Resin-modified inorganic phosphate cement for solid freeform fabrication

• US 7,455,805 B2
• Filed: 10/28/2003
• Issued: 11/25/2008
• Est. Priority Date: 10/28/2003
• Status: Expired due to Fees

• Current Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Original Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Inventors: Lambright, Terry M., Farr, Isaac, Oriakhi, Christopher
• Primary Examiner(s): Tentoni; Leo B
• Application Number:
  US10/696,330
• Publication Number:
  US 20050089636A1
• Time in Patent Office: 1,855 Days
• Field of Search: 264/78, 264/113, 264/463, 264/494
• US Class Current: 264/463
• CPC Class Codes: B28B 1/00 Producing shaped prefabricated articles from the material using presses B28B3/00; shaping on moving conveyors B28B5/00; producing tubular articles B28B21/00 ; producing articles with embedded elements B28B23/00
• CPC Class Codes: B28B 1/001 Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00
• 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 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• 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 2111/00181 Mixtures specially adapted for three-dimensional printing (3DP), stereo-lithography or prototyping
• CPC Class Codes: C04B 22/16 containing phosphorus in the anion, e.g. phosphates
• CPC Class Codes: C04B 24/2641 Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 28/28 containing organic polyacids, e.g. polycarboxylate cements , i.e. ionomeric systems
• CPC Class Codes: C04B 28/344 the phosphate binder being present in the starting composition solely as one or more phosphates

Abstract

A method for solid free-form fabrication of a three-dimensional object includes depositing a particulate blend in a defined region, the particulate blend including radical source particulates, polyacid particulates, multivalent cation particulates, and a calcium phosphate source particulates, ink-jetting a liquid phase binder onto a predetermined area of the particulate blend to form hydrated cement in the predetermined area, wherein the liquid phase binder is acidic and includes reactive monomers, and hardening the hydrated cement.

Claims

1. A method for solid free-form fabrication of a three-dimensional object, comprising:

depositing a particulate blend in a defined region, said particulate blend including radical source particulates, polyacid particulates, multivalent cation particulates, and calcium phosphate source particulates;

ink-jetting a liquid phase binder onto a predetermined area of said particulate blend to form hydrated cement in said predetermined area, wherein said liquid phase binder is acidic and includes reactive monomers; and

setting said hydrated cement.

2. The method of claim 1, further comprising removing a portion of said particulate blend that does not form said hydrated cement.

3. The method of claim 1, wherein said setting said hydrated cement further comprises:

performing a polymerization setting reaction;

performing an acid/base setting reaction; and

performing a re-precipitation setting reaction.

4. The method of claim 1, wherein said reactive monomers comprise one of 2-hydroxyethylmethacrylate or 2-hydroxybutylmethacrylate.

5. The method of claim 1, wherein said radical source particulates comprise one of benzophenone or an ultraviolet/blue light initiator.

6. The method of claim 5, further comprising radiating said hydrated cement with ultraviolet light.

7. The method of claim 1, wherein said polyacid particulates comprise one of polyacrylic acid (PAA), polyvinyl pyrrolidone-co-maleic acid, or polyethylene-co-methacrylic acid.

8. The method of claim 1, wherein said multivalent cation particulates comprise one of calcium (2+) or aluminum (3+).

9. The method of claim 1, wherein said calcium phosphate source particulates comprises one of mono-calcium phosphate, di-calcium phosphate, tri-calcium phosphate, or tetra-calcium phosphate.

10. The method of claim 1, wherein said liquid phase binder further comprises one of phytic acid, itaconic acid, diglycolic acid, or phosphoric acid.

11. The method of claim 1, wherein said liquid phase binder further comprises multifunctional monomers including glycol dimethacrylate.

12. The method of claim 1, wherein said particulate blend further comprises reaction accelerators.

13. The method of claim 12, wherein said reaction accelerators comprise one of tartaric acid, citric acid, glutamic acid, diglycolic acid, DL aspartic acid, iminodiacetic acid, itaconic acid, or NH4H2PO4.

14. The method of claim 1, wherein said particulate blend further comprises strengthening agents.

15. The method of claim 14, wherein said strengthening agents comprise nanocomposites.

16. The method of claim 15, wherein said nanocomposites comprise one of PEO/clay nanocomposites, hydroxyapatite nanocomposites, layered double hydroxide (LDH) nanocomposites, or organophillic nanocomposites.

17. The method of claim 1, wherein said liquid phase binder comprises colorants.

18. The method of claim 1, wherein said aqueous binder comprises water, organic acid, water soluble acrylic monomers, mineral acid, catalyst, dye colorants, pigment colorants, pyrrolidone, 1,5-hexanediol, liponic ethylene glycol, and surfynol 465.