Method of manufacturing three-dimensional structure, three-dimensional structure, and three-dimension formation composition

Patent metadata

Field	Value
Publication number	US-2016001506-A1
Application number	US-201514754910-A
Country	US
Kind code	A1
Filing date	Jun 30, 2015
Priority date	Jul 2, 2014
Publication date	Jan 7, 2016
Grant date	—

Abstract

There is provided a method of manufacturing a three-dimensional structure, in which the three-dimensional structure is manufactured by laminating a layer, the method including: forming the layer using a three-dimension formation composition containing particles, a binding resin, and a solvent; applying a binding solution containing a binder to the layer; and removing the particles, which are not bound by the binder, using a removing solution after repeating the forming of the layer and the applying of the binding solution, in which, in the removing of the unbound particles, the binding resin has a water-soluble functional group whose pKa in water is less than the pH of the removing solution.

First claim

What is claimed is:

1 . A method of manufacturing a three-dimensional structure, in which the three-dimensional structure is manufactured by laminating a layer, the method comprising:
forming the layer using a three-dimension formation composition containing particles, a binding resin, and a solvent; applying a binding solution containing a binder to the layer; and removing the particles, which are not bound by the binder, using a removing solution after repeating the forming of the layer and the applying of the binding solution, wherein, in the removing of the unbound particles, the binding resin has a water-soluble functional group whose pKa in water is less than the pH of the removing solution.

2 . The method of manufacturing a three-dimensional structure according to claim 1 ,
wherein the pKa of the water-soluble functional group in water is 6 or less.

3 . The method of manufacturing a three-dimensional structure according to claim 1 ,
wherein the water-soluble functional group is a carboxyl group or a sulfo group.

4 . The method of manufacturing a three-dimensional structure according to claim 1 ,
wherein the binding resin having a carboxyl group as the water-soluble functional group contains one or more selected from the group consisting of a reaction product of an olefin-maleic anhydride copolymer with ammonia, polyacrylic acid, carboxymethyl cellulose, polystyrene carboxylic acid, a acrylamide-acrylic acid copolymer, and alginic acid, and salts thereof.

5 . The method of manufacturing a three-dimensional structure according to claim 1 ,
wherein the binding resin having a sulfo group as the water-soluble functional group contains lignin sulfonic acid or a salt thereof.

6 . The method of manufacturing a three-dimensional structure according to claim 1 ,
wherein the weight average molecular weight of the binding resin in the three-dimension formation composition is 50000 to 200000.

7 . The method of manufacturing a three-dimensional structure according to claim 1 ,
wherein, in the applying of the binding solution, the binding resin has a structure of acid anhydride, and, in the removing of the unbound particles, the binding resin has a structure of an ammonium salt of a carboxyl group and has an amide group (—CONH 2 ).

8 . The method of manufacturing a three-dimensional structure according to claim 1 ,
wherein, in the applying of the binding solution, the binding resin has a cyclic chemical structure, and, in the removing of the unbound particles, the cyclic chemical structure of the binding resin is ring-opened.

9 . The method of manufacturing a three-dimensional structure according to claim 8 ,
wherein the cyclic chemical structure is a five-membered or six-membered cyclic structure.

10 . A three-dimensional structure, which is manufactured by the method of manufacturing a three-dimensional structure according to claim 1 .

11 . A three-dimensional structure, which is manufactured by the method of manufacturing a three-dimensional structure according to claim 2 .

12 . A three-dimensional structure, which is manufactured by the method of manufacturing a three-dimensional structure according to claim 3 .

13 . A three-dimensional structure, which is manufactured by the method of manufacturing a three-dimensional structure according to claim 4 .

14 . A three-dimensional structure, which is manufactured by the method of manufacturing a three-dimensional structure according to claim 5 .

15 . A three-dimensional structure, which is manufactured by the method of manufacturing a three-dimensional structure according to claim 6 .

16 . A three-dimensional structure, which is manufactured by the method of manufacturing a three-dimensional structure according to claim 7 .

17 . A three-dimensional structure, which is manufactured by the method of manufacturing a three-dimensional structure according to claim 8 .

18 . A three-dimensional structure, which is manufactured by the method of manufacturing a three-dimensional structure according to claim 9 .

19 . A three-dimension formation composition, which is used in the method of manufacturing a three-dimensional structure according to claim 1 , the composition comprising:
particles; a binding resin; and a solvent, wherein, in the removing of the unbound particles, the binding resin has a water-soluble functional group whose pKa in water is less than the pH of the removing solution.

20 . A three-dimension formation composition, which is used in the method of manufacturing a three-dimensional structure according to claim 2 , the composition comprising:
particles; a binding resin; and a solvent, wherein, in the removing of the unbound particles, the binding resin has a water-soluble functional group whose pKa in water is less than the pH of the removing solution.

Assignees

• Seiko Epson Corp

Inventors

• Hirata Koki
• Fukumoto Hiroshi
• Kato Shinichi
• Sato Chigusa

Classifications

• C08L33/26

  Homopolymers or copolymers of acrylamide or methacrylamide · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B29C67/0081 Primary

  Operations & Transport · mapped topic

• C08L25/18

  Homopolymers or copolymers of aromatic monomers containing elements other than carbon and hydrogen · CPC title

• C08L1/286

  substituted with acid radicals, e.g. carboxymethyl cellulose [CMC] (C08L1/282 takes precedence) · CPC title