Electrostatic 3-D development apparatus using cold fusing

Patent metadata

Field	Value
Publication number	US-10369744-B2
Application number	US-201615098825-A
Country	US
Kind code	B2
Filing date	Apr 14, 2016
Priority date	Apr 14, 2016
Publication date	Aug 6, 2019
Grant date	Aug 6, 2019

Abstract

Layers of build and support material on an intermediate transfer surface are exposed to a solvent using a solvent application station to make the build material tacky, without affecting the support material. Then, the intermediate transfer surface moves past a transfuse station (the transfuse station is positioned to receive the layers after exposure to the solvent) and a platen moves relative to the intermediate transfer surface to contact the platen to one of the layers on the intermediate transfer surface. The intermediate transfer surface transfers a layer of the build material and the support material to the platen each time the platen contacts the layers on the intermediate transfer surface at the transfuse station to successively form a freestanding stack of the layers of build and support material on the platen.

First claim

What is claimed is:

1. A three-dimensional (3-D) printer comprising:
an intermediate transfer surface;
a build material development station positioned to electrostatically transfer build material to said intermediate transfer surface;
a support material development station positioned to electrostatically transfer support material to said intermediate transfer surface, said build material development station and said support material development station transfer layers of said build material and said support material to said intermediate transfer surface;
a first solvent application station positioned to expose said layers on said intermediate transfer surface to a solvent that makes said layers tacky;
a transfuse station adjacent said intermediate transfer surface, said transfuse station is positioned to receive said layers after exposure to said solvent as said intermediate transfer surface moves past said transfuse station; and
a platen moving relative to said intermediate transfer surface, said intermediate transfer surface transfers a layer of said build material and said support material to said platen each time said platen contacts one of said layers on said intermediate transfer surface at said transfuse station to successively form a freestanding stack of said layers on said platen;
a second solvent application station positioned to apply said solvent to said layers on said platen to make the top layer on said platen tacky prior to said platen moving to said transfuse station;
a heater adjacent said platen, said platen moves from said transfuse station to said heater to heat said layers and join each of said layers together;
a pressure roller adjacent said heater, said platen moves to said pressure roller to press each of said layers together; and
a curing station positioned to apply UV light to said layers to cure said layers.

2. The 3-D printer according to claim 1 , said layers being tacky after exposure to said solvent promotes transfer of said layers from said intermediate transfer surface to said layers on said platen.

3. The 3-D printer according to claim 1 , said solvent forms bonds between polymers of said build material, without affecting said support material.

4. The 3-D printer according to claim 1 , said build material development station, said support material development station, said first solvent application station, and said transfuse station are positioned relative to said intermediate transfer surface such that a point on said intermediate transfer surface, when said intermediate transfer surface moves in a process direction, first passes said build material development station and said support material development station, then passes said first solvent application station, and then passes said transfuse station.

5. A three-dimensional (3-D) printer comprising:
an intermediate transfer belt (ITB);
a build material development station positioned to electrostatically transfer build material to said ITB;
a support material development station positioned to electrostatically transfer support material to a location of said ITB where said build material is located on said ITB, said support material dissolves in different solvents relative to solvents that dissolve said build material, said build material development station and said support material development station transfer layers of said build material and said support material to said ITB, each of said layers is on a discrete area of said ITB and is in a pattern;
a first solvent application station positioned to expose said layers on said ITB to a solvent that makes said layers tacky;
a transfuse station adjacent said ITB, said transfuse station comprises a roller on a first side of said ITB supporting said ITB, said transfuse station is positioned to receive said layers after exposure to said solvent as said ITB moves past said transfuse station; and
a platen moving relative to said ITB, said ITB transfers a layer of said build material and said support material to said platen each time said platen contacts one of said layers on a second side of said ITB at said transfuse station to successively form a freestanding stack of said layers on said platen, said first side being opposite said second side;
a second solvent application station positioned to apply said solvent to said layers on said platen to make the top layer on said platen tacky prior to said platen moving to said transfuse station;
a heater adjacent said platen, said platen moves from said transfuse station to said heater to heat said layers and join each of said layers together;
a pressure roller adjacent said heater, said platen moves to said pressure roller to press each of said layers together; and
a curing station positioned to apply UV light to said layers to cure said layers.

6. The 3-D printer according to claim 5 , said layers being tacky after exposure to said solvent promotes transfer of said layers from said ITB to said layers on said platen.

7. The 3-D printer according to claim 5 , said solvent forms bonds between polymers of said build material, without affecting said support material.

8. The 3-D printer according to claim 5 , said build material development station, said support material development station, said first solvent application station, and said transfuse station are positioned relative to said ITB such that a point on said ITB, when said ITB moves in a process direction, first passes said build material development station and said support material development station, then passes said first solvent application station, and then passes said transfuse station.

9. A three-dimensional (3-D) printer comprising:
an intermediate transfer belt (ITB);
a build material development station positioned to electrostatically transfer ultraviolet (UV) curable build material to said ITB;
a support material development station positioned to electrostatically transfer support material to a location of said ITB where said UV curable build material is located on said ITB, said support material dissolves in different solvents relative to solvents that dissolve said UV curable build material, said build material development station and said support material development station transfer layers of said UV curable build material and said support material to said ITB, each of said layers is on a discrete area of said ITB and is in a pattern;
a first solvent application station positioned to expose said layers on said ITB to a solvent that makes said build material tacky, without affecting said support material;
a transfuse station adjacent said ITB, said transfuse station comprises a roller on a first side of said ITB supporting said ITB, said transfuse station is positioned to receive said layers after exposure to said solvent as said ITB moves past said transfuse station;
a platen moving relative to said ITB, said ITB transfers a layer of said UV curable build material and said support material to said platen each time said platen contacts one of said layers on a second side of said ITB at said transfuse station to successively form a freestanding stack of said layers on said platen, said first side being opposite said second side;
a second solvent application station positioned to apply said solvent to said layers on said platen to make the top layer on said platen tacky prior to said platen moving to said transfuse station;
a heater adjacent said platen, said platen moves from said transfuse station to said heater to heat said layers and join each of said layers together;
a pressure roller adjacent said heater, said platen moves to said pressure roller to press each of said layers together; and
a curing station positioned to apply UV light to said layers to cure sa

Assignees

• Xerox Corp

Inventors

• Winters James A
• Ruiz Erwin
• Mcconville Paul J
• Lefevre Jason M
• Liu Chu-Heng

Classifications

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title

• B29C64/223

  Foils or films, e.g. for transferring layers of building material from one working station to another · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B29C64/165 Primary

  using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber · CPC title

• B29K2105/251

  Particles, powder or granules (expandable particles B29K2105/046) · CPC title