Brown body including a metal nanoparticle binder

Patent metadata

Field	Value
Publication number	US-11845129-B2
Application number	US-201716076162-A
Country	US
Kind code	B2
Filing date	Jul 31, 2017
Priority date	Jul 31, 2017
Publication date	Dec 19, 2023
Grant date	Dec 19, 2023

Abstract

According to examples, a brown body has from about 0.02 wt. % to about 10 wt. % of a metal nanoparticle binder, in which the metal nanoparticle binder is selectively located within an area of the brown body to impart a strength greater than about 1 kPa to the area.

First claim

What is claimed is:

1. A brown body comprising:
from about 0.02 wt. % to about 10 wt. % of a metal nanoparticle binder present in a selectively located area of the brown body to impart a tensile strength from about 1 kPa to about 100 kPa to the area, wherein the selectively located area of the brown body is an overhang or a bottom of a bridge, wherein the wt. % that is present in the selectively located area is proportional to a predicted internal stress for the overhang or the bottom of the bridge; and
wherein less than 0.02 wt. % of metal nanoparticle binder present in other areas of the brown body.

2. The brown body of claim 1 , wherein the metal nanoparticle binder is selected from the group consisting of AIN SiC, Si13N4, WC, A12O3, A1(OH)3, Fe2O3, Fe3O4, MgO, SiO2 TiO2, Y2O3, ZnO, ZrO2, BaCO3, In2O3, SnO2, carbon, magnesium, aluminum, iron, titanium, niobium, tungsten, chromium, tantalum, cobalt, nickel, vanadium, zirconium, molybdenum, palladium, platinum, copper, silver, gold, cadmium, zinc, and combinations thereof.

3. The brown body of claim 1 , wherein the metal nanoparticle binder is present in an amount ranging from about 0.02 wt. % to about 5 wt. %.

4. The brown body of claim 1 , wherein the metal nanoparticle binder is present in an amount ranging from about 0.02 wt. % to about 0.5 wt. %. powder.

5. The brown body of claim 1 , further comprising a build material powder.

6. The brown body of claim 5 , wherein a metal present in the metal nanoparticle binder is the same as a metal in the build material powder.

7. The brown body of claim 5 , wherein a metal present in the metal nanoparticle binder is different from a metal in the build material powder.

8. The brown body of claim 1 , wherein the metal nanoparticle binder is selectively located within the area chosen from bottoms of cantilevers, sides of the brown body, edges, fine features, high tolerance areas of the brown body, areas of the brown body with large compression due to geometry, and combinations thereof.

9. A method comprising:
spreading a layer of build material powder;
selectively depositing from about 0.02 wt.% to about 10 wt. % of a metal nanoparticle binder onto the layer of the build material powder; and
applying energy at a temperature greater than about 300° C. to form a brown body; and
wherein the metal nanoparticle binder is selectively located within an area of the brown body that is an overhang or a bottom of a bridge, and wherein the metal nanoparticle binder is selectively deposited to impart a tensile strength from about 1 kPa to about 100 kPa to the area that is the overhang or the bottom of a bridge; and wherein less than 0.02 wt. % of metal nanoparticle binder is present in other areas of the brown body.

10. The method of claim 9 , wherein the brown body has sufficient strength to support itself without breaking at a temperature during annealing.

11. The method of claim 9 , wherein the brown body has sufficient strength to support itself without sagging.

12. The method of claim 9 , further comprising, prior to selectively depositing the metal nanoparticle binder, determining areas of the brown body where the metal nanoparticle binder is to be selectively deposited to impart additional strength to the determined areas.

13. The method of claim 9 , wherein selectively depositing the metal nanoparticle binder further comprises selectively depositing the metal nanoparticle binder in areas of the brown body where expected stress exceeds a certain level.

14. The method of claim 9 , wherein selectively depositing the metal nanoparticle binder further comprises selectively depositing the metal nanoparticle binder in areas of the brown body that include bottoms of cantilevers, sides of the brown body, edges, fine features, high tolerance areas of the brown body, areas of the brown body with large compression due to geometry, and combinations thereof.

15. A brown body, comprising:
a green body including a build material powder, a polymer binder, and from about 0.02 wt. % to about 10 wt. % of a metal nanoparticle binder; and
wherein the metal nanoparticle binder is selectively located within an area of the brown body that is an overhang or a bottom of a bridge to impart a tensile strength from about 1 kPa to about 100 kPa to the overhang or the bottom of a bridge; and wherein less than 0.02 wt. % of metal nanoparticle binder is present in other areas of the brown body.

Assignees

• Hewlett Packard Development Co

Inventors

• Erickson Kristopher J
• Anthony Thomas C

Classifications

• B22F10/28 Primary

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B22F1/054

  Nanosized particles · CPC title

• B22F10/14

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

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title

• B33Y70/10

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title