . The three-dimensional article of  claim 32 , wherein the solid particles comprise thermoplastic particles. 
     
     
         34 . (canceled) 
     
     
         35 . The three-dimensional article of  claim 26 , wherein the activator compound comprises an amine compound. 
     
     
         36 . The three-dimensional article of  claim 35  wherein the activator compound comprises an aminosilane compound. 
     
     
         37 . The three-dimensional article of  claim 26 , wherein the 1,1-di-activated vinyl compound comprises a methylene dicarbonyl compound, a dihalo vinyl compound, a dihaloalkyl disubstituted vinyl compound, or a cyanoacrylate compound, or a multifunctional form of any thereof, or a combination of any thereof. 
     
     
         38 . The three-dimensional article of  claim 37 , wherein the 1,1-di-activated vinyl compound comprises:
 a dialkyl methylene malonate;   a diaryl methylene malonate;   a multifunctional form of a dialkyl methylene malonate; or   a multifunctional form of a diaryl methylene malonate; or   a combination of any thereof.   
     
     
         39 . The three-dimensional article of  claim 38 , wherein the 1,1-di-activated vinyl compound comprises:
 diethyl methylene malonate;   a multifunctional form of diethyl methylene malonate comprising a transesterification adduct of diethyl methylene malonate and at least one polyol;   dimethyl methylene malonate; or   a multifunctional form of dimethyl methylene malonate comprising a transesterification adduct of dimethyl methylene malonate and at least one polyol; or   a combination of any thereof.   
     
     
         40 . The three-dimensional article of  claim 39 , wherein the 1,1-di-activated vinyl compound comprises a transesterification adduct of diethyl methylene malonate and a diol. 
     
     
         41 . The three-dimensional article of  claim 40 , wherein the diol comprises an alkane diol. 
     
     
         42 . The three-dimensional article of  claim 41 , wherein the alkane diol comprises 1,5-pentane diol and/or 1,6-hexanediol. 
     
     
         43 . A three-dimensional article obtained by a process for producing an article by three-dimensional printing, the process comprising:
 positioning a layer of solid particles in a planar bed, wherein the solid particles comprise an activator compound chemically and/or physically adsorbed onto surfaces of the solid particles;   applying a liquid binder over a predetermined area of the layer of solid particles, the liquid binder comprising a 1,1-di-activated vinyl compound, or a multifunctional form thereof, or a combination thereof;   infiltrating gaps between the solid particles with the liquid binder in the predetermined area of the layer of solid particles to form a first cross-sectional layer of an article; and   reacting the 1,1-di-activated vinyl compound, or multifunctional form thereof, or combination thereof, thereby solidifying the liquid binder and binding the solid particles in the first cross-sectional layer of the article.   
     
     
         44 . A method comprising:
 producing an article by three-dimensional printing utilizing a 1,1-di-activated vinyl compound, or a multifunctional form thereof, or a combination thereof as a binder in the three-dimensional printing.   
     
     
         45 . The method of  claim 44  wherein the three-dimensional printing is carried out using a process for producing an article by three-dimensional printing, the process comprising:
 positioning a layer of solid particles in a planar bed, wherein the solid particles comprise an activator compound chemically and/or physically adsorbed onto surfaces of the solid particles; 
 applying a liquid binder over a predetermined area of the layer of solid particles, the liquid binder comprising a 1,1-di-activated vinyl compound, or a multifunctional form thereof, or a combination thereof; 
 infiltrating gaps between the solid particles with the liquid binder in the predetermined area of the layer of solid particles to form a first cross-sectional layer of an article; and 
 reacting the 1,1-di-activated vinyl compound, or multifunctional form thereof, or combination thereof, thereby solidifying the liquid binder and binding the solid particles in the first cross-sectional layer of the article 
 wherein the process produces a three-dimensional article comprising 
 a plurality of cross-sectional layers bonded together, each cross-sectional layer comprising: 
 a solid binder comprising a reaction product of a 1,1-di-activated vinyl compound, or a multifunctional form thereof, or a combination thereof; and 
 a plurality of solid particles in the solid binder, wherein the solid particles comprise an activator compound chemically and/or physically absorbed onto surfaces of the solid particles.