Method for additive manufacturing

Patent metadata

Field	Value
Publication number	US-2017246802-A1
Application number	US-201515517977-A
Country	US
Kind code	A1
Filing date	Oct 13, 2015
Priority date	Oct 16, 2014
Publication date	Aug 31, 2017
Grant date	—

Abstract

An additive elastomeric manufactured part having an elongation at break of at least 50% may be made by a method comprising the following. A material comprising a prepolymer and filler is first dispensed through a nozzle to form an extrudate deposited on a base. The base, nozzle or combination thereof is moved while dispensing the material so that there is horizontal displacement between the base and nozzle in a predetermined pattern to form an initial layer of the material on the base. Subsequent layers are then formed on the initial layer by repeating the dispensing and movement on top of the initial layer and layers that follow.

First claim

1 . A method of additive manufacturing comprising,
(i) providing a material comprised of a prepolymer and filler, the filler having a product of the iodine number in mg/g multiplied by the oil absorption number in ccs/100 grams of at least 6,000, (ii) dispensing said material through a nozzle to form an extrudate deposited on a base, (iii) moving the base, nozzle or combination thereof while dispensing the material so that there is horizontal displacement between the base and nozzle in a predetermined pattern to form an initial layer of the material on the base, and (iv) repeating steps (ii) and (iii) to form a successive layer of the material adhered on the initial layer to form an additive manufactured part.

2 . The method of claim 1 , wherein the method further comprises repeating step (iv) such that a plurality of successive layers are adhered and built up forming the additive manufactured part.

3 . (canceled)

4 . (canceled)

5 . The method of claim 1 , wherein the prepolymer is comprised of an isocyanate terminated prepolymer.

6 . The method of claim 1 , wherein the material is comprised of two separate components with a first component being comprised of the prepolymer and filler and the second component being comprised of a reactive material that reacts with the prepolymer of the first component.

7 . The method of claim 6 , wherein the first and second components are contacted and mixed prior to dispensing through the nozzle.

8 . The method of claim 6 , wherein the prepolymer is comprised of an isocyanate terminated prepolymer and the reactive constituent is comprised of an isocyanate reactive material.

9 . The method of claim 8 , wherein the isocyanate reactive material is comprised of a polyol having a backbone comprised of an amine group.

10 . The method of claim 1 , wherein the extrudate has a cross-sectional shape that is a polygon.

11 . The method of claim 10 , wherein the predetermined pattern is such that extrudates having voids between them are first formed followed by dispensing of extrudates that deposit in said voids to form the initial layer or subsequent layer.

12 . The method of claim 11 , wherein at least a portion of the cross-sectional shape is a trapezoid.

13 . The method of claim 1 , wherein the prepolymer is comprised of a polyether isocyanate terminated prepolymer.

14 . The method of claim 1 , wherein the filler is comprised of a filler having an oil absorption number of at least 80 ccs/100 grams.

15 . The method of claim 14 , wherein the filler has a product of the iodine number in mg/g multiplied by the oil absorption number in ccs/100 grams of at least 7000.

16 . The method of claim 1 , wherein the material is one component and the prepolymer cures upon exposure to moisture.

17 . An additive manufactured article made by the method of claim 1 .

18 . An elastomeric additive manufactured article comprised of at least two layers of a plurality of material extrudates adhered together and is comprised of polyurethane and a filler, wherein the filler has a product of oil absorption number of at least 6,000 having a tensile elongation at break of at least 50%.

19 . The additive manufactured article of claim 18 , wherein the tensile elongation at break is at least 100%.

20 . The additive manufactured article of claim 19 is comprised of polyurethane and a filler, wherein the filler has a product of oil absorption number times iodine number of at least 7000.

Assignees

• Dow Global Technologies Llc

Inventors

• Pyzik Aleksander J
• Matteucci Scott T
• Jialanella Gary L
• Dermody Daniel L
• Leugers Mary Anne

Classifications

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B29K2075/00

  Use of {PU, i.e.} polyureas or polyurethanes {or derivatives thereof}, as moulding material · CPC title

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title

• B29K2105/0097

  Glues or adhesives, e.g. hot melts or thermofusible adhesives · CPC title

• B29L2023/22

  Tubes or pipes, i.e. rigid (bent tubes not for use as pipe couplings B29L2023/004) · CPC title