Functional inorganics and ceramic additive manufacturing

Patent metadata

Field	Value
Publication number	US-2016107331-A1
Application number	US-201514882951-A
Country	US
Kind code	A1
Filing date	Oct 14, 2015
Priority date	Oct 17, 2014
Publication date	Apr 21, 2016
Grant date	—

Abstract

The present disclosure relates to systems, methods and resins for additive manufacturing. In one embodiment, a method for additive manufacturing of a ceramic structure includes providing a resin including a preceramic polymer and inorganic ceramic filler particles dispersed in the preceramic polymer. The preceramic polymer is configured to convert to a ceramic phase. The method includes functionalizing inorganic ceramic filler particles with a reactive group and applying an energy source to the resin to create at least one layer of the ceramic phase from the resin.

First claim

What is claimed is:

1 . A method for additive manufacturing of a ceramic structure, the method comprising:
providing a resin, the resin including a preceramic polymer and inorganic ceramic filler particles dispersed in the preceramic polymer, wherein the preceramic polymer is configured to convert to a ceramic phase, and wherein the inorganic ceramic filler particles are functionalized with a reactive group and configured to convert to the ceramic phase; and applying an energy source to the resin to create at least one layer of the ceramic phase from the resin.

2 . The method of claim 1 , wherein the preceramic polymer is polycarbosilane.

3 . The method of claim 1 , wherein the ceramic phase is silicon carbide.

4 . The method of claim 1 , wherein the inorganic ceramic filler particles are functionalized with a reactive group.

5 . The method of claim 1 , wherein the energy source is a laser source for curing at least one of the preceramic polymer and ceramic filler particles.

6 . The method of claim 1 , wherein the resin is provided in a bath for additive manufacturing.

7 . The method of claim 1 , wherein the inorganic ceramic filler particles include functional groups configured to decompose and a ceramic phase, wherein the ceramic phase remains during fabrication.

8 . The method of claim 1 , wherein applying an energy source to the resin includes free form fabrication of a three-dimensional article formed of silicon carbide.

9 . The method of claim 1 , further comprising processing an article formed by the layer and one or more additional layers, wherein processing includes exposure of layers to at least one of thermal, plasma, microwave and electromagnetic radiation, and curing methods in general.

10 . A system for resin based additive manufacturing of ceramics, the system comprising:
a bath configured to contain a resin, the resin including a preceramic polymer and inorganic ceramic filler particles dispersed in the preceramic polymer, wherein the preceramic polymer is configured to convert to a ceramic phase, wherein the inorganic ceramic filler particles are functionalized with a reactive group and configured to convert to the ceramic phase; an energy source proximate to the bath; and a controller coupled to the energy source and configured to apply the energy source to the resin to create at least one layer of the ceramic phase from the resin.

11 . The system of claim 10 , wherein the preceramic polymer is polycarbosilane.

12 . The system of claim 10 , wherein the ceramic phase is silicon carbide.

13 . The system of claim 10 , wherein the inorganic ceramic filler particles are functionalized with a reactive group.

14 . The system of claim 10 , wherein the energy source is a laser source for curing at least one of the preceramic polymer and ceramic filler particles.

15 . The system of claim 10 , wherein the resin is provided in a bath for additive manufacturing.

16 . The system of claim 10 , wherein the inorganic ceramic filler particles include functional groups configured to decompose and a ceramic phase, wherein the ceramic phase remains during fabrication.

17 . The system of claim 10 , wherein applying an energy source to the resin includes free form fabrication of a three-dimensional article formed of silicon carbide.

18 . The system of claim 10 , further comprising processing an article formed by the layer and one or more additional layers, wherein processing includes exposure of layers to at least one of thermal, plasma, microwave and electromagnetic radiation, and curing methods in general.

19 . A resin for additive manufacturing of ceramics, the resin comprising:
a preceramic polymer wherein the preceramic polymer is configured to convert to a ceramic phase; and inorganic ceramic filler particles dispersed in the preceramic polymer, wherein the inorganic ceramic filler particles are functionalized with a reactive group and configured to convert to the ceramic phase.

20 . The resin of claim 1 , wherein the ceramic phase is silicon carbide.

Assignees

• United Technologies Corp

Inventors

• Schmidt Wayde R

Classifications

• B33Y70/10

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

• B28B1/001 Primary

  Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00) · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• C08K9/04

  Ingredients treated with organic substances {(treated with macromolecular compounds C08K9/08)} · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title