Composition

Patent metadata

Field	Value
Publication number	US-2020406351-A1
Application number	US-201816499484-A
Country	US
Kind code	A1
Filing date	Mar 15, 2018
Priority date	Mar 15, 2018
Publication date	Dec 31, 2020
Grant date	—

Abstract

An example of a composition includes a host metal present in an amount ranging from about 95.00 weight percent to about 99.99 weight percent, based on a total weight of the composition. A flow additive is also present in an amount ranging from about 0.01 weight percent to about 5.00 weight percent, based on the total weight of the composition. The flow additive consists of an organic material that is pyrolyzable at a pyrolysis temperature that is less than a sintering temperature of the host metal. The composition is spreadable, having a Hausner Ratio less than 1.25.

First claim

What is claimed is:

1 . A composition, comprising:
a host metal present in an amount ranging from about 95.00 weight percent to about 99.99 weight percent, based on a total weight of the composition; a flow additive present in an amount ranging from about 0.01 weight percent to about 5.00 weight percent, based on the total weight of the composition, wherein the flow additive consists of an organic material that is pyrolyzable at a pyrolysis temperature that is less than a sintering temperature of the host metal; and wherein the composition is spreadable, having a Hausner Ratio less than 1.25.

2 . The composition as defined in claim 1 wherein the composition comprises particles of the host metal and particles of the flow additive.

3 . The composition as defined in claim 2 wherein the particles of the host metal have an average host metal particle size less than 20 micrometers.

4 . The composition as defined in claim 2 wherein the primary particles of the flow additive have an average flow additive primary particle size ranging from about 1 to about 3 orders of magnitude smaller than an average host metal particle size.

5 . The composition as defined in claim 4 wherein the average flow additive primary particle size ranges from about 5 nanometers to about 200 nanometers.

6 . The composition as defined in claim 1 wherein the flow additive is a polymer having a glass transition temperature greater than about 5 degrees above a spread temperature.

7 . The composition as defined in claim 1 wherein the flow additive is hydrophobic.

8 . The composition as defined in claim 1 wherein the flow additive is to undergo pyrolysis to yield volatile decomposition products and non-volatile carbon-rich residue, the volatile decomposition products being at least about 90 percent of a pre-pyrolyzed weight of the flow additive.

9 . The composition as defined in claim 1 wherein the flow additive is a nano-powder produced by drying an aqueous dispersion of polymer nano-particles.

10 . The composition as defined in claim 9 wherein the drying is freeze drying.

11 . The composition as defined in claim 9 wherein the polymer nano-particles include a heteropolymer including a hydrophobic component that makes up from about 65% to about 99.9% of the heteropolymer, and a hydrophilic component that makes up from about 0.1% to about 35% of the heteropolymer, and wherein the hydrophobic component has a lower glass transition temperature than the hydrophilic component.

12 . The composition as defined in claim 9 wherein the aqueous dispersion of polymer nano-particles is produced by emulsion polymerization or co-polymerization of vinyl monomers, vinyl ester monomers, acrylate monomers, methacrylate monomers, styrene monomers, ethylene, maleate esters, fumarate esters, itaconate esters, or mixtures thereof.

13 . The composition as defined in claim 9 wherein the aqueous dispersion of polymer nano-particles is produced by emulsion polymerization or co-polymerization of monomers including: styrene, α-methyl styrene, p-methyl styrene, methyl methacrylate, hexyl acrylate, hexyl methacrylate, butyl acrylate, butyl methacrylate, ethyl acrylate, ethyl methacrylate, propyl acrylate, propyl methacrylate, 2-ethylhexyl acrylate, 2-ethylhexyl methacrylate, octadecyl acrylate, octadecyl methacrylate, stearyl methacrylate, vinylbenzyl chloride, isobornyl acrylate, tetrahydrofurfuryl acrylate, 2-phenoxyethyl methacrylate, benzyl methacrylate, benzyl acrylate, ethoxylated nonyl phenol methacrylate, isobornyl methacrylate, cyclohexyl methacrylate, trimethyl cyclohexyl methacrylate, t-butyl methacrylate, n-octyl methacrylate, lauryl methacrylate, trydecyl methacrylate, alkoxylated tetrahydrofurfuryl acrylate, isodecyl acrylate, isobornylmethacrylate, isobornyl acrylate, dimethyl maleate, dioctyl maleate, acetoacetoxyethyl methacrylate, diacetone acrylamide, N-vinyl imidazole, N-vinylcarbazole, N-vinyl-caprolactam, and combinations thereof.

14 . A three-dimensional (3D) printing kit, comprising:
a build material composition, including:
a host metal present in an amount ranging from about 95.00 weight percent to about 99.99 weight percent, based on a total weight of the build material composition; and
a flow additive present in an amount ranging from about 0.01 weight percent to about 5.00 weight percent, based on the total weight of the build material composition, wherein the flow additive consists of an organic material that is pyrolyzable at a pyrolysis temperature less than a sintering temperature of the host metal, wherein the build material composition is spreadable, having a Hausner Ratio less than 1.25; and
a binder agent to be applied to at least a portion of a layer of the build material composition via an inkjet printhead to pattern a cross-section of an intermediate part.

15 . A method for making a three-dimensional printing build material composition, comprising:
combining a host metal and a flow additive to form a build material mixture, the host metal being present in an amount ranging from about 95.00 weight percent to about 99.99 weight percent based on a total weight of the build material mixture and the flow additive being present in an amount ranging from about 0.01 weight percent to about 5.00 weight percent based on the total weight of the build material mixture, wherein the flow additive consists of an organic material that is pyrolyzable at a pyrolysis temperature that is less than a sintering temperature of the host metal; and mixing the build material mixture until a build material composition having a Hausner Ratio less than 1.25 is formed.

Assignees

• Hewlett Packard Development Co

Inventors

• Kasperchik Vladek
• Mckinnell James
• Shaarawi Mohammed S
• Monroe Michael G
• Hower Jason

Classifications

• B22F1/16

  Metallic particles coated with a non-metal (coated with lubricating or binding agents or with organic material B22F1/10) · CPC title

• B22F1/102

  Metallic powder coated with organic material · CPC title

• B22F1/10 Primary

  Metallic powder containing lubricating or binding agents; Metallic powder containing organic material · CPC title

• B22F1/05

  Metallic powder characterised by the size or surface area of the particles · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title