Method for producing a treated, 3D printed object

Patent metadata

Field	Value
Publication number	US-11833749-B2
Application number	US-201816763591-A
Country	US
Kind code	B2
Filing date	Dec 18, 2018
Priority date	Dec 19, 2017
Publication date	Dec 5, 2023
Grant date	Dec 5, 2023

Abstract

The present invention relates to a method for producing a treated object, comprising the steps of: applying a layer of particles to a target area; applying a liquid binder to a selected portion of the layer in accordance with a cross-section of the object, so that the particles in the selected portion are bonded; repeating the steps of applying a layer of particles and applying a binder for a plurality of layers so that the bonded portions of the adjacent layers are bonded to form an object, wherein at least a part of the particles comprises a meltable polymer. A binder which cures by cross-linking is preferably selected as the binder. The obtained object is at least partially contacted with a liquid heated to ≥T or with a powder bed heated to ≥T in order to obtain the treated object. T represents a temperature of ≥25° C., the liquid does not represent a solvent or a reaction partner for the binder present in the object and the meltable polymer, and the powder bed is different from the particles of the meltable polymer. The invention also relates to a treated object that can be obtained by the method according to the invention.

First claim

The invention claimed is:

1. A method of producing a treated article, comprising:
applying a layer of particles to a target surface, wherein at least some of the particles include a fusible polymer;
selectively binding particles of the layer by applying a liquid binder to a selected portion of the layer corresponding to a cross section of an article, wherein the liquid binder binds the particles in the selected portion to form a bonded portion;
repeating the steps of applying particles and selectively binding particles for a multitude of layers, wherein the repeating further comprises binding bonded portions of adjacent layers to obtain a bonded article; and
contacting at least a portion of the bonded article with a liquid heated to >T or a powder bed heated to >T and sintering the portion of the bonded article to form a treated article, wherein T is a temperature of >25° C., wherein the liquid is not a solvent or coreactant for the liquid binder and the fusible polymer, and the powder bed is different than the particles of the fusible polymer.

2. The method as claimed in claim 1 , wherein the binder cures under crosslinking.

3. The method as claimed in claim 1 , wherein the binder has a softening temperature greater than a softening temperature of the fusible polymer, wherein the softening temperature is defined as the point of intersection of the curves for storage modulus E′ and loss modulus E″ in a temperature-dependent dynamic-mechanical analysis.

4. The method as claimed in claim 1 , wherein the binder has a bonding force of 22 0.5 N/mm2 based on a tensile shear test according to DIN EN 1465 of test specimens made from the fusible polymer.

5. The method as claimed in claim 1 , wherein the liquid is put under pressure at least at times during the contacting of the article with the heated liquid.

6. The method as claimed in claim 1 , wherein the temperature T is additionally >1° C. below a softening temperature of the fusible polymer, wherein the softening temperature is defined as the point of intersection of the curves for storage modulus E′ and loss modulus E″ in a temperature-dependent dynamic-mechanical analysis.

7. The method as claimed in claim 1 , wherein the temperature T is additionally >95% of a breakdown temperature of binder present in the article, wherein the breakdown temperature is defined as the temperature at which a loss of mass of >10% is established in a thermogravimetric analysis at a heating rate of 5° C./min in an air flow.

8. The method as claimed in claim 1 , wherein the temperature T is additionally selected such that a modulus of elasticity of the fusible polymer at the temperature T is >105 Pa to <108 Pa, said modulus of elasticity being based on a temperature-dependent dynamic-mechanical analysis.

9. The method as claimed in claim 1 , wherein the contacting of the bonded article with the liquid or the powder bed is conducted for >5 minutes to <24 hours.

10. The method as claimed in claim 1 , wherein the temperature T is >40° C. to <300° C.

11. The method as claimed in claim 1 , wherein the fusible polymer comprises PEEK, PAEK, PEKK, polyethersulfones, polyimide, polyetherimide, polyesters, polyamides, polycarbonates, polyurethanes, polyvinylchloride, polyoxymethylene, polyvinylacetate, polyacrylates, polymethacrylates, TPE, polystyrene, polyethylene, polypropylene, or a blend thereof.

12. The method as claimed in claim 1 , wherein the liquid comprises a silicone oil, a fluorinated hydrocarbon, a polyethylene wax, saltwater, a metal melt, an ionic liquid, or a mixture thereof.

13. The method as claimed in claim 1 , wherein the powder bed comprises particles of glass, polytetrafluoroethylene, silicon dioxide, aluminum oxide, metal, or a mixture thereof.

Assignees

• Covestro Deutschland Ag
• Stratasys Inc

Inventors

• Achten Dirk
• Buesgen Thomas
• Wagner Roland
• Kuenzel Jonas
• Kessler Michael
• Mettmann Bettina

Classifications

• 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

• B22F1/105

  containing inorganic lubricating or binding agents, e.g. metal salts · CPC title

• B22F10/14

  by jetting of binder onto a bed of metal powder · CPC title

• B29C64/30

  Auxiliary operations or equipment · CPC title

• B29C71/02

  Thermal after-treatment {(B29C71/0063 and B29C71/0072 take precedence)} · CPC title