JP2019519404A - 積層造形多孔質無機構造およびそれから作製される複合体のための方法 - Google Patents
積層造形多孔質無機構造およびそれから作製される複合体のための方法 Download PDFInfo
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- JP2019519404A JP2019519404A JP2018567146A JP2018567146A JP2019519404A JP 2019519404 A JP2019519404 A JP 2019519404A JP 2018567146 A JP2018567146 A JP 2018567146A JP 2018567146 A JP2018567146 A JP 2018567146A JP 2019519404 A JP2019519404 A JP 2019519404A
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- B32B18/00—Layered products essentially comprising ceramics, e.g. refractory products
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Abstract
Description
(i)有機反応性材料および無機微粒子を含む混合物を提供することと、
(ii)ノズルを介してこの混合物を分配して、基材上に堆積された押出物を形成することと、
(iii)所定のパターンで基材とノズルとの間に水平変位が存在するように、混合物を分配しながら基材、ノズル、またはそれらの組み合わせを移動させ、基材上に混合物の初期層を形成することと、
(iv)ステップ(ii)および(iii)を繰り返して、初期層上に接着した混合物の連続層を形成して、積層造形部品を形成することと、
(v)有機反応性材料を反応させて、加熱時に炭素を形成する熱硬化性材料を形成することと、
(vi)熱硬化性材料が分解し、無機微粒子を結合する炭素相を形成する温度まで積層造形部品を雰囲気中で加熱して多孔質無機部品を形成することと、を含む。
ポリエーテルイソシアネート末端ポリウレタンプレポリマーを、米国特許第8,729,168号の比較例6に記載のように調整し、全ての実施例に使用した。
Cabot Corp.から入手可能な30グラムのプレポリマーおよび10グラムのELFTEX(商標)S7100カーボンブラック(カーボンブラック充填剤)(39%容量)を、DAC 400 Speed Mixer(FlackTek Inc、Landrum SC)を用いて2000RPMで2分間混合し、印刷可能な混合物を形成した。次いで、0.35gの触媒2,2’−ジモルホリノジエチルエーテル(DMDEE)を添加し、配合物を2分間以上混合した。充填剤は、約117cc/100gのOANおよび189mg/gのヨウ素価を有していた。次いで、この材料をプラスチックバッグに移し、10ccのシリンジバレル内に押し出し、白色のSmoothflowピストンで栓をし、EFDスナップオンエンドキャップでキャップした(全てNordson Corporation、Westlake OHから購入した)。
印刷可能な混合物が、14体積%のカーボンブラック充填剤、30%の銅粉末(製品番号41205、Alfa Aesar、Haverhill、MA、0.5〜1.5μm)を含み、残部がプレポリマーおよび触媒であることを除いて、実施例1を繰り返した。実施例1と同じ方法で、印刷可能な混合物を印刷し、硬化させ、熱分解させた。炭素結合相によって結合された多孔質銅、カーボンブラック複合体を形成し、これは硬化された積層造形部品の形状を保持した。この多孔質無機体を、空気中で、実施例1の窒素熱処理と同じ方法で空気中900℃までさらに加熱した。多孔質酸化銅体を形成した。
印刷可能な混合物が、16.9体積%のカーボンブラック充填剤、32.9%のケイ素粉末(製品番号US1121、US Research Nanomaterials、Houston、TX、1〜3μmを含み、残部がプレポリマーおよび触媒であることを除いて、実施例2を繰り返した。実施例2と同じ方法で、印刷可能な混合物を印刷し、硬化させ、熱分解させた。炭素結合相によって結合された多孔質ケイ素、カーボンブラック複合体を形成し、これは硬化された積層造形部品の形状を保持した。この多孔質無機体を、実施例2のように空気中で空気中900℃までさらに加熱した。多孔質二酸化ケイ素体を形成した。
印刷可能な混合物が、24.4%の二酸化チタン粉末(製品番号US1017M、US Research Nanomaterials、Houston、TX、Anatase 1.5μm)を含み、平均粒径であり、残部がプレポリマーおよび触媒であることを除いて、実施例2を繰り返した。実施例2と同じ方法で、印刷可能な混合物を印刷し、硬化させ、熱分解させた。炭素結合相によって結合された多孔質チタニア体を形成し、これは硬化された積層造形部品の形状を保持した。この多孔質無機体を、実施例2と同じ方法で、空気中で900℃までさらに加熱した。多孔質チタニア体を形成した。
印刷可能な混合物が、36.6体積%のカーボンブラック充填剤、14.9%の二酸化チタン粉末を含み、残部がプレポリマーおよび触媒であることを除いて、実施例2を繰り返した。実施例2と同じ方法で、印刷可能な混合物を印刷し、硬化させ、熱分解させた。炭素結合相によって結合された多孔質チタニア、カーボンブラック複合体を形成し、これは硬化された積層造形部品の形状を保持した。この部品をさらに窒素雰囲気下で1500℃まで加熱して炭素熱還元を行い、硬化された積層造形部品の形状を保持した多孔質TiN(X線回折によって判定)体を形成した。
印刷可能な混合物が、24.2体積%のカーボンブラック充填剤、10.1%の三酸化タングステン粉末(製品番号11828、Alfa−Aesar、Haverhill、MA、10〜20μm)を含み、残部がプレポリマーおよび触媒であることを除いて、実施例2を繰り返した。実施例2と同じ方法で、印刷可能な混合物を印刷し、硬化させ、熱分解させた。炭素結合相によって結合された多孔質酸化タングステン、カーボンブラック複合体を形成し、これは硬化された積層造形部品の形状を保持した。
30gのプレポリマーおよび10gの微粉砕炭素繊維(250μm、CF−MLD250、Asbury Carbon、Asbury、NJ)を容器に添加し、2000RPMで2分間混合した。3.5gのELFTEX(商標)S7100カーボンブラック(Cabot Corp.)を添加し、2000RPMで2分間混合した。0.35gの触媒2,2’−ジモルホリノジエチルエーテル(DMDEE)を添加し、2000RPMで2分間混合した。その後、混合物をプラスチックバッグに移し、3D印刷に使用されるシリンジに押し出した。
46重量%のプレポリマー、46重量%の無機充填剤、7重量%のカーボンブラック充填剤、および1重量%の触媒を、実施例1と同じ方法で混合し、使用した触媒は、2,2’−ジモルホリノジエチルエーテル(Huntsman Corp.、Woodlands、TXから入手可能なJEFFCAT DMDEE触媒)であった。無機充填剤は、平均粒径14.3μm(d50)を有する、アルミナ、シリカ、マグネシア、およびFe2O3(Ceramiques Techniques et Industrielles s.a.、Salindres、Franceの噴霧乾燥混合物であった。アルミナ対シリカの比は、3対1であった。マグネシア+Fe2O3の量は、無機充填剤の総重量の2%であり、マグネシウム対鉄の比は、1:1であった。粉末を容器に添加し、2000RPMで2分間混合した。0.35gの触媒(DMDEE)を添加し、2000RPMで2分間混合した。その後、混合物をプラスチックバッグに移し、3D印刷に使用されるシリンジに押し出す。
Claims (33)
- 多孔質無機部品を積層造形する方法であって、
(i)有機反応性材料および無機微粒子を含む混合物を提供することと、
(ii)ノズルを介して前記混合物を分配して、基材上に堆積された押出物を形成することと、
(iii)所定のパターンで前記基材と前記ノズルとの間に水平変位が存在するように、前記混合物を分配しながら、前記基材、前記ノズル、またはそれらの組み合わせを移動させ、前記基材上に前記混合物の初期層を形成することと、
(iv)ステップ(ii)および(iii)を繰り返して、前記初期層上に接着した前記混合物の連続層を形成して、積層造形部品を形成することと、
(v)前記有機反応性材料を反応させて、加熱時に炭素を形成する熱硬化性材料を形成することと、
(vi)前記熱硬化性材料が分解し、前記無機微粒子を結合する炭素相を形成する温度まで前記積層造形部品を雰囲気中で加熱して、前記多孔質無機部品を形成することと、を含む、方法。 - 前記方法が、前記多孔質無機部品に液体を浸潤させ、次いで前記液体を凝固させて複合部品を形成することをさらに含む、請求項1に記載の方法。
- 前記有機反応性材料が、樹脂、モノマー、プレポリマーである、請求項1または2に記載の方法。
- 前記混合物が、少なくとも約20Paの降伏応力を有する、請求項1に記載の方法。
- 前記混合物がせん断減粘性である、請求項3に記載の方法。
- 前記有機反応性材料が、プレポリマーを含み、前記プレポリマーが、イソシアネート末端プレポリマーである、請求項1〜5のいずれか一項に記載の方法。
- 前記プレポリマーが、アクリレートモノマー、オリゴマー、またはプレポリマーをさらに含む、請求項6に記載の方法。
- 前記混合物が、2つの別個の成分を含み、第1の成分が、前記有機反応性材料および前記無機微粒子を含み、第2の成分が、前記第1の成分の前記有機反応性材料と反応する反応性材料を含む、請求項1に記載の方法。
- 前記第1の成分および前記第2の成分は、前記ノズルを介して分配する前に接触させて混合される、請求項8に記載の方法。
- 前記第1の成分および前記第2の成分は、インライン静的ミキサー、動的ミキサー、またはこれらの組み合わせの中で接触させて混合される、請求項9に記載の方法。
- 前記静的ミキサーは、少なくとも2つの区域を有し、各区域が、異なる静的ミキサー要素を含む、請求項10に記載の方法。
- 前記プレポリマーは、イソシアネート末端プレポリマーを含み、反応性構成成分が、イソシアネート反応性材料を含む、請求項8に記載の方法。
- 前記第2の成分が水を含む、請求項8に記載の方法。
- 前記イソシアネート反応性材料がポリオールを含む、請求項12に記載の方法。
- 前記イソシアネート反応性材料が、アミン基を含む主鎖を有するポリオールを含む、請求項14に記載の方法。
- 前記混合物が、1成分であり、水分に暴露されると硬化するプレポリマーを含む、請求項1〜5のいずれか一項に記載の方法。
- 多孔質積層造形物品であって、前記積層造形物品全体にわたって炭素結合相によって共に結合された少なくとも2つの無機微粒子層を含む、多孔質積層造形物品。
- 前記多孔質積層造形物品が、35%〜80%の多孔度と、少なくとも0.5MPaの圧縮強度を有する、請求項17に記載の多孔質積層造形物品。
- 前記圧縮強度が少なくとも1MPaである、請求項18に記載の多孔質積層造形物品。
- 前記多孔度が少なくとも50%であり、前記多孔度が前記積層造形物品全体にわたって連続している、請求項17〜19のいずれか一項に記載の多孔質積層造形物品。
- 前記無機微粒子が、以下の炭素、セラミック、または金属のうちの少なくとも1つの微粒子である、請求項17〜20のいずれか一項に記載の多孔質積層造形物品。
- 前記無機微粒子が、ウィスカー、短繊維、小板、不規則な形状の粒子、等尺性の粒子、またはそれらの混合物である、請求項17〜21のいずれか一項に記載の多孔質積層造形物品。
- 前記炭素結合相が、前記多孔質積層造形物品の約0.5重量%〜10重量%の量で存在する、請求項17〜22のいずれか一項に記載の多孔質積層造形物品。
- 前記炭素結合相の量が1%〜4%である、請求項23に記載の多孔質積層造形物品。
- 前記無機微粒子が短炭素繊維を含む、請求項17〜24のいずれか一項に記載の多孔質積層造形物品。
- 前記多孔質積層造形物品の前記無機微粒子が、前記凝固した液体の連続マトリックス中に包まれ、分散されている、請求項17〜25のいずれか一項に記載の多孔質積層造形物品を含む複合物品。
- 前記凝固した液体が金属または有機樹脂である、請求項26に記載の複合物品。
- 前記凝固した液体が、架橋されて熱硬化性材料を形成している前記有機樹脂である、請求項26に記載の複合物品。
- 前記凝固した液体が前記金属である、請求項26に記載の複合物品。
- 前記金属が、前記無機微粒子、炭素結合相、またはそれらの両方と反応して1つ以上の新しい相を形成する金属である、請求項29に記載の複合物品。
- 前記無機微粒子がカーボンブラックを含む、請求項26に記載の積層造形物品。
- 前記多孔質無機部品が、その後、前記多孔質無機部品を形成するために使用される雰囲気とは異なる雰囲気下で加熱され、前記無機微粒子を、それ自体、前記炭素結合相および前記無機微粒子、またはそれらの両方とさらに焼結もしくは反応させる、請求項1に記載の方法。
- 前記無機微粒子が、ムライトを形成する化合物を含む、請求項32に記載の方法。
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