JP7101181B2 - 焼結可能コアおよびポリマー被覆を有する粒子、その使用、並びにそれを使用する付加製造法 - Google Patents
焼結可能コアおよびポリマー被覆を有する粒子、その使用、並びにそれを使用する付加製造法 Download PDFInfo
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Description
(1) 焼結可能なコア及び該コアの少なくともの一部上のポリマー被覆をそれぞれが有する複数の粒子であって、
前記ポリマー被覆は、熱、触媒作用又は溶媒処理による分解により除去可能なポリマーを含み、前記ポリマー被覆は、前記粒子の総重量に対して0.10~10.00重量%の量で存在する、粒子。
(2) 熱、触媒作用又は溶媒処理による分解により除去可能な前記ポリマーは、ポリオレフィン、ポリ(メタ)アクリレート、ポリアルキレンオキシド、ポリウレタン、ポリエステル、ポリカーボネート、ポリビニルピロリドン、及び共重合体(コポリマー)、並びにこれらの混合物からなるポリマータイプの群から選択される、(1)に記載された粒子。
(3) 熱、触媒作用又は溶媒処理による分解により除去可能な前記ポリマーは、1,000~50,000の重量平均分子量(Mw)を有するポリビニルピロリドンである、(1)または(2)に記載された粒子。
(4) 前記ポリマー被覆は、界面活性剤、好ましくは非イオン性界面活性剤、及び/又は、好ましくはポリオールを含む湿潤剤を含む、(1)から(3)までのいずれか1項に記載された粒子。
(5) 前記焼結可能コアは、金属、合金、セラミックス又はサーメットからできている、(1)から(4)までのいずれか1項に記載された粒子。
(6) 前記焼結可能コアはステンレス鋼からできている、(1)から(5)までのいずれか1項に記載された粒子。
(7) 95重量%以上の粒子が50μm以下の直径を有する粒度分布(X95≦50μm)を有する、(1)から(6)までのいずれか1項に記載された粒子。
(8) 付加製造プロセス、とりわけ、粉末床インクジェットヘッド3Dプリンティングプロセスにおける、(1)から(7)までのいずれか1項において定義された粒子の使用。
(9) 前記粒子の予備結合に液体バインダー組成物を使用し、該液体バインダー組成物は、ポリオレフィン、ポリ(メタ)アクリレート、ポリアルキレンオキシド、ポリウレタン、ポリエステル、ポリカーボネート、ポリビニルピロリドン、及び共重合体、並びにこれらの混合物からなる群から選択されるポリマータイプのポリマーを含み、同じポリマータイプが前記粒子の前記ポリマー被覆に存在する、(8)に記載された使用。
(10) (1)から(7)までのいずれか1項に記載された粒子をバインダー組成物と結合させることにより得ることが可能なグリーン部品。
(11) 前記バインダーは、ポリオレフィン、ポリ(メタ)アクリレート、ポリウレタン、ポリエステル、ポリカーボネート、ポリビニルピロリドン、及び共重合体、並びにこれらの混合物からなる群から選択されるポリマータイプのポリマーを含み、同じポリマータイプが前記粒子の前記ポリマー被覆に存在する、(10)に記載されたグリーン部品。
(12) 2.7MPa以上、好ましくは3.0MPa以上のグリーン強度を有する、(10)又は(11)に記載されたグリーン部品。
(13) (1)から(6)までのいずれか1項に記載された粒子をバインダー相により結合させてグリーン部品を成形する工程と、熱処理、溶媒抽出又は触媒作用により前記バインダー相及び前記ポリマー被覆を除去してブラウン部品を成形する工程と、前記ブラウン部品を焼結して前記粒子の前記コアの原料から構成される目的物を得る工程とを含む、付加製造法。
(14) 粉末床インクジェット3Dプリンティング法である、(13)に記載された付加製造法。
以下の用語を続く発明を実施するための形態において使用する。
本発明の粒子は、コアの表面の少なくとも一部上にポリマー被覆が塗布されている焼結可能コアを有する。焼結可能粒子は3D製造プロセスに好適に用いられる任意の原料から構成され得、一般的に、コア用には無機原料が用いられる。焼結可能粒子のコアは、任意の金属、合金、ガラス、セラミックス原料又はこれらの混合物で製造することができる。
グリーン部品を成形するために粒子を使用する間、液体バインダー組成物(「インク」)を使用して粒子同士を予備的に結合させる。液体バインダー組成物は通常、本発明の粒子のポリマー被覆中におけるポリマー用に上で列挙した同一群のポリマーから選択されるポリマーを含む。液体バインダー組成物(「インク」)中に存在するポリマーは、ポリマー被覆中に存在するポリマーと同一タイプのポリマーであることが好ましいが、このことは必須ではなく、ポリマーは異なるタイプのポリマーであってもよい。ポリマーが同一タイプのポリマーである実施形態は、例えば、ポリマー被覆中のポリマーとインク中に存在するポリマーの両方がポリビニルピロリドンであり、好ましくはそのそれぞれが1,000~50,000、より好ましくは5,000~30,000の範囲のMwを有するような実施形態である。この実施形態は、様々な焼結可能コア、例えば、ステンレス鋼製の焼結可能コアに適用することができる。
粒子Aの調製
990gのガスアトマイズステンレス鋼粒子316L(公称組成(重量%)がC0.03、Mn2.00、P0.045、S0.030、Si1.00、Cr16.00~18.00、Ni10.00~14.00、Mo2.00~3.00、残部FeのCarTech(登録商標)316Lの商標名にてCarpenterから入手可能)を混練槽に投入し、オーバーヘッド攪拌機のシャフト用の開口部及び液体の添加を可能とする別の開口部を有する蓋で覆った。
被覆溶液Aの添加後に得られた粒子を200℃で3時間乾燥させる前に150℃で2時間予備乾燥させること以外は粒子Aと同じ方法で粒子A´を調製した。
被覆溶液Aの代わりに被覆溶液Bを使用すること以外は粒子Aと同じ方法で粒子Bを調製した。被覆溶液Bは、7.5gのPVP(Mw=25,000)を50mlの溶液(水84.4%、エチレングリコール10%、15,000のMwを有するPVP5%、Tego Wet 500(非イオン性界面活性剤、オキシラン2-メチル、オキシラン、モノ(3,5,5-トリメチルヘキシル)エーテルを含むポリマー、CAS 204336-40-3)0.5%、及びアシッドレッド色素(CAS 3734-67-6)0.1%)へと添加することにより得られる溶液である。
被覆溶液Aの代わりに上記被覆溶液Bを使用し、150℃の代わりに120℃の温度で予備乾燥を行うこと以外は粒子A´と同じ方法で粒子B´を調製した。
基準粒子として、ガスアトマイズステンレス鋼粒子316L(CarTech 316Lの商標名にてCarpenterから入手可能)を何ら更なる処理をせずに使用した。
規定寸法のプラスチックモールドを用いて、グリーン強度を評価するための三点曲げ試験の実施に必要な30mm × 10mm(長さ × 幅)、おおよそ6mm(高さ)のTRSバーを作製した。
ISO 3995:1985に従う抗折力(TRS)、三点曲げ試験によりGSを得る。
を使用して最大グリーン強度を得ることができるが、これらの語句は以下の意味を有する(図2も参照のこと)。
GS:グリーン強度(MPa)
P:力(N)
S=支持ローラー間の距離(mm)
h:試験片の高さ(mm)
b:試験片の幅(mm)(図2のL(四角試験片の幅)と等しい)
グリーン強度を測定するために、TRSバーの寸法を測定した。その後、ISO 3995:1985に従い三点曲げ装置でTRSバーの試験を行った。フォーストランスデューサー(TH-UM T-Hydronics Inc)でフォースシグナルを受信し、フォースインディケーター(Nobel Elektronik BKI-5)で記録した。原料及び結果については以下の表1にまとめている。
被覆溶液タイプA:
7.5gのPVP(Mw=25,000)を50mlの溶液(水74.65%、トリエチレングリコール12%、1,2ヘキサンジオール5%、非イオン性界面活性剤3.25%、25,000~30,000のMwを有するPVP5%、及びシアン色素0.1%)へと添加することにより調製した溶液
被覆溶液タイプB:
7.5gのPVP(Mw=25,000)を50mlの溶液(水84.4%、エチレングリコール10%、15,000のMwを有するPVP5%、Tego Wet 500(非イオン性界面活性剤、オキシラン2-メチル、オキシラン、モノ(3,5,5-トリメチルヘキシル)エーテルを含むポリマー、CAS 204336-40-3)0.5%、及びアシッドレッド色素(CAS 3734-67-6)0.1%)へと添加することにより調製した溶液
湿潤インクA:
水74.65%、トリエチレングリコール12%、1,2ヘキサンジオール5%、非イオン性界面活性剤3.25%、25,000~30,000のMwを有するPVP5%、及びシアン色素0.1%
湿潤インクB:
水84.4%、エチレングリコール10%、15,000のMwを有するPVP5%、Tego Wet 500(非イオン性界面活性剤、オキシラン2-メチル、オキシラン、モノ(3,5,5-トリメチルヘキシル)エーテルを含むポリマー、CAS 204336-40-3)0.5%、及びアシッドレッド色素(CAS 3734-67-6)0.1%
被覆溶液A/Bに添加したPVP(25,000のMw)の量を1重量%(粒子A及びB)ではなく2重量%の理論上のPVP含有量に到達するように増加させること以外はポリマー粒子A及びBと類似の方法でポリマー粒子C及びDを調製した。それゆえ、316Lステンレス鋼粒子の量は980gに減少させた。
被覆溶液タイプA´:
16.25gのPVP(Mw=25,000)を50mlの溶液(水74.65%、トリエチレングリコール12%、1,2ヘキサンジオール5%、非イオン性界面活性剤3.25%、25,000~30,000のMwを有するPVP5%、及びシアン色素0.1%)へと添加することにより調製した溶液
被覆溶液タイプB´:
16.25gのPVP(Mw=25,000)を50mlの溶液(水79.9%、エチレングリコール10%、15,000のMwを有するPVP5%、Tego Wet 500(非イオン性界面活性剤、オキシラン2-メチル、オキシラン、モノ(3,5,5-トリメチルヘキシル)エーテルを含むポリマー、CAS 204336-40-3)2.5%、BYK DYNWET 800 N 2.5%、及びアシッドレッド色素(CAS 3734-67-6)0.1%)へと添加することにより調製した溶液
湿潤インクA:
水74.65%、トリエチレングリコール12%、1,2ヘキサンジオール5%、非イオン性界面活性剤3.25%、25,000~30,000のMwを有するPVP5%、及びシアン色素0.1%
湿潤インクB:
水84.4%、エチレングリコール10%、15,000のMwを有するPVP5%、Tego Wet 500(非イオン性界面活性剤、オキシラン2-メチル、オキシラン、モノ(3,5,5-トリメチルヘキシル)エーテルを含むポリマー、CAS 204336-40-3)0.5%、及びアシッドレッド色素(CAS 3734-67-6)0.1%
Claims (14)
- ステンレス鋼からなる焼結可能なコア及び該コアの少なくともの一部上のポリマー被覆をそれぞれが有する複数の粒子であって、
前記ポリマー被覆は、ポリスチレンを標準物質として使用したGPC法により測定された重量平均分子量(Mw)が1,000~50,000g/モルであるポリビニルピロリドンが、前記ポリマー被覆の総重量の80重量%以上を占め、
前記ポリマー被覆は、熱、触媒作用又は溶媒処理による分解により除去可能であり、前記ポリマー被覆は、前記粒子の総重量に対して0.10~10.00重量%の量で存在する、粒子。 - 前記ポリマー被覆は、界面活性剤及び/又は湿潤剤を含む、請求項1に記載された粒子。
- 非イオン性界面活性剤である前記界面活性剤を含む、請求項2に記載された粒子。
- ポリオールである前記湿潤剤を含む、請求項2又は請求項3に記載された粒子。
- 95重量%以上の粒子が、S-ISO 13320-1に従うレーザー回折法により測定して50μm以下の直径を有する粒度分布(X95≦50μm)を有する、請求項1から請求項4までのいずれか1項に記載された粒子。
- 付加製造プロセスにおける、請求項1から請求項5までのいずれか1項に記載された粒子の使用。
- 前記付加製造プロセスが、粉末床インクジェットヘッド3Dプリンティング法である、請求項6に記載された使用。
- 前記粒子の予備結合に液体バインダー組成物を使用し、該液体バインダー組成物は、ポリビニルピロリドンを含み、同じポリマータイプが前記粒子の前記ポリマー被覆に存在し、同じポリマータイプの各々のポリマーは、ポリスチレンを標準物質として使用したGPC法により測定された重量平均分子量(Mw)が1,000~50,000g/モルである、請求項6又は請求項7に記載された使用。
- 請求項1から請求項5までのいずれか1項に記載された粒子がバインダー組成物により結合されたグリーン部品。
- 前記バインダーは、ポリビニルピロリドンを含み、同じポリマータイプが前記粒子の前記ポリマー被覆に存在し、同じポリマータイプの各々のポリマーは、ポリスチレンを標準物質として使用したGPC法により測定された重量平均分子量(Mw)が1,000~50,000g/モルである、請求項9に記載されたグリーン部品。
- 2.7MPa以上のグリーン強度を有する、請求項9又は請求項10に記載されたグリーン部品。
- 3.0MPa以上のグリーン強度を有する、請求項9又は請求項10に記載されたグリーン部品。
- 請求項1から請求項5までのいずれか1項に記載された粒子をバインダー組成物により結合させてグリーン部品を成形する工程と、
熱処理、溶媒抽出又は触媒作用により前記バインダー組成物及び前記ポリマー被覆を除去してブラウン部品を成形する工程と、
前記ブラウン部品を焼結して前記粒子の前記コアの原料から構成される目的物を得る工程と
を含む、付加製造法。 - 粉末床インクジェットヘッド3Dプリンティング法である、請求項13に記載された付加製造法。
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CN104858422B (zh) * | 2015-05-22 | 2017-05-31 | 东莞劲胜精密组件股份有限公司 | 一种用于3d打印的不锈钢复合粉料及其制备方法 |
US10818405B2 (en) * | 2015-07-09 | 2020-10-27 | Furukawa Electric Co., Ltd. | Metal fine particle-containing composition |
CN108883577B (zh) * | 2016-05-12 | 2021-01-01 | 惠普发展公司,有限责任合伙企业 | 三维(3d)打印 |
CN106042408A (zh) * | 2016-06-22 | 2016-10-26 | 武汉易制科技有限公司 | 一种用于3d打印的粉末材料及粉末3d打印成形方法 |
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2017
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- 2018-02-09 JP JP2019543978A patent/JP7101181B2/ja active Active
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WO2009060803A1 (ja) | 2007-11-05 | 2009-05-14 | Sumitomo Metal Mining Co., Ltd. | 銅微粒子とその製造方法及び銅微粒子分散液 |
WO2016068899A1 (en) | 2014-10-29 | 2016-05-06 | Hewlett-Packard Development Company, L.P. | Three-dimensional (3d) printing method |
JP2016223005A (ja) | 2015-03-18 | 2016-12-28 | 株式会社リコー | 立体造形用粉末材料、立体造形用キット、立体造形用グリーン体、立体造形物及び立体造形用グリーン体の製造方法、立体造形物及び立体造形用グリーン体の製造装置 |
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EP3363561A1 (en) | 2018-08-22 |
WO2018149748A1 (en) | 2018-08-23 |
EP3582912A1 (en) | 2019-12-25 |
CN110545937A (zh) | 2019-12-06 |
JP2020511593A (ja) | 2020-04-16 |
KR20190120248A (ko) | 2019-10-23 |
CN116159996A (zh) | 2023-05-26 |
ZA201905495B (en) | 2022-12-21 |
EP3582912C0 (en) | 2023-09-27 |
EP3582912B1 (en) | 2023-09-27 |
US20200001359A1 (en) | 2020-01-02 |
KR102434963B1 (ko) | 2022-08-22 |
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