Three-dimensional printing

Patent metadata

Field	Value
Publication number	US-12233457-B2
Application number	US-201817047503-A
Country	US
Kind code	B2
Filing date	Sep 21, 2018
Priority date	Sep 21, 2018
Publication date	Feb 25, 2025
Grant date	Feb 25, 2025

Abstract

Examples of a three-dimensional (3D) printing kit include a particulate build material and a binder fluid. The particulate build material includes from about 80 wt % to 100 wt % metal particles based on a total weight of the particulate build material. In some examples, the binder fluid includes water, polymer particles in an amount ranging from about 1 wt % to about 40 wt % based on a total weight of the binder fluid, and a blocked polyisocyanate adhesion promoter in an amount ranging from about 0.05 wt % to about 5 wt % based on the total weight of the binder fluid. In some other examples, the binder fluid includes water and the polymer particles, and the 3D printing kit further includes an adhesion promoter fluid which includes water and the blocked polyisocyanate adhesion promoter.

First claim

What is claimed is:

1. A three-dimensional printing kit, comprising:
a particulate build material including from about 80 wt % to 100 wt % metal particles based on a total weight of the particulate build material; and
a separate binder fluid including:
water;
polymer particles in an amount ranging from about 1 wt % to about 40 wt % based on a total weight of the binder fluid, wherein the polymer particles are polymerized monomers of vinyl acetate, vinyl chloride, vinylidene chloride, vinylbenzyl chloride, vinyl ester, vinyl pyrrolidone, styrene, ethylene, maleate esters, fumarate esters, itaconate esters, α-methyl styrene, p-methyl styrene, methyl methacrylate, hexyl acrylate, hexyl methacrylate, hydroxyethyl acrylate, butyl acrylate, butyl methacrylate, ethyl acrylate, ethyl methacrylate, propyl acrylate, propyl methacrylate, 2-ethylhexyl acrylate, 2-ethylhexyl methacrylate, octadecyl acrylate, octadecyl methacrylate, stearyl methacrylate, 2-phenoxyethyl methacrylate, vinylbenzyl chloride, isobornyl acrylate, tetrahydrofurfuryl acrylate, 2-phenoxyethyl methacrylate, benzyl methacrylate, benzyl acrylate, ethoxylated nonyl phenol methacrylate, isobornyl methacrylate, ethylene glycol dimethacrylate, diethylene glycol dimethacrylate, triethylene glycol dimethacrylate, cyclohexyl methacrylate, trimethyl cyclohexyl methacrylate, t-butyl methacrylate, n-octyl methacrylate, lauryl acrylate, lauryl methacrylate, trydecyl methacrylate, alkoxylated tetrahydrofurfuryl acrylate, isodecyl acrylate, dimethyl maleate, dioctyl maleate, acetoacetoxyethyl methacrylate, diacetone acrylamide, N-vinyl imidazole, N-vinylcarbazole, N-vinyl-caprolactam, pentaerythritol tri-acrylate, pentaerythritol tetra-acrylate, pentaerythritol tri-methacrylate, pentaerythritol tetra-methacrylate, glycidyl acrylate, glycidyl methacrylate, tetrahydrofuryl acrylate, tetrahydrofuryl methacrylate, diacetone acrylamide, t-butyl acrylamide, divinylbenzene, 1,3-butadiene, acrylonitrile, methacrylonitrile, derivatives thereof, or mixtures thereof; and

a blocked polyisocyanate adhesion promoter in an amount ranging from about 1.5 wt % to about 3.0 wt % based on the total weight of the binder fluid.

2. The three-dimensional printing kit as defined in claim 1 wherein the metal particles are selected from the group consisting of aluminum, aluminum alloys, titanium, titanium alloys, copper, copper alloys, cobalt, cobalt alloys, chromium, chromium alloys, nickel, nickel alloys, vanadium, vanadium alloys, tin, tin alloys, tungsten, tungsten alloys, tungsten carbide, tantalum, tantalum alloys, molybdenum, molybdenum alloys, magnesium, magnesium alloys, gold, gold alloys, silver, silver alloys, zirconium, zirconium alloys, ferrous alloys, stainless steel, steel, and an admixture thereof.

3. The three-dimensional printing kit as defined in claim 1 wherein the polymer particles have a glass transition temperature higher than 60° C. and an average particle size of 1 nm or more.

4. The three-dimensional printing kit as defined in claim 1 wherein the blocked polyisocyanate adhesion promoter is an anionic blocked polyisocyanate or a non-ionic blocked polyisocyanate.

5. The three-dimensional printing kit as defined in claim 4 wherein the blocked polyisocyanate adhesion promoter has the structure:

wherein:
R is independently selected from the group consisting of a C2 to C10 branched or straight-chained alkyl, a C6 to C20 alicyclic compound, a C6 to C20 aromatic compound, and combinations thereof; and
Z is (BL) 3-X (DL) X , wherein BL is selected from the group consisting of a phenol blocking group, a lactam blocking group, an oxime blocking group, an azole blocking group, a diketene blocking group, a formate blocking group, and combinations thereof;
x is from 0 to 1; and DL is an anionic or a non-ionic hydrophilic dispersing group.

6. The three-dimensional printing kit as defined in claim 1 wherein the blocked polyisocyanate adhesion promoter is a cationic blocked polyisocyanate.

7. The three-dimensional printing kit as defined in claim 1 wherein the metal particles of the particulate build material are uncoated metal particles.

8. The three-dimensional printing kit as defined in claim 1 wherein the particulate build material is devoid of a polymer resin.

9. The three-dimensional printing kit as defined in claim 1 wherein the metal particles have a D50 particle size distribution value ranging from about 0.5 μm to about 200 μm.

10. The three-dimensional printing kit as defined in claim 1 wherein the polymer particles have a core-shell morphology.

11. The three-dimensional printing kit as defined in claim 1 wherein the polymer particles are copolymer particles.

12. The three-dimensional printing kit as defined in claim 1 wherein the polymer particles have an average particle size ranging from about 100 nm to about 250 nm.

13. The three-dimensional printing kit as defined in claim 1 wherein the polymer particles have a weight average molecular weight ranging from about 5,000 Mw to about 2,000,000 Mw.

14. A three-dimensional printing kit, comprising:
a particulate build material including from about 80 wt % to 100 wt % metal particles based on a total weight of the particulate build material; and
a separate binder fluid including:
water;
polymer particles in an amount ranging from about 1 wt % to about 40 wt % based on a total weight of the binder fluid, wherein the polymer particles are copolymer particles of methyl methacrylate, styrene, butyl acrylate, and methacrylic acid; and
a blocked polyisocyanate adhesion promoter in an amount ranging from about 0.05 wt % to about 5 wt % based on the total weight of the binder fluid.

15. The three-dimensional printing kit as defined in claim 14 wherein the metal particles are selected from the group consisting of aluminum, aluminum alloys, titanium, titanium alloys, copper, copper alloys, cobalt, cobalt alloys, chromium, chromium alloys, nickel, nickel alloys, vanadium, vanadium alloys, tin, tin alloys, tungsten, tungsten alloys, tungsten carbide, tantalum, tantalum alloys, molybdenum, molybdenum alloys, magnesium, magnesium alloys, gold, gold alloys, silver, silver alloys, zirconium, zirconium alloys, ferrous alloys, stainless steel, steel, and an admixture thereof.

16. The three-dimensional printing kit as defined in claim 14 wherein the blocked polyisocyanate adhesion promoter is an anionic blocked polyisocyanate or a non-ionic blocked polyisocyanate.

17. The three-dimensional printing kit as defined in claim 16 wherein the blocked polyisocyanate adhesion promoter has the structure:

wherein:
R is independently selected from the group consisting of a C2 to C10 branched or straight-chained alkyl, a C6 to C20 alicyclic compound, a C6 to C20 aromatic compound, and combinations thereof; and
Z is (BL) 3-X (DL) X , wherein BL is selected from the group consisting of a phenol blocking group, a lactam blocking group, an oxime blocking group, an azole blocking group, a diketene blocking group, a formate blocking group, and combinations thereof; x is from 0 to 1; and DL is an anionic or a non-ionic hydrophilic dispersing group.

18. The three-dimensional printing kit as defined in claim 14 wherein the blocked polyisocyanate adhesion promoter is a cationic blocked polyisocyanate.

Assignees

• Hewlett Packard Development Co

Inventors

• Chen Tienteh
• Guo Dennis Z

Classifications

• B22F10/14

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

• B22F10/20

  Direct sintering or melting · CPC title

• B29C64/165

  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

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B33Y30/00

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