Rapid prototyping material systems

• US 6,742,456 B1
• Filed: 11/14/2002
• Issued: 06/01/2004
• Est. Priority Date: 11/14/2002
• Status: Expired due to Term

• Current Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Original Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Inventors: Lambright, Terry M., Kasperchik, Vladek
• Primary Examiner(s): Eickholt, Eugene H.
• Application Number:
  US10/295,132
• Publication Number:
  US 20040094058A1
• Time in Patent Office: 565 Days
• Field of Search: 101/483, 101/401.1, 264/16, 264/69, 264/111, 264/123, 264/162.9, 264/287.84, 264/308, 264/600, 264/634, 264/636, 264/808, 264/816, 264/204.1, 430/287.1, 430/276.1, 430/286.1, 430/302, 430/303, 156/284, 156/305, 156/59, 426/546
• US Class Current: 101/483
• CPC Class Codes: B33Y 70/10 Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
• CPC Class Codes: C04B 35/624 Sol-gel processing
• CPC Class Codes: Y10S 264/72 Processes of molding by spraying

Abstract

A rapid prototyping system preferably includes a basic component in powder form selected from the group consisting of a metal oxide, and one or more aluminosilicate glasses; an acidic component (polymeric, oligomeric or polymerizable low molecular weight acid or hydrolyzable acidic metal salt); and an aqueous binder capable of stimulating a crosslinking reaction between the basic component and the acidic component to form a three-dimensional printed object.

Claims

1. A rapid prototyping material system, which comprises:

a basic component selected from the group consisting of a metal oxide, and one or more aluminosilicate glasses;

an acidic component; and

an aqueous binder capable of initiating a crosslinking reaction between said basic component and said acidic component to form a three-dimensional printed object;

wherein said basic component remains in a dry powder form prior to an application of said aqueous binder.

2. A rapid prototyping system according to claim 1, wherein said acidic component is one or more acidic components selected from the group consisting of an organic polyacid, a monomer acid, a monomer having anions capable of forming hydrogel salts that are cross-linkable with metal ions from said basic metal oxide, and a hydrolyzable metal salt capable of forming an oxysalt polymer matrix with said basic metal oxide.

3. A rapid prototyping system according to claim 1, wherein said basic component is a metal oxide, and said acidic component is a polycarboxylic acid.

4. A rapid prototyping system according to claim 3, wherein said metal oxide is zinc oxide.

5. A rapid prototyping system according to claim 1, wherein said basic component is a metal oxide, and said acidic component is at least one component selected from the group consisting of orthophosphoric acid and polyphosphoric acid.

6. A rapid prototyping system according to claim 5, wherein cations from said metal in said metal oxide are capable of mediating crosslinking of phosphate anionic species from said orthophosphoric acid and/or said polyphosphoric acid.

7. A rapid prototyping system according to claim 5, wherein said metal in said metal oxide is selected from the group consisting of Be, Zn, Cu, Mg, Ca, Sr and Ba.

8. A rapid prototyping system according to claim 1, wherein said basic component is a metal oxide, and said acidic component is a metal chloride or sulfate that forms an oxysalt bond with said metal oxide.

9. A rapid prototyping system according to claim 8, wherein each of said basic component and said acidic component includes Zn and/or Mg.

10. A rapid prototyping material system which comprises:

a basic component selected from the group consisting of a metal oxide, and one or more aluminosilicate glasses;

an acidic component; and

an aqueous hinder capable of initiating a crosslinking reaction between said basic component and said acidic component to form a three-dimensional printed object;

wherein said basic component is one or more varieties of said aluminosilicate glass, and said acidic component is at least one component selected from the group consisting of orthophosphoric acid and polyphosphoric acid.

11. A rapid prototyping system comprising:

basic component including one or more varieties of aluminosilicate glass;

an acidic component selected from the group consisting of an organic polyacid and contains one or more functional groups selected from the group consisting of —

COOH, —

SO₃H, and —

PO₃H₂; and

an aqueous binder capable of initiating a crosslinking reaction between said basic component and said acidic component to form a three-dimensional printed object.

12. A rapid prototyping system according to claim 11, wherein said basic and acidic components combine to form glass-ionomer cements, and said system further comprises a complexing agent for adjusting reaction kinetics between said acidic component and said basic component.

13. A rapid prototyping system according to claim 12, wherein said complexing agent is L- or D-tartaric acid.

14. A rapid prototyping system comprising:

a basic component selected from the group consisting of a metal oxide, and one or more aluminosilicate glasses;

an acidic component; and

an aqueous binder capable of initiating a crosslinking reaction between said basic component and said acidic component to form a three-dimensional printed object;

wherein said acidic and said basic component are mixed together in a dry powder form prior to the addition of said aqueous binder, said acidic component being an organic polyacid of an average molecular weight ranging from about 500 to about 1,000,000.

15. A rapid prototyping system according to claim 14, wherein said organic polyacid is of an average molecular weight ranging from about 2,000 to about 150,000.

16. A rapid prototyping system comprising:

a basic component selected from the group consisting of a metal oxide, and one or more aluminosilicate glasses;

an acidic component; and

an aqueous binder capable of initiating a crosslinking reaction between said basic component and said acidic component to form a three-dimensional printed object;

wherein said basic component is in a powder form, and said acidic component is stored separately in a liquid form, and mixed with said aqueous binder.

17. A rapid prototyping system comprising:

a basic component selected from the group consisting of a metal oxide, and one or more aluminosilicate glasses;

an acidic component; and

an aqueous binder capable of initiating a crosslinking reaction between said basic component and said acidic component to form a three-dimensional printed object;

wherein said acidic and said basic component are combined together in a dry powder form prior to the addition of said aqueous binder, and said aqueous binder is separately mixed with additional amounts of said acidic component.

18. A rapid prototyping system according to claim 17, wherein said acidic component in said dry powder has a higher average molecular weight than said acidic component that is mixed with said aqueous binder.

19. A rapid prototyping system comprising:

a basic component selected from the group consisting of a metal oxide, and one or more aluminosilicate glasses;

an acidic component; and

an aqueous binder capable of initiating a crosslinking reaction between said basic component and said acidic component to form a three-dimensional printed object;

wherein said acidic component further includes unsaturated covalently polymerizable unsaturated acidic moieties of a monomeric or oligomeric nature, and/or salts or other acid derivative groups of said moieties; and

said system further includes a polymerization initiator.

20. A composition for rapid prototyping, which comprises:

a basic component and an acidic component mixed together in a dry powder form, wherein said basic component is selected from the group consisting of a metal oxide, and one or more aluminosilicate glasses, and said acidic component is one or more acidic components selected from the group consisting of an organic polyacid, a monomer acid, a monomer having anions capable of forming hydrogel salts that are cross-linkable with metal ions from said basic metal oxide, and a hydrolyzable metal salt capable of forming an oxysalt polymer matrix with said basic metal oxide.

21. A composition according to claim 20, wherein said acid component is an organic polyacid of an average molecular weight ranging from about 2,000 to about 1,000,000.

22. A composition according to claim 21, wherein said organic polyacid is of an average molecular weight ranging from about 10,000 to about 150,000.

23. A composition according to claim 20, wherein said acid component is an organic polyacid having a higher average molecular weight than that of a separate acid component that is mixed with an aqueous binder capable of stimulating a crosslinking reaction between a basic component and said acidic component to form a three-dimensional printed object.

24. A composition according to claim 20, wherein said acidic component further includes unsaturated covalently polymerizable acidic moieties of a monomeric or oligomeric nature, and/or salts or other acid derivative groups of said moieties;

and said composition further includes a polymerization initiator.

25. A composition for rapid prototyping, which comprises:

an acidic component mixed with an aqueous binder capable of stimulating a crosslinking reaction between a basic component and said acidic component to form a three-dimensional printed object, the basic component being selected from the group consisting of a metal oxide, and one or more aluminosilicate glasses in powder form prior to an application of said aqueous binder, and the acid component being one or more acidic components selected from the group consisting of an organic polyacid, a monomer acid, a monomer having anions capable of forming hydrogel salts that are cross-linkable with metal ions from said basic metal oxide, and a hydrolyzable metal salt capable of forming an oxysalt polymer matrix with said basic metal oxide.

26. A composition according to claim 25, wherein said acidic component further includes unsaturated covalently polymerizable acidic moieties of a monomeric or oligomeric nature, and/or salts or other acid derivative groups of said moieties;

and said composition further includes a polymerization initiator.

27. A method for printing a three-dimensional object, which comprises:

iteratively infiltrating individual layers of powder including a basic component with an aqueous binder solution capable of stimulating a crosslinking reaction between said basic component and an acidic component, the infiltrated powder layers being formed adjacent to one another to form said three-dimensional printed object,

wherein said basic component is selected from the group consisting of a metal oxide, and one or more aluminosilicate glasses, and said acid component is mixed with said powder and/or said aqueous binder solution.

28. A method according to claim 27, wherein said acid component is selected from the group consisting of an organic polyacid, a monomer acid, a monomer having anions capable of forming hydrogel salts that are cross-linkable with metal ions from said basic metal oxide, and a hydrolyzable metal salt capable of forming an oxysalt polymer matrix with said basic metal oxide.

29. A method according to claim 27, wherein said basic component is a metal oxide, and said acidic component is a polycarboxylic acid.

30. A method according to claim 29, wherein said metal oxide is zinc oxide.

31. A method according to claim 27, wherein said basic component is a metal oxide, and said acidic component is at least one component selected from the group consisting of orthophosphoric acid and polyphosphoric acid.

32. A method according to claim 31, wherein cations from said metal in said metal oxide are capable of crosslinking with phosphate anions from said orthophosphoric acid and/or said polyphosphoric acid.

33. A method according to claim 32, wherein said metal in said metal oxide is selected from the group consisting of Be, Zn, Cu, Mg, Ca, Sr and Ba.

34. A method according to claim 27, wherein said basic component is one or more varieties of said aluminosilicate glass, and said acidic component is at least one component selected from the group consisting of orthophosphoric acid and polyphosphoric acid.

35. A method according to claim 27, wherein said basic component is a metal oxide, and said acidic component is a metal chloride or sulfate that forms an oxysalt bond with said metal oxide.

36. A method according to claim 35, wherein each of said basic component and said acidic component includes Zn and/or Mg.

37. A method according to claim 27, wherein said basic component is one or more varieties of said aluminosilicate glass, and said acidic component is an organic polyacid and contains containing one or more functional groups selected from the group consisting of —

COOH, —

SO₃H, and —

PO₃H₂.

38. A rapid prototyping system according to claim 37, wherein said basic and acidic components combine to form glass-ionomer cements, and said system further comprises a complexing agent for adjusting reaction kinetics between said acidic component and said basic component.

39. A method according to claim 38, wherein said complexing agent is L-or D-tartaric acid.

40. A method according to claim 27, wherein said acidic component is mixed with said dry powder prior to the addition of said aqueous binder, said acidic component being an organic polyacid of an average molecular weight ranging from about 2,000 to about 1,000,000.

41. A method according to claim 40, wherein said organic polyacid is of an average molecular weight ranging from about 10,000 to about 150,000.

42. A method according to claim 27, wherein said acidic component is entirely separate from said powder, and is mixed with said aqueous binder.

43. A method according to claim 27, wherein said acidic component is mixed with said dry powder prior to the addition of said aqueous binder, and said aqueous binder is separately mixed with additional amounts of said acidic component.

44. A method according to claim 43, wherein said acidic component mixed with said dry powder has a higher average molecular weight than said acidic component that is mixed with said aqueous binder.

45. A method according to claim 44, wherein said acidic component further includes unsaturated covalently polymerizable acidic moieties of a monomeric or oligomeric nature, and/or salts or other acid derivative groups of said moieties;

and said system further includes a polymerization initiator.

46. A rapid prototyping material system, which comprises:

a basic component including one or more aluminosilicate glasses;

an acidic component; and

an aqueous binder capable of initiating a crosslinking reaction between said basic component and said acidic component to form a three-dimensional printed object.

47. A rapid prototyping system according to claim 46, wherein said acidic component is at least one component selected from the group consisting of orthophosphoric acid and polyphosphoric acid.

48. A rapid prototyping system according to claim 46, wherein said acidic component is an organic polyacid and contains one or more functional groups selected from the group consisting of —

COOH, —

SO₃H, and —

PO₃H₂.

49. A rapid prototyping system according to claim 48, wherein said basic and acidic components combine to form glass-ionomer cements, and said system further comprises a complexing agent for adjusting reaction kinetics between said acidic component and said basic component.

50. A rapid prototyping system according to claim 49, wherein said complexing agent is L- or D-tartaric acid.

51. A rapid prototyping system according to claim 46, wherein said acidic and said basic component are mixed together in a dry powder form prior to the addition of said aqueous binder, said acidic component being an organic polyacid of an average molecular weight ranging from about 500 to about 1,000,000.

52. A rapid prototyping system according to claim 51, wherein said organic polyacid is of an average molecular weight ranging from about 2,000 to about 150,000.

53. A rapid prototyping system according to claim 46, wherein said acidic component further includes unsaturated covalently polymerizable unsaturated acidic moieties of a monomeric or oligomeric nature, and/or salts or other acid derivative groups of said moieties;

and said system further includes a polymerization initiator.