Feedstocks for additive manufacturing and methods for their preparation and use
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B29B-009/12
B29B-009/16
B29C-037/00
B29C-059/00
B29C-059/16
B29C-064/00
B29C-064/106
B29C-070/64
B29C-071/04
B33Y-010/00
B33Y-070/00
C08K-009/10
C08L-055/02
C08L-069/00
C08L-079/08
B29K-069/00
B29K-055/02
B29K-105/00
B29C-035/08
B29C-059/02
출원번호
US-0508416
(2015-07-29)
등록번호
US-10144152
(2018-12-04)
국제출원번호
PCT/US2015/042692
(2015-07-29)
국제공개번호
WO2016/036449
(2016-03-10)
발명자
/ 주소
Rothfuss, Christopher J.
출원인 / 주소
EMPIRE TECHNOLOGY DEVELOPMENT LLC
대리인 / 주소
IP Spring
인용정보
피인용 횟수 :
0인용 특허 :
6
초록▼
Feedstocks for additive manufacturing are provided. The feedstock may include a matrix material, and one or more capsules disposed in the matrix material, wherein the one or more capsules are configured to be removable from a surface portion when the matrix material is solidified to form one or more
Feedstocks for additive manufacturing are provided. The feedstock may include a matrix material, and one or more capsules disposed in the matrix material, wherein the one or more capsules are configured to be removable from a surface portion when the matrix material is solidified to form one or more cavities in the surface portion. Methods of depositing the feedstocks and objects formed from the feedstocks are also provided.
대표청구항▼
1. A feedstock for additive manufacturing, the feedstock comprising: a matrix material; andone or more capsules disposed in the matrix material,wherein the one or more capsules are configured to be removable from at least a surface portion of the matrix material when the matrix material is solidifie
1. A feedstock for additive manufacturing, the feedstock comprising: a matrix material; andone or more capsules disposed in the matrix material,wherein the one or more capsules are configured to be removable from at least a surface portion of the matrix material when the matrix material is solidified, to form one or more cavities in the surface portion, and wherein the one or more capsules comprise at least one of a sacrificial material, a gas, or a vacuum and a coating that encapsulates the sacrificial material, gas, or vacuum. 2. The feedstock of claim 1, wherein the one or more capsules comprise nano-scale capsules having an average diameter of about 10 nm to 1000 nm, micro-scale capsules having an average diameter of about 1 μm to 1000 μm, or both, wherein the one or more capsules are disposed in at least the surface portion of the matrix material, wherein the one or more capsules comprise solid capsules, hollow capsules, or both, and wherein the matrix material comprises at least one thermoplastic polymer, at least one thermoset polymer, at least one photoactive polymer, or any combination thereof. 3. The feedstock of claim 1, wherein the one or more capsules are disposed substantially uniformly throughout the matrix material. 4. The feedstock of claim 2, wherein the thermoplastic polymer is polyphenylsulfone, acrylonitrile butadiene styrene, polycarbonate, polyamide, polyetherimide, polystyrene, or any combination thereof, wherein the thermoset polymer is polyvinylether, polyacrylate, epoxy resin, polyurethane, phenol-formaldehyde resin, melamine resin, polyamide, polyester, or any combination thereof, and wherein the photoactive polymer is polyacrylate, polyvinylether, epoxy, acrylate, methacrylate, epoxide, or any combination thereof. 5. The feedstock of claim 1, wherein the sacrificial material and the coating both are soluble in water, soluble in acid, soluble in an organic solvent, or any combination thereof. 6. The feedstock of claim 1, wherein the sacrificial material and the coating both are photosensitive. 7. The feedstock of claim 1, wherein the sacrificial material is polar salt, sugar, gelatin, soluble wax, or any combination thereof. 8. The feedstock of claim 1, wherein the sacrificial material is poly(propylene carbonate), polynorborene, polyimide, poly(benzoxazole), or any combination thereof. 9. The feedstock of claim 1, wherein the coating comprises wax, sugar, gelatin, cellulose, polymers, or any combination thereof. 10. The feedstock of claim 1, wherein the coating is configured to isolate the matrix material from the sacrificial material, gas, or vacuum. 11. The feedstock of claim 1, wherein the additive manufacturing is a powder-based processes, an extrusion-based process or a liquid-vat process. 12. The feedstock of claim 11, wherein the powder-based process is three-dimensional printing, laser sintering, or selective mask sintering, wherein the extrusion-based process is fused deposition modeling, multiphase jet solidification, or jetted photopolymer, and wherein the liquid-vat process is stereolithography. 13. The feedstock of claim 1, wherein a melting temperature of the one or more capsules is different than a melting temperature of the matrix material and wherein the one or more capsules are configured to be impenetrable to a wavelength of light that polymerizes the matrix material. 14. The feedstock of claim 1, further comprising one or more reinforcement structures that extend between the matrix material and the one or more capsules, wherein the reinforcement structure remains extended from the matrix material after removal of the one or more capsules, and wherein the one or more reinforcement structures comprise micro-scale fiber having an average diameter of about 1 μm to 1000 μm, nano-scale fiber having an average diameter of about 10 nm to 1000 nm, or both. 15. A method of making a feedstock for additive manufacturing, the method comprising: covering one or more capsules with a coating, wherein the one or more capsules include at least one of a sacrificial material, a gas, or a vacuum and the coating encapsulates the sacrificial material, gas, or vacuum;mixing the one or more capsules with a matrix material; andfeeding the one or more capsules and matrix material into an additive manufacturing extruder, wherein the one or more capsules are configured to be removable from a surface portion of the matrix material when the matrix material is solidified, to form one or more cavities in the surface portion. 16. The method of claim 15, wherein the mixing is performed before feeding the one or more capsules and matrix material into the additive manufacturing extruder. 17. The method of claim 15, wherein the mixing is performed while feeding the one or more capsules and matrix material into the additive manufacturing extruder. 18. The method of claim 15, wherein the mixing is performed in the additive manufacturing extruder. 19. The method of claim 15, wherein the one or more capsules and the matrix material are fed into the additive manufacturing extruder separately. 20. The feedstock of claim 1, wherein the coating is configured to release the sacrificial material, gas, or vacuum during removal of the one or more capsules from the surface portion of the matrix material. 21. The method of claim 15, wherein the one or more capsules include one or more reinforcement structures extending from the one or more capsules. 22. A feedstock for additive manufacturing, the feedstock comprising: a matrix material;one or more capsules disposed in the matrix material; andone or more reinforcement structures that extend between the matrix material and the one or more capsules,wherein the one or more capsules are configured to be removable from at least a surface portion of the matrix material when the matrix material is solidified, to form one or more cavities in the surface portion. 23. The feedstock of claim 22, wherein the one or more reinforcement structures comprise micro-scale fiber having an average diameter of about 1 μm to 1000 μm, nano-scale fiber having an average diameter of about 10 nm to 1000 nm, or both. 24. The feedstock of claim 22, wherein the reinforcement structure remains extended from the matrix material after removal of the one or more capsules.
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이 특허에 인용된 특허 (6)
Priedeman, Jr., William R., Build materials containing nanofibers for use with extrusion-based layered depositions systems.
Juskey Frank J. (Coral Springs FL) Suppelsa Anthony B. (Coral Springs FL) Dorinski Dale W. (Coral Springs FL), Method of forming a three-dimensional printed circuit assembly.
Ozaki Tatsuhiko,JPX ; Suzuki Toshiharu,JPX ; Matsueda Hirokazu,JPX, Method of providing leveling property to photocurable resin composition layers in production process of three-dimensiona.
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