USRE37875EExpiredUtilityPatentIndex 74

Solid imaging process using component homogenization

Priority: Apr 30, 1997Filed: Nov 13, 2000Granted: Oct 15, 2002

Est. expiryApr 30, 2017(expired)· nominal 20-yr term from priority

B22F 12/67B22F 12/44B22F 12/43B22F 10/32B22F 1/12B22F 1/09B22F 10/28B33Y 70/10B33Y 70/00Y02P10/25B29K 2105/0088B29K 2105/0064C23C 26/00C22C 12/00B22F 2998/00B29C 64/165C23C 26/02C22C 21/00C22C 28/00B33Y 10/00

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Claims

Abstract

Solid objects are formed in an imagewise layering process in which components of a dispersion are homogenized to form an alloy. Imagewise exposure of the layers to radiation to form an alloy permits separation of the exposed, homogenized regions from non-exposed, non-homogenized regions. As each layer is formed and imagewise homogenized, contiguous layer regions are bonded together to form a homogenized, three-dimensional object which may be separated from surrounding dispersion.

Claims

exact text as granted — not AI-modified

What is claimed is:

1. A process for producing a homogenized, three-dimensional, integral object by imagewise thermal radiation of a dispersion, the dispersion containing components A and B, comprising the steps of:
a) providing the dispersion containing components A and B;
b) forming the dispersion into a layer;
c) homogenizing the dispersion by applying imagewise thermal radiation to form an alloy of components A and B; and
repeating steps a)-c) by applying each successive layer of the dispersion onto the previous layer of the dispersion, such that each new homogenized region becomes integral with the previous homogenized region to form the homogenized, three-dimensional, integral object.

2. The process as claimed in claim 1 , further comprising separating the integral object from non-imaged areas of the dispersion.

3. The process as claimed in claim 1 , wherein the alloy comprising the integral object has a different melting point than the dispersion of components A and B.

4. The process as claimed in claim 1 , wherein components A and B are polymers, metals or ceramics.

5. The process as claimed in claim 1 , wherein components A and B are polymers and the alloy formed by imagewise thermal radiation is a polymer alloy.

6. The process as claimed in claim 5 , wherein one of the polymer components is liquid and one of the polymer components is particulate.

7. The process as claimed in claim 1 , wherein components A and B are metals and the alloy formed by imagewise thermal radiation is a metal alloy.

8. The process as claimed in claim 1 , wherein the alloy is a metal ceramic.

9. The process as claimed in claim 1 , wherein component A is a solid and component B is a liquid.

10. The process as claimed in claim 9 , wherein component A is particulate.

11. The process as claimed in claim 9 , wherein component A is crystalline.

12. The process as claimed in claim 9 , wherein component A is in sheet form or powder form.

13. The process as claimed in claim 9 , wherein component A and component B differ in density, and the temperature of the dispersion is maintained so as to retard or prevent separation of the components.

14. The process of claim 9 , wherein component A and component B differ in density, and the dispersion of components A and B comprises a solid phase alloy of A and B dispersed in liquid component B.

15. The process as claimed in claim 1 , wherein the dispersion further comprises a thermal dye.

16. The process as claimed in claim 1 , wherein component A has a melting point MpA, component B has a melting point MpB, and MpA is higher than MpB, and wherein homogenization forms an alloy having an eutectic which is different from MpB.

17. The process of claim 16 , wherein the integral article is separated from the dispersion based on different melting points.

18. The process as claimed in claim 5 , wherein the polymer alloy of component A/component B is polycaprolactone/poly(vinylchloride), polycaprolactone/Saran, polycaprolactone/bisphenol A polycarbonate, poly(vinyl methyl ether)/phenoxy, poly(ethylene oxide)/phenoxy, poly(ethylene oxide)/poly(acrylic acid), BPA polycarbonate/PHFA, or polystyrene/polyphenylene oxide.

19. The process as claimed in claim 7 , wherein components A and B are bismuth and magnesium or aluminum and gallium.

20. A process for producing a homogenized, three-dimensional, integral object of components A and B, comprising the steps of:
a) providing a layer of liquid component B;
b) homogenizing components A and B by adding solid or liquid component A in an imagewise manner to a surface of the layer of liquid component B for forming an alloy layer of components A and B, which alloy layer hardens upon homogenization;
c) repeating steps a)-b) by applying each successive alloy layer of homogenized region onto the previous alloy layer, such that each new homogenized region becomes integral with the previous homogenized region to form the homogenized, three-dimensional, integral object.

21. The process as claimed in claim 20 , wherein the imagewise addition of components is carried out by ink or powder jetting one component onto the previous layer.

22. The process as claimed in claim 1 , wherein the process is carried out in an inert atmosphere, a reducing atmosphere, an oxidizing atmosphere, or under a vacuum.

23. The process as claimed in claim 1 , wherein one of the components A and B is in an above solidus state in the layer of the dispersion of step b).

24. The process as claimed in claim 1 , where one component of the alloy is a polymer and the other component of the alloy is a polymer or a metal.

25. A process for producing a homogenized, three- dimensional, integral object by imagewise thermal radiation of a dispersion, comprising the steps of;
( a ) providing the dispersion containing components A and B;
( b ) homogenizing the dispersion by applying a thermal radiation exposure in a series of lines defining an image;
( c ) repeating steps a-b with subsequent application of dispersion and exposure, such that each new homogenized region becomes integral with the previous homogenized region to form the homogenized, three - dimensional, integral object.

26. The process of claim 25 wherein the dispersion of components A and B has a thickness and adequate exposure is provided to homogenize components A and B greater than said thickness.

27. The process of claim 26 wherein said dispersion of components A and B is provided on a surface and said surface is preheated by thermal radiation.

28. The process of claim 25 wherein said dispersion is a mixture of powders.

29. The process of claim 25 wherein said dispersion is a mixture of a liquid and a powder.

30. The process of claim 25 wherein components A and B of the dispersion have a concentration of said concentration is varied during the production of said object whereby said object has a variation of properties.

31. The process of claim 25 wherein said object has cantilevered or other unsupported sections.

32. A method for forming an integral object from a composition in a layer- by - layer process wherein properties within said object are changed, said process comprising the steps:

providing a layer of composition;

homogenizing said composition;

changing the properties of regions of the layer of composition by exposing the composition to imaging radiation and repeating steps a-b with subsequent applications of composition and exposure, such that a portion of each new imaged composition region becomes integral with the previous imaged composition region to form an integral three dimensional object;

wherein the properties within said integral object are changed by varying the imaging radiation time, temperature, and/or intensity.

33. A method according to claim 32 wherein said imaging radiation is thermal.

34. A process for producing a homogenized, three- dimensional, integral object by imagewise radiation of a dispersion, the dispersion containing components A and B, comprising the steps of:
a ) providing the dispersion containing components A and B;
b ) forming the dispersion into a layer;
c ) thermally homogenizing the dispersion by applying imagewise radiation to form an alloy of components A and B; and
d ) repeating steps a ) -c ) by applying each successive layer of the dispersion onto the previous layer of the dispersion, such that each new homogenized region becomes integral with the previous homogenized region to form the homogenized, three - dimensional, integral object.

35. A process according to claim 34 , wherein said dispersion comprises polymer A and polymer and/or monomer B components.

36. A process according to claim 35 , wherein polymerization of B as well as thermal homogenization of A and B occurs.

37. A process according to claim 36 , wherein said polymerization is an acrylate polymerization.

38. A process according to claim 35 , wherein the dispersion further comprises an initiator.

39. A process according to claim 38 , wherein polymerization of B as well as thermal homogenization of A and B occurs.

40. A process according to claim 39 , wherein said polymerization is an acrylate polymerization.

41. A process according to claim 38 , wherein said initiator is a free- radical photoinitiator.

42. A process according to claim 41 , wherein polymerization of B as well as thermal homogenization of A and B occurs.

43. A process according to claim 42 , wherein said polymerization is an acrylate polymerization.

44. A process for producing a homogenized coating from a dispersion of polymer A and polymer and/or monomer B components, comprising the steps of;
a ) providing the dispersion containing components A and B;
b ) forming the dispersion into a layer;
c ) thermally homogenizing the dispersion by applying imaging radiation to form an alloy of components A and B.

45. A process according to claim 44 , wherein polymerization of B as well as thermal homogenization of A and B occurs.

46. A process according to claim 44 , wherein the dispersion further comprises an initiator.

47. A process according to claim 46 , wherein polymerization of B as well as thermal homogenization of A and B occurs.

48. A process according to claim 44 , wherein said layer of dispersion is formed on a surface.

49. A process according to claim 48 , wherein said homogenized alloy of components A and B adheres to said surface.

50. A process according to claim 49 , wherein polymerization of B as well as thermal homogenization of A and B occurs.

51. A method for forming an integral object from a composition in a layer- by - layer process wherein properties within said object are changed, said process comprising the steps:

providing a layer of composition;

thermally changing the properties of regions of the layer of composition by exposing the composition to imaging radiation and repeating steps a-b with subsequent applications of composition and exposure, such that a portion of each new imaged composition region becomes integral with the previous imaged composition region to form an integral three dimensional object;

wherein the properties within said integral object are changed by varying the imaging radiation time, temperature, and/or intensity.

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