Resin powder material, laser powder molding method and device

Patent metadata

Field	Value
Publication number	US-2017190905-A1
Application number	US-201515312991-A
Country	US
Kind code	A1
Filing date	Jan 28, 2015
Priority date	Jan 28, 2015
Publication date	Jul 6, 2017
Grant date	—

Abstract

Molded bodies formed from PA- 12 resin lose elasticity by absorbing water and lose strength as a result. Due to this, application to only some products used in low humidity environments is possible, which is a problem that needed to be addressed. This resin powder material, for use in powder laminate molding methods, is characterized in that the resin powder is a polybutylene terephthalate resin which has a crystallization temperature lower than that of homopolybutylene terephthalate resins.

First claim

1 . A resin powder material used for a powder laminate molding method,
wherein said resin powder is a polybutylene terephthalate resin having a crystallization temperature lower than that of a homopolybutylene terephthalate resin, and wherein said polybutylene terephthalate resin has a melting point of from 200 to 215° C.

2 . (canceled)

3 . The resin powder material according to claim 1 , wherein said polybutylene terephthalate resin comprises, as a main component, polybutylene terephthalate copolymer containing a copolymer component.

4 . The resin powder material according to claim 1 , wherein said polybutylene terephthalate copolymer comprises a copolymer component in an amount of from 3 to 30 mol %.

5 . A resin powder material used for a powder laminate molding method,
wherein said resin powder is a polybutylene terephthalate resin having a crystallization temperature lower than that of a homopolybutylene terephthalate resin, and wherein said polybutylene terephthalate is as copolymer comprising an isophthalic acid component in an amount of from 5 to 15 mol %.

6 . The resin powder material according to claim 5 , wherein a stress is applied by a step of pulverizing in a manner of applying at least either shock or shearing action to pellets of a polybutylene terephthalate resin composition.

7 . The resin powder material according to claim 6 , wherein said pulverizing step is a step of pulverizing said pellets at a temperature of normal temperature or less.

8 . The resin powder material according to claim 1 , wherein said polybutylene terephthalate resin is alloyed with a polyethylene terephthalate resin or polycarbonate resin in an alloy ratio of from 5 to 40 wt %.

9 . A resin powder material used for a powder laminate molding method,
wherein said resin powder is a polybutylene terephthalate resin having a crystallization temperature lower than that of a homopolybutylene terephthalate resin, and wherein said polybutylene terephthalate resin comprises an inorganic substance having an average primary particle diameter of 100 nm or less in an amount of 0.05 or more but less than 1.0 wt %.

10 . The resin powder material according to claim 1 , wherein the resin powder material comprises a flame retardant mixed with said polybutylene terephthalate resin.

11 . A resin powder material used for a powder laminate molding method,
wherein said resin powder is a polybutylene terephthalate resin having a crystallization temperature lower than that of a homopolybutylene terephthalate resin, and wherein the resin powder material comprises an inorganic substance having a major axis direction size of 300 μm or less in an amount of from 5 to 40 wt % mixed with said polybutylene terephthalate resin.

12 . A resin powder material used for a powder laminate molding method,
wherein said resin powder is a polybutylene terephthalate resin having a crystallization temperature lower than that of a homopolybutylene terephthalate resin, and wherein the resin powder material comprises inorganic substance beads having an average primary particle diameter and 50% average particle diameter of 100 μm or less in an amount of at least from 5 to 40 wt % mixed with said polybutylene terephthalate resin.

13 . A resin powder material used for a powder laminate molding method,
wherein said resin powder is a polybutylene terephthalate resin having a crystallization temperature lower than that of a homopolybutylene terephthalate resin, and wherein said polybutylene terephthalate resin has a Hausner ratio of 1.34 or less at room temperature.

14 . A resin powder material used for a powder laminate molding method,
wherein said resin powder is a polybutylene terephthalate resin having a crystallization temperature lower than that of a homopolybutylene terephthalate resin, and wherein said polybutylene terephthalate resin has an angle of repose of 40° or less at room temperature.

15 . A laser powder molding method comprising:
the step of arranging a resin powder material; and the laser irradiating step of irradiating a laser on said arranged resin powder material to sinter or melt a place which said laser is irradiated on; wherein said arranging step and said laser irradiating step are sequentially repeated to prepare a laminate molded body, wherein said resin powder material is a polybutylene terephthalate resin having a crystallization temperature lower than that of a homopolybutylene terephthalate resin, wherein the laser powder molding method includes the step of arranging another member prior to arranging said resin powder material, and wherein at said laser irradiating step, when an underlayer of the place to be laser irradiated is said resin powder material, a laser is irradiated on said another member at an energy lower than that of a place of said resin powder material arranged.

16 . (canceled)

17 . The laser powder molding method according to claim 15 , wherein said another member is a member comprising a resin or metal.

18 . The laser powder molding method according to claim 15 , wherein a temperature of a place arranging said resin powder material is retained at a crystallization temperature or less of said polybutylene terephthalate resin.

19 . The laser powder molding method according to claim 15 , wherein said another member has a rigidity higher than that of a molded body of said polybutylene terephthalate resin.

20 . A laser powder molding device having a roller or blade and a laser light source comprising:
arranging a resin powder material by using said roller or blade; and irradiating a laser on said arranged resin powder material from said laser light source to sinter or melt a place irradiated, wherein said arranging step and said laser irradiating step are sequentially repeated to prepare a laminate molded body, wherein said resin powder material is a polybutylene terephthalate resin having a crystallization temperature lower than that of a homopolybutylene terephthalate resin, and wherein said polybutylene terephthalate resin has a melting point of from 200 to 215° C.

Assignees

• Hitachi Ltd

Inventors

• Arai Satoshi
• Tsunoda Shigeharu

Classifications

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title

• B29C64/40

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

• B29K2105/251

  Particles, powder or granules (expandable particles B29K2105/046) · CPC title

• C08K3/36

  Silica · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title