초록 ▼

Photocurable ceramic resins having solids loadings in excess of 40 volume percent and a viscosity of less than 3000 mPa.multidot.s are suitable for multi-layer fabrication of green ceramic parts by stereolithography and similar techniques. The green ceramic parts, which may be of traditional ceramic

Photocurable ceramic resins having solids loadings in excess of 40 volume percent and a viscosity of less than 3000 mPa.multidot.s are suitable for multi-layer fabrication of green ceramic parts by stereolithography and similar techniques. The green ceramic parts, which may be of traditional ceramic materials, sinterable metals, or combinations thereof, exhibit low shrinkage upon firing or sintering, and may be used for such applications as rapid prototyping, biocompatible ceramic parts, ceramic cores for investment casting, ceramic molds for metal casting, and the like.

대표청구항 ▼

[ What is claimed is:] [1.] A process for the preparation of a multi-layer ceramic green body, comprising:a) selecting an aqueous photopolymerizable ceramic resin comprising:i) from 40 to about 80 volume percent of one or more sinterable powders;ii) one or more photopolymerizable monomer(s);iii) an

[ What is claimed is:] [1.] A process for the preparation of a multi-layer ceramic green body, comprising:a) selecting an aqueous photopolymerizable ceramic resin comprising:i) from 40 to about 80 volume percent of one or more sinterable powders;ii) one or more photopolymerizable monomer(s);iii) an effective amount of a photoinitiator; andiv) a dispersant; rein said photopolymerizable ceramic resin has a viscosity at 25.degree. C. of less than 3000 mPa.multidot.s;b) coating a substrate with a first layer of said photopolymerizable ceramic resin;c) irradiating at least a portion of said layer with an energy source effective to activate said photoinitiator and induce photopolymerization of said layer to form a polymerized ceramic layer;d) coating said polymerized ceramic layer with a further layer of photopolymerizable ceramic resin;e) irradiating said further layer with an energy source effective to activate said photoinitiator and induce photopolymerization of said further layer to form a further polymerized ceramic layer;f) repeating steps d) and e) until a green ceramic body of a desired size and shape has been obtained. [21.] A process for the preparation of a multi-layer ceramic green body, comprising:a) selecting a photopolymerizable ceramic resin comprising:i) from 40 to about 80 volume percent of one or more sinterable powders;ii) a photopolymerizable liquid;iii) an effective amount of a photoinitiator; andiv) a dispersant; rein said photopolymerizable ceramic resin has a viscosity of 25.degree. C. of less than 3000 mPa.multidot.s;b) coating a substrate with a first layer of said photopolymerizable ceramic resin;c) irradiating at least a portion of said layer with an energy source effective to activate said photoinitiator and induce photopolymerization of said layer to form a polymerized ceramic layer;d) coating said polymerized ceramic layer with a further layer of photopolymerizable ceramic resin;e) irradiating said further layer with an energy source effective to activate said photoinitiator and induce photopolymerization of said further layer to form a further polymerized ceramic layer;f) repeating steps d) and e) until a green ceramic body of a desired size and shape has been obtained; rein said photopolymerizable ceramic resin further comprises an index of refraction altering substance. [22.] A process for the preparation of a multi-layer ceramic green body, comprising:a) selecting an aqueous photopolymerizable ceramic resin having a continuous aqueous phase and a dispersed sinterable powder phase, comprising:i) from 40 to about 80 volume percent of one or more sinterable powders;ii) one or more photopolymerizable monomers;iii) an effective amount of a photoinitiator; andiv) a dispersant; rein said photopolymerizable ceramic resin has a viscosity at 25.degree. C. of less than 3000 mPa.multidot.s;b) coating a substrate with a first layer of said photopolymerizable ceramic resin;c) irradiating at least a portion of said layer with an energy source effective to activate said photoinitiator and induce photopolymerization of said layer to form a polymerized ceramic layer;d) coating said polymerized ceramic layer with a further layer of photopolymerizable ceramic resin;e) irradiating said further layer with an energy source effective to activate said photoinitiator and induce photopolymerization of said further layer to form a further polymerized ceramic layer;f) repeating steps d) and e) until a green ceramic body of a desired size and shape has been obtained; rein said photopolymerizable ceramic resin further comprises an index of refraction altering substance soluble in the continuous aqueous phase of said aqueous photopolymerizable ceramic resin, said index of refraction altering substance present in an amount of from about 5 weight percent to about 30 weight percent based on the weight of said continuous aqueous phase containing said index of refraction altering substance, wherein said index of refraction altering substance comprises ethylene glycol. [23.] A process for the preparation of a multi-layer ceramic green body, comprising:a) selecting an aqueous photopolymerizable ceramic resin comprising:i) from 40 to about 80 volume percent of one or more sinterable powders;ii) one or more photopolymerizable monomers;iii) an effective amount of a photoinitiator; andiv) a dispersant; rein said photopolymerizable ceramic resin has a viscosity at 25.degree. C. of less than 3000 mPa.multidot.s;b) coating a substrate with a first layer of said photopolymerizable ceramic resin;c) irradiating at least a portion of said layer with an energy source effective to activate said photoinitiator and induce photopolymerization of said layer to form a polymerized ceramic layer;d) coating said polymerized ceramic layer with a further layer of photopolymerizable ceramic resin;e) irradiating said further layer with an energy source effective to activate said photoinitiator and induce photopolymerization of said further layer to form a further polymerized ceramic layer;f) repeating steps d) and e) until a green ceramic body of a desired size and shape has been obtained; and rein said photopolymerizable ceramic resin further comprises an effective amount of an anti-skinning agent.