Surface modified particulate and sintered or injection molded products

Patent metadata

Field	Value
Publication number	US-2017120326-A1
Application number	US-201615369152-A
Country	US
Kind code	A1
Filing date	Dec 5, 2016
Priority date	Jul 11, 2013
Publication date	May 4, 2017
Grant date	—

Abstract

Disclosed are interfacially modified particulate and polymer composite material for use in injection molding processes, such as metal injection molding and additive process such as 3D printing. The composite material is uniquely adapted for powder metallurgy processes. Improved products are provided under process conditions through surface modified powders that are produced by extrusion, injection molding, additive processes such as 3D printing, Press and Sinter, or rapid prototyping.

First claim

1 - 24 . (canceled)

25 . A method of making an shaped article with an injection molding manufacturing system, the method comprises molding a composite to form a green preform, with the system comprising a heated injector and a mold cavity, the composite comprising a thermoplastic comprising about 70 to 1 wt. % of a thermoplastic polymer; and about 99 to 30 wt. % of a particulate, dispersed in the polymer, the particulate having a particle size of less than 500 microns, and an exterior coating of interfacial modifier in an amount of about 0.02 to 2.0 wt. %, all percentages based on the weight of the composite; and
sintering the green preform to remove the polymer and bond the particulate forming the object; wherein the particulate comprises a metal alloy particle, a ceramic particle, a bi-metal particle or blends thereof.

26 . The method of claim 25 wherein the preform is sintered in one step with no debonding step.

27 . The method of claim 25 wherein the ceramic particle is a tungsten carbide.

28 . The method of claim 25 wherein the alloy particle is a stainless steel.

29 . The method of claim 25 wherein the ceramic particle comprises glass.

30 . The method of claim 29 wherein the particle is a hollow sphere or a solid sphere.

31 . The method of claim 25 wherein the bi-metal particle comprises at least two of copper, iron, nickel, tungsten or molybdenum.

32 . The method of claim 25 wherein the preform is also mechanically shaped prior to sintering.

33 . The method of claim 25 wherein the preform object is sintered at a temperature greater than about 1000° C.

34 . The method of claim 28 wherein in sintering the preform object, the preform object is sintered by increasing the temperature at a rate greater than 100° C. per hour beginning at an initial temperature.

35 . The method of claim 25 wherein the initial temperature is less than 100° C.

36 . The method of claim 25 wherein the preform object comprises a first composite and a second composite, the second composite comprising either a particulate or a polymer different than the first.

37 . The method of claim 25 wherein the sintering is conducted a reducing atmosphere

38 . The method of claim 25 wherein the green preform composite has a volume packing of greater than 80%.

39 . The method of claim 25 wherein the green preform composite has a volume packing of greater than 85%.

40 . The method of claim 25 wherein the green preform composite has a volume packing of greater than 90%.

Assignees

• Tundra Composites Llc

Inventors

• Heikkila Kurt

Classifications

• B22F3/225

  by injection molding · CPC title

• B29C64/118

  using filamentary material being melted, e.g. fused deposition modelling [FDM] · CPC title

• D01F1/10 Primary

  Other agents for modifying properties · CPC title

• B22F10/40

  Structures for supporting workpieces or articles during manufacture and removed afterwards · CPC title

• B22F1/062

  Fibrous particles · CPC title