CN105408091A - 陶瓷支撑结构 - Google Patents

陶瓷支撑结构 Download PDF

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Publication number
CN105408091A
CN105408091A CN201480026474.1A CN201480026474A CN105408091A CN 105408091 A CN105408091 A CN 105408091A CN 201480026474 A CN201480026474 A CN 201480026474A CN 105408091 A CN105408091 A CN 105408091A
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ceramic precursor
precursor material
ceramic
solvent
polymeric matrix
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CN201480026474.1A
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CN105408091B (zh
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本杰明·A·德穆思
亚当·R·帕夫洛斯基
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Stratasys Inc
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Stratasys Inc
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    • B29C64/118—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
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    • B28—WORKING CEMENT, CLAY, OR STONE
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    • B28B1/00—Producing shaped prefabricated articles from the material
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Abstract

一种用于增材制造的陶瓷前体支撑结构，其在热加工后在多种溶剂中是可溶的。

Description

陶瓷支撑结构
技术领域
本公开内容涉及熔融可加工的陶瓷前体材料(pre-ceramicmaterial)用于作为在增材制造(叠层制造或添加制造，additivemanufacturing)中的支撑结构的应用的用途。
背景技术
增材制造技术，也认可为三维打印技术，通过热塑性材料的层-层沉积来建造三维物件。利用塑料纤丝将材料递送至挤出喷嘴。加热该喷嘴以使材料熔融并且可以通过计算机控制在水平和垂直两个方向上移动。通过挤出热塑性材料的小球以形成层来生产三维物件。热塑性材料的层在挤出后硬化。经常采用支撑材料来帮助建造某些三维物件。支撑结构是通过物理或化学手段可以从接触的其它挤出材料去除的热塑性材料。某些支撑材料在某些液体中是选择性地可溶的。可以选择热塑性支撑材料和所述液体的组合物(组成，composition)以使该液体溶解支撑材料，但不溶解用于所需物件的构造的预定材料。
发明内容
涉及陶瓷的增材制造的一个实施方案是这样一种方法，其中挤出陶瓷前体粉末的热塑性纤丝以形成三维制品。在增材制造的某些应用中，利用牺牲“支撑”层来帮助形成产生预期三维产品的“建造(构建，build)”层。随后将支撑层去除以产生最终物件。在在依照本公开内容的陶瓷的增材制造期间，热塑性聚合物携带陶瓷前体粉末以形成含有热塑性粘合剂的三维生坯陶瓷部件。对于本公开内容的目的，可以预期具有陶瓷前体的热塑性聚合物作为支撑层又作为建造层。然后使这些部件经过物件煅烧期间的粘合剂去除和烧结循环，导致在某些实施方案中的陶瓷化。由于用于烧结的高温所致，传统热塑性支撑层不合适，简单地因为该温度远高于聚合物的降解温度。支撑结构的降解又会有害地影响得到建造层和预期制品。这已经限制了利用传统增材制造实践生产的三维陶瓷物件的类型。
本公开内容涉及烧结前(pre-sintered)支撑层或结构用于增材制造的用途，所述支撑层或结构在煅烧或烧结后在多种溶剂中是可溶的。组合物是增材制造的原料，其具有聚合物基体(聚合物基质，polymericmatrix)和陶瓷前体化合物，其中烧结后的支撑层在溶剂中是可溶的或可去除的。通常，使用熔融加工技术制造原料以形成适合于利用增材制造工艺和设备的应用的纤丝。
对于本公开内容的目的，陶瓷表示已经经过热过程或煅烧而形成无水或基本无水的材料的材料。生坯陶瓷(陶瓷坯，greenceramic)是还没有经过热过程的材料。利用其中通过烧结前的支撑层支撑烧结前的建造层的增材制造，可以生产生坯可陶瓷化制品(greenceramifiablearticle)。在生坯制品的煅烧后，通过热降解从建造层和支撑层二者去除聚合物粘合剂，并且在这样做时，将建造层通过另外的热加工或烧结转化到陶瓷组合物中。在该过程期间，支撑层维持建造层的形状和结构支撑。在去除聚合物粘合剂的情况下，剩余的支撑层的材料在溶剂中是可溶的或可去除的。可以使现有的陶瓷支撑结构的整个物件经过在那里将其去除的溶剂，由此留下通过建造层形成的成品陶瓷制品。
详述
用于增材制造的烧结前的支撑结构可以用于帮助三维陶瓷制品的形成。使用熔融加工技术制造用于烧结前的支撑结构的原料(进料或给料，feedstock)以形成在某些实施方案中适合于利用增材制造工艺和设备的应用的纤丝(细丝，filament)。采用支撑结构纤丝与建造结构纤丝以通过增材制造生成三维物件。
在某些实施方案中，可以利用增材制造技术来生产生坯可陶瓷化制品。生坯可陶瓷化制品通过聚合物基体和陶瓷前体化合物的支撑组合物支撑。在高温下煅烧该生坯制品后，可以使包括烧结后的支撑结构的整个物件经过溶剂浴，在那里陶瓷支撑结构被去除，从而留下成品陶瓷制品。
预期作为支撑结构的支撑层原料(supportlayerfeedstock)主要是在聚合物基体中陶瓷前体粉末或粉末掺混物。聚合物用作用于陶瓷前体粉末或粉末掺混物的粘合剂。聚合物基体赋予必要的用于产生模制或打印的支撑结构的强度。另外，它赋予制备用于增材制造工艺的原料所需的期望物理性能。聚合物基体可以是能够熔融加工并且充当用于增材制造的原料的任何热塑性聚合物。它们包括烃聚合物和非烃聚合物二者。在某些实施方案中，聚合物基体可以是聚乙烯、乙烯-辛烯共聚物或其组合。聚合物基体的其他非限制性实例包括其他聚烯烃、聚乳酸聚合物和丙烯腈丁二烯苯乙烯聚合物或其组合。在陶瓷前体原料中包括的聚合物基体的量的范围可以为约0.1重量％至约25重量％。在某些实施方案中，包括的聚合物基体可以为约0.5重量％至约5重量％。在一些实施方案中，原料通常为挤出纤丝的形式。
适合用于增材制造的陶瓷前体材料是粉末或微米尺寸化合物，其在多种溶剂中以陶瓷前体或烧结状态是可溶的。在一些实施方案中，陶瓷前体是能够在高热下形成半固体的酸不稳定矿物。预期的应用表明，在某些实施方案中，在形成后，支撑结构在低于700℃时必须不会软化。另外，支撑结构在低于1200℃时必须不会熔化。陶瓷前体材料的非限制性实例包括碳酸钙，碳酸钠，铝酸钠或碳化钙。具有本公开内容的知识的本领域普通技术人员能够选择具体的材料以匹配预期的增材制造制品。例如，在其中烧结不超过850℃的应用中，也可以使用碳酸钠。在超过碳酸钙的950℃极限的应用中，可以使用铝酸钠，高至1500℃。在需要极高热的应用中，可以采用碳化钙，高至2000℃。原料中陶瓷前体材料的量可以为至少50％。在某些实施方案中，陶瓷前体材料大于75％，并且甚至大于95％。
在一些实施方案中，使用熔剂(flux)来降低陶瓷前体材料的总体熔点并由此增强烧结过程的效率。熔剂可以是任何玻璃或陶瓷材料，去在陶瓷前体材料的软化点以下流动。熔剂材料的非限制性实例包括由三氧化硼、氧化硅，二氧化锆、氧化锂、氟、二氧化钛及其组合组成的玻璃熔料(玻璃烧结料或玻璃粉，glassfrit)。包括在原料组合物中的熔剂的量可以多至20％。在一个实施方案中，合适的熔剂是得自德国法兰克福FerroCorporation的FerroFrits90740F。在另一个实施方案中，熔剂可以包括具有的熔点为600℃至1000℃的硅酸盐。熔剂可以在熔融加工期间添加到原料中。
在备选的实施方案中，可以将多种加工添加剂用于原料的形成。加工助剂的非限制性实例包括蜡、水分清除剂、润滑剂和脱粘剂(debinder)。在熔融可加工组合物中包括的加工添加剂的量为约0.5重量％至约5重量％。
将包含组分的原料混合和经过熔融加工。可以将原料粒化并随后形成为适合用于增材制造的纤丝。在一些实施方案中，纤丝具有大约300MPa至1600MPa的模量。
原料的熔融加工通常在双螺杆挤出机中进行。在某些实施方案中，所述加工在同步旋转、分段的双螺杆挤出机中进行。在这样的情况下，双螺杆挤出机的长度∶直径比为至少32∶1。在另一个实施方案中，双螺杆挤出机的长度∶直径比为至少40∶1。典型的温度分布的范围可以为120-220℃，其中典型的螺杆转速有效地在约200-300RPM的范围内。可以使拉模压力(阴模压力，diepressure)以确保所有陶瓷前体材料结合到热塑性粘合剂中。本领域技术人员将意识到用来实现本发明的熔融可加工组合物的最佳混合的优选螺杆设计和温度分布。
含有陶瓷前体材料的原料在增材制造中用作用于陶瓷制品的支撑结构。利用该支撑结构或层与建造层来形成三维制品或物件。这些材料能够承受将生坯陶瓷制品变为其期望的陶瓷形式必需的高温。本领域技术人员能够选择恰当的原料来匹配特定的陶瓷。此外，取决于期望的成品制品，可以选择增材制造设备和技术。增材制造设备的一个实例是可获自StratasysLtd，Minneapolis，MN的MakerbotReplicator2X增材制造打印机。
利用烧结前的建造结构形成的制品，连同烧结前的支撑结构或层，在高温下进行煅烧。在生坯陶瓷制品的煅烧期间，所述支撑结构或层承受高温并且不会变形，由此不会有害地影响预期的陶瓷制品。随后该支撑结构或层可以在合适的溶剂中去除。支撑结构或层的去除导致成品陶瓷制品。合适的溶剂将取决于原料中使用的陶瓷前体材料。非限制性实例包括：水，碳酸溶液(碳酸盐溶液，carbonatedsolution)和酸性溶液(acidicsolution)。本领域技术人员能够基于原料中选择的陶瓷前体材料而选择具体的溶剂。
实例
用于实例1的复配程序
对于实例1，将乙烯-辛烯共聚物树脂PE1和碳酸钙粉末进行干混，随后使用重力进料器进料到27mm装有拉丝模具(stranddie)的同步转动的双螺杆挤出机(32∶1，L∶D)(商购自LeistritzCorporation.Allendale.NJ)。使用以下温度分布，在螺杆转速为250rpm下加工样品：区域1-10＝180℃，模具＝160℃。所得的挤出物的线材随后连续地加工到皮带上，通过风扇冷却到室温，并粒化为0.64cm小球。所得小球用于压制6mm方形片，6mm厚。
用于CE1和实例2的压制程序
使用加热滚筒液压机(商购自DakeCorporation，GrandHaven，MI)，制备实例2中的片。将来自实例1的大约110g的小球散布在等同于之前列出的尺寸的铝框架中，并用铝箔覆盖。在最小压力下，使加热到175℃的顶部和底部滚筒接触在铝框架中的实例1的小球达3分钟。在3分钟后，向该材料施加15吨的压力达5分钟，之后，将所述材料取出并允许以未规定的速率冷却到室温。使用之前显示的可陶瓷化聚合物重复此程序以生产CE1的10x10x0.6cm的片。
将三个铝框架垂直地堆叠。将CE1的片放置在底部。将实例1的片切成等边十字形，5cm宽且外径为4英寸，适合于之前使用的铝框架。将用于制备CE1的可陶瓷化材料的小球放置在第二框架的空腔中。将CE1的第三个片放置在顶部，并依照样品压制程序制备实例2。由CE1制成的具有10x10x0.6cm的最终尺寸且具有实例1的十字形的实例2在内部地居中。
实例2到实例3的陶瓷化和溶解
以未规定的速率在马弗炉(商购自ThermoFisherScientificCorporation，Weldham，MA)中将实例2加热至950℃达20分钟。从炉中取出此材料并允许以未规定的速率冷却到室温。这种转化得到类似实例2的初始尺寸的完全陶瓷化的、的完整制品。在水浴中浸没后，实例2中，来自实例1的CaCO3材料整个溶解，仅留下等于CE1材料的尺寸的实例3。
实例4
以与实例1类似的方式，将含有适合作为支撑层的陶瓷前体材料的纤丝挤出，并卷绕到线轴上。还以与实例1类似的方式生产含有适合作为建造层的陶瓷前体材料的纤丝，并卷绕到线轴上。将线轴装载到可得自StratasysLtd，Minneapolis，MN的MakerBotReplicator2X增材制造打印机中。将来自每个线轴的纤丝依照打印机加载程序进料到MakerBot2X挤出喷嘴中。
选择需要支撑层和建造层(其中该建造层90°悬垂)的三维制品的CAD文件并加载到MakerBot2X中。.
在约160至200℃的温度并以范围在20至100mm/s的打印速度(其中能够实现加速)打印装载的纤丝。将所述材料打印到加热至约100℃的标准Kapton带上。以5至95％的填实率打印纤丝。层高度为0.10至0.35mm。
将具有由陶瓷前体纤丝构建的建造层和支撑层的打印制品经过热处理。在惰性的、氧化性的或还原性的气体下，将打印的制品放置在马弗炉中并加热至约450℃，以用热的方法取出任何热塑性材料和水。随后在惰性的、氧化性的或还原性的气体下，将打印的制品进一步加热至超过750℃，以能够实现烧结并由此生成陶瓷制品或基本上陶瓷的制品。
以适当的速率冷却所述制品，以便不产生热裂化或翘曲(变形，warping)。该制品没有表现出支撑层或建造层的任何翘曲。建造层的结构通过热处理后保持的支撑层材料支撑。随后将该制品浸没在恰当的溶剂中以溶解或分散支撑层。将包含剩余的建造材料的制品从溶剂中取出并干燥。
表1给出了用于实例1的配方
表1：用于实例1的配方
PE1 CaCO3
CE1 25 75

Claims (15)

1.一种组合物，所述组合物包含具有聚合物基体和陶瓷前体材料的增材制造原料，其中所述陶瓷前体材料在溶剂中是可去除的。
2.根据权利要求1的组合物，其中所述聚合物基体是聚烯烃、聚乳酸聚合物和丙烯腈丁二烯苯乙烯聚合物或其组合中的一种或多种。
3.根据权利要求1的组合物，其中所述陶瓷前体材料是碳酸钙、碳酸钠、铝酸钠或其组合。
4.根据权利要求1的组合物，所述组合物还包含熔剂材料和聚合物加工助剂或其组合中的一种或多种。
5.根据权利要求4的组合物，其中所述熔剂材料包括具有三氧化硼、氧化硅、二氧化锆、氧化锂、氟、二氧化钛及其组合的玻璃熔料。
6.根据权利要求1的组合物，其中所述溶剂包括水、碳酸溶液和酸性溶液。
7.根据权利要求1的组合物，其中所述增材制造原料适合作为支撑结构。
8.一种组合物，所述组合物包含用于增材制造的原料，其中所述原料是聚合物基体和陶瓷前体材料，所述陶瓷前体材料在热加工后在溶剂中是可去除的。
9.一种方法，所述方法包括通过使用聚合物基体和陶瓷前体材料的原料的增材制造来生产制品，其中所述陶瓷前体材料在烧结后在溶剂中是可去除的。
10.一种方法，所述方法包括利用增材制造产生生坯制品，其中所述生坯制品具有通过源自聚合物基体和陶瓷前体材料的支撑层支撑的建造层，其中所述陶瓷前体材料在溶剂中是可去除的。
11.根据权利要求10的方法，所述方法还包括煅烧所述生坯制品。
12.根据权利要求11的方法，所述方法还包括通过溶剂去除所述支撑层。
13.根据权利要求11的方法，其中所述溶剂包括水、碳酸溶液和酸性溶液。
14.一种制品，所述制品包括用于增材制造的纤丝，其中所述纤丝是聚合物基体和陶瓷前体材料，其中所述陶瓷前体材料在溶剂中是可去除的。
15.一种制品，所述制品包括生坯陶瓷制品，其中所述生坯陶瓷制品通过聚合物基体和陶瓷前体材料的支撑组合物支持，其中所述陶瓷前体材料在溶剂中是可去除的。
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