Methods for solid freeform fabrication

Patent metadata

Field	Value
Publication number	US-10370530-B2
Application number	US-201615054500-A
Country	US
Kind code	B2
Filing date	Feb 26, 2016
Priority date	Feb 26, 2016
Publication date	Aug 6, 2019
Grant date	Aug 6, 2019

Abstract

The present invention provides high performance polymer (HPP) compositions, methods, processes, and systems for the manufacture of three-dimensional articles made of polymers using molding or 3D printing. The HPP compositions comprise a first HPP dissolved in a solvent and a second HPP present as a solid.

First claim

We claim:

1. A method for manufacturing a three-dimensional article, the method comprising:
a. depositing a powder of a first high performance polymer (HPP) on a build plate to form a powder bed;
b. depositing a composition at selected locations on the powder bed wherein the composition comprises:
a homogeneous mixture of a second HPP dissolved in a solvent;
wherein the composition further comprises particles of a third HPP that are dispersed in the homogeneous mixture of the second HPP and the solvent; and
wherein the particles of the third HPP are insoluble in the homogeneous mixture;

c. exposing the deposited composition to a stimulus to form a polymer layer of the three-dimensional article; and
d. repeating steps (a)-(c) to manufacture remainder of the three-dimensional article.

2. The method of claim 1 , wherein the composition has a viscosity of about 1 cP to about 50 cP.

3. The method of claim 1 , wherein the second HPP comprises a polyketone.

4. The method of claim 2 , wherein the polyketone comprises polyetheretherketone (PEEK), polyaryletherketone (PAEK), polyetherketone (PEK), polyetherketoneketone (PEKK) polyetheretheretherketone (PEEEK), polyetheretherketoneketone (PEEKK), polyetherketoneetheretherketone (PEKEKK), or polyetherketoneketoneketone (PEKKK).

5. The method of claim 1 , wherein the third HPP comprises polyimides, polyketones, reduced forms of polyketones, and polyethersulfones, and wherein the third HPP is not soluble in the solvent.

6. The method of claim 1 , where the stimulus is radiation or heat.

7. The method of claim 5 , wherein radiation is ultraviolet radiation, visible radiation, infrared radiation, electron beam radiation, or combinations thereof.

8. The method of claim 1 , further comprising the step of curing wherein curing is done by chemical curing or thermal curing.

9. The method of claim 5 , wherein the thermal curing is carried out at about 300° C. or above.

10. A method for manufacturing a three-dimensional article, the method comprising:
a. depositing a composition comprising:
a homogeneous mixture of a first high performance polymer (HPP) dissolved in a solvent;
wherein the composition further comprises particles of a second HPP that are dispersed in the homogeneous mixture of the first HPP and the solvent; and
wherein the particles of the second HPP are insoluble in the homogeneous mixture;
into a mold to form the three-dimensional article; and

b. removing the three-dimensional article from the mold.

11. The method of claim 10 , wherein the first HPP comprises a polyketone.

12. The method of claim 10 , wherein the second HPP comprises polyimides, polyketones, reduced forms of polyketones, and polyethersulfones, and wherein the second HPP is not soluble in the solvent.

13. The method of claim 10 , further comprising the step of curing wherein curing is done by chemical curing or thermal curing.

14. The method of claim 13 , wherein the thermal curing is carried out at a temperature below the glass transition temperature of the first HPP.

15. The method of claim 13 , wherein the thermal curing is carried out at a temperature above the glass transition temperature of the first HPP.

Assignees

• Boydston Andrew J
• Goetz Adam Edward
• Lee Chang Uk
• Peterson Gregory Isaac
• Ganter Mark A
• Storti Duane W
• Yurtoglu Mete
• Ricoh Co Ltd
• Univ Washington

Inventors

• Boydston Andrew J
• Goetz Adam Edward
• Lee Chang-Uk
• Peterson Gregory Isaac
• Ganter Mark A
• Storti Duane W
• Yurtoglu Mete

Classifications

• B29K2995/0077

  Yield strength; Tensile strength · CPC title

• C08L71/00

  Compositions of polyethers obtained by reactions forming an ether link in the main chain (of polyacetals C08L59/00; of epoxy resins C08L63/00; of polythioether-ethers C08L81/02; of polyether-sulfones C08L81/06); Compositions of derivatives of such polymers · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• C08L61/16 Primary

  of ketones with phenols · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title