Jettable temporary solubolized peek binders to create removable support materials

Patent metadata

Field	Value
Publication number	US-12233596-B2
Application number	US-202016805560-A
Country	US
Kind code	B2
Filing date	Feb 28, 2020
Priority date	Feb 28, 2020
Publication date	Feb 25, 2025
Grant date	Feb 25, 2025

Abstract

The present invention provides methods, processes, and systems for the manufacture of three-dimensional articles made of polymers using 3D printing. A layer of prepolymer is deposited on a build plate to form a powder bed. Then, solutions of first and/or second binding agents are printed on the powder bed in a predetermined pattern. After a predetermined period of time, sequential layers are printed to provide the three-dimensional article. The removable binding agent is then removed. The removable binding agent may be solubilized polyetheretherketone. Examples of solubilized polyetheretherketone include, but are not limited to, sulfonated polyetheretherketone and/or nitrated polyetheretherketone. The three-dimensional object can be cured to produce the three-dimensional article composed of the final polymers.

First claim

We claim:

1. A method for manufacturing a three-dimensional article, the method comprising:
(a) depositing a powder on a build plate to form a powder bed;
(b) printing, at selected locations on the powder bed, a solution of a first binding agent;
(c) printing, at selected locations on the powder bed, a solution of a second binding agent;
(d) exposing the first binding agent to a stimulus to form a polymer layer;
repeating steps (a), (b), and (d) to manufacture the remainder of the three-dimensional article; and
removing the second binding agent;

wherein the first and second binding agents are each printed at least once; wherein the first and second binding agents are printed at different selected locations on the power bed; and
wherein the second binding agent comprises a solubilized nitrated polyetheretherketone.

2. The method according to claim 1 , wherein particles bound by the second binding agent provide physical support to selected locations bound by the first binding agent.

3. The method according to claim 1 , wherein the first and second binding agents are applied to the powder bed simultaneously.

4. The method according to claim 1 , wherein stimulus comprises heat, light, oxidation, acid catalysis, base catalysis, transition metal catalysis, or combination thereof.

5. The method according to claim 1 , wherein removing the second binding agent releases powder previously bound by the second binding agent.

6. The method according to claim 1 , wherein the removing the second binding agent comprises removing the second binding agent with a solvent.

7. The method according to claim 1 , wherein the powder is selected from the group consisting of prepolymers, polymers, ceramics, metals, and plastics.

8. The method according to claim 1 , wherein the first binding agent is selected from the group consisting of prepolymers, polymers, copolymers, block copolymers, and plastics.

9. The method according to claim 8 , wherein the first binding agent is heated to a temperature of between 200° C. and 400° C.

10. The method according to claim 6 , wherein the solvent is an aqueous and/or alcohol solvent.

Assignees

• Saito Akira
• Takimoto Koji
• Boydston Andrew J
• Lee Chang Uk
• Ganter Mark A
• Storti Duane W
• Ricoh Co Ltd

Inventors

• Saito Akira
• Takimoto Koji
• Boydston Andrew J
• Lee Chang-Uk
• Ganter Mark A
• Storti Duane W

Classifications

• B29C64/112 Primary

  using individual droplets, e.g. from jetting heads · CPC title

• B33Y40/20

  Post-treatment, e.g. curing, coating or polishing · CPC title

• B29C64/40

  Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title