Infiltrated Articles Prepared by a Laser Sintering Method and Method of Manufacturing the Same

• US 20070045891A1
• Filed: 08/22/2006
• Published: 03/01/2007
• Est. Priority Date: 08/23/2005
• Status: Abandoned Application

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: Valspar Sourcing, Inc. (Sherwin-Williams Company)
• Inventors: Boehler, Paul, Martinoni, Raffaele
• Application Number:
  US11/466,154
• Publication Number:
  US 20070045891A1
• Time in Patent Office: Days
• US Class Current: 264/128
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B33Y 40/20 Post-treatment, e.g. curing, coating or polishing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

Abstract

A composition and method of infiltrating an article of manufacture prepared by a laser sintering process is disclosed. The infiltration process maintains the dimensions and flexibility of the article, increases the strength of the article, and improves the physical and esthetic properties of the article.

Claims

1. A method of infiltrating an article prepared by a laser sintering method comprising the steps of:

(a) applying a liquid infiltrant to the article for a sufficient time to allow the liquid infiltrant to infiltrate the article, said liquid infiltrant comprising;

(i) an elastomeric material;

(ii) a vehicle; and

(iii) an optional colorant;

(b) drying the infiltrated article of step (a);

(c) optionally, repeating steps (a) and (b) until the article is infiltrated to a desired degree.

2. The method of claim 1 wherein dimensions of the article after infiltration differ from the original dimensions by less than 1%.

3. The method of claim 1 wherein the method is free of a crosslinking step.

4. The method of claim 1 wherein the article is a flexible article, and the flexibility of the article after infiltration is essentially identical to the flexibility of the article prior to infiltration.

5. The method of claim 1 wherein the elastomeric material is present in the liquid infiltrant in an amount of about 20% to about 60% by weight of the liquid infiltrant.

6. The method of claim 1 wherein the elastomeric material comprises a naturally occurring resin, a synthetic resin, or a mixture thereof.

7. The method of claim 1 wherein the naturally occurring resin comprises a natural rubber latex.

8. The method of claim 7 wherein the natural rubber latex is prevulcanized.

9. The method of claim 6 wherein the synthetic resin comprises styrene-butadiene rubber, butadiene rubber, isoprene rubber, poly(ethylene-co-propylene-co-diene) rubber, butyl rubber, nitrile rubber, acrylonitrile-butadiene rubber, acrylonitrile-chloroprene rubber, chloroprene rubber, a silicone, a fluorocarbon elastomer, poly(vinylidene fluoride-co-hexafluoropropene), a polysulfide rubber, a polyurethane, acrylate-butadiene rubber, ethylene-propylene rubber, styrene-isoprene rubber, vinylpyridine-butadine, vinylpyridine-styrene-butadiene, carboxylic-acrylonitrile-butadiene, carboxylic-styrene-butadiene, chlorobutyl rubber, bromobutyl rubber, a poly(propylene oxide), a polyesterurethane, a polyetherurethane, an acrylic elastomer, an ethylene-acrylic elastomer, a chlorosulfonated polyethylene, a polyether, and mixtures thereof.

10. The method of claim 1 wherein the vehicle of the liquid infiltrant comprises water.

11. The method of claim 10 wherein the vehicle further comprises an organic solvent.

12. The method of claim 11 wherein the organic solvent comprises an alcohol, a ketone, a glycol, a glycol ether, or mixtures thereof.

13. The method of claim 1 wherein the colorant is present in the liquid infiltrant in an amount of about 0.1% to about 15%, by weight.

14. The method of claim 1 wherein the infiltrated article is dried in step (b) at a temperature of about 20°

C. to about 80°

C.

15. The method of claim 1 wherein the infiltrated article is dried in step (b) by applying a vacuum.

16. The method of claim 1 wherein the liquid infiltrant is applied to the article by dipping the article into the liquid infiltrant.

17. The method of claim 1 wherein the liquid infiltrant is applied to the article by spraying the liquid infiltrant onto the article.

18. An infiltrated article prepared by the method of claim 1.

19. The infiltrated article of claim 18 wherein the article is substantially nonporous.

20. The infiltrated article of claim 18 wherein the article exhibits improved tear strength and elongation at break compared to the article prior to infiltration.

21. The infiltrated article of claim 18 wherein the article is infiltrated through the total volume of the article.

22. The infiltrated article of claim 18 wherein less than the total volume of the article is infiltrated.