Method for making hybrid ceramic/metal, ceramic/ceramic body by using 3D printing process

Patent metadata

Field	Value
Publication number	US-10697305-B2
Application number	US-201614991413-A
Country	US
Kind code	B2
Filing date	Jan 8, 2016
Priority date	Jan 8, 2016
Publication date	Jun 30, 2020
Grant date	Jun 30, 2020

Abstract

This invention relates to a product and a method of preparing ceramic and/or ceramic hybrid materials through the construction of a printed die. The printed die being made by three dimensional printing or additive manufacturing processes possesses both an external geometry and an internal geometry.

First claim

The invention claimed is:

1. A method of forming a composite structure comprising:
adding a first material into a die having a cavity, wherein the cavity includes at least one protrusion within the cavity;
curing the first material to form a three dimensional body;
removing the die during the curing of the first material, thereby leaving at least one void where the at least one protrusion once existed;
adding a binder material to the at least one void after curing the first material; and
adding at least one other material into the at least one void, wherein the at least one other material is a ceramic material added by injection.

2. The method of claim 1 , wherein the first material is added by injection.

3. The method of claim 1 , wherein the first material is an inorganic material.

4. The method of claim 1 , wherein the at least one protrusion within the cavity is a hollow or a solid protrusion.

5. The method of claim 1 , wherein the at least one protrusion is hollow.

6. The method of claim 1 , wherein the at least one protrusion is of a non-linear geometry.

7. The method of claim 1 , wherein the die is removed by heating in the range of 300-600° C.

8. The method of claim 1 , further comprising incorporating the binder prior to adding the at least one other material.

9. The method of claim 1 , wherein the binder is applied to the at least one void, the at least one other material, or to both.

10. The method of claim 1 , wherein the at least one void has an aspect ratio in the range of 100:1 to 5:1.

11. The method of claim 1 , wherein the at least one void has an aspect ratio of greater than 20:1.

12. The method of claim 1 , wherein the binder material is non-metallic.

13. The method of claim 1 , wherein the cavity is produced by additive manufacturing the die.

14. The method of claim 13 , wherein the die is fabricated from thermoset or thermoplastic polymer.

15. The method of claim 1 , further comprising sintering or curing the at least one other material.

16. The method of claim 15 , wherein the sintering or curing of the at least one other material occurs at a temperature in the range of 1,000-1,600° C.

17. A method of forming a composite structure comprising:
adding a first material into a die having a cavity, wherein the cavity includes at least one protrusion within the cavity;
curing the first material to form a three dimensional body;
removing the die during the curing of the first material, thereby leaving at least one void where the at least one protrusion once existed;
adding a binder material to the at least one void after curing the first material; and
adding at least one other material into the at least one void;
wherein the first material is a ceramic slurry and the at least one other material is an alumina rod inserted into the void.

18. The method of claim 17 , wherein the cavity is produced by additive manufacturing the die.

19. The method of claim 17 , wherein the die is fabricated from thermoset or thermoplastic polymer.

20. The method of claim 17 , wherein the at least one protrusion within the cavity is a hollow or a solid protrusion.

21. The method of claim 17 , wherein the at least one protrusion is of a non-linear geometry.

22. The method of claim 17 , wherein the at least one void has an aspect ratio in the range of 100:1 to 5:1.

23. The method of claim 17 , further comprising sintering or curing the at least one other material.

Assignees

• Gen Electric

Inventors

• Yang Xi
• Peterson Brian

Classifications

• B28B7/348

  of plastic material or rubber · CPC title

• B28B7/342

  which are at least partially destroyed, e.g. broken, molten, before demoulding; Moulding surfaces or spaces shaped by, or in, the ground, or sand or soil, whether bound or not; Cores consisting at least mainly of sand or soil, whether bound or not · CPC title

• B28B1/263

  Plastics · CPC title

• B28B1/26

  by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor (B28B1/52 takes precedence){; specially for manufacturing articles starting from a ceramic slip; Moulds therefor (of tubular articles B28B21/08)} · CPC title

• C04B35/14

  based on silica · CPC title