Moldable composition for use in hand or machine forming an article

• US 9,999,922 B1
• Filed: 10/09/2014
• Issued: 06/19/2018
• Est. Priority Date: 10/09/2014
• Status: Expired due to Fees

• Current Assignee: Metal Adventures Inc.
• Original Assignee: William George Struve
• Inventors: Struve, William George
• Primary Examiner(s): Patel, Devang R
• Application Number:
  US14/510,830
• Time in Patent Office: 1,349 Days
• CPC Class Codes: B22F 1/10 Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
• CPC Class Codes: B22F 10/20 Direct sintering or melting
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/34 of powder characteristics, e.g. density, oxidation or flowability
• CPC Class Codes: B22F 12/53 Nozzles
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 3/20 by extruding
• CPC Class Codes: B22F 9/08 by casting, e.g. through sieves or in water, by atomising or spraying using electric discharge B22F9/14
• CPC Class Codes: B22F 9/18 with reduction of metal compounds
• 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: Y02P 10/25 Process efficiency

Abstract

A moldable composition for use in hand or machine forming an article. In one embodiment, the composition including at least 78 wt. % of one fine metal-based powder; a water dispersible binder; and between about 2 wt. % and about 20 wt. % water, wherein the extrusion rate of the composition through about a 1½ mm nozzle is between about 0.05 gm/min and about 5 gm/min at a pressure of 120 PSI. The composition may further include up to about 2 wt. % of molding additives to improve the stability of the composition during molding and to improve the physical properties of the composition after drying.

Claims

1. An extruded composition for use in machine forming an article, said extruded composition comprising:

(a) at least one fine, sinterable metal-based powder;

(b) a water dispersible binder; and

(c) the balance water, wherein the extrusion rate of said extruded composition through about a 1½

mm nozzle is between about 18,000 Pascal seconds and about 1,800,000 Pascal seconds at a pressure of 120 PSI.

2. The composition according to claim 1, further including up to about 2 wt. % of molding additives to improve the stability of said extruded composition by reducing the rate of oxidation of the metal-based powder during storage and forming and to improve the physical properties of the article after forming and drying by remaining hand carvable prior to sintering.

3. The composition according to claim 2, wherein the molding additives are selected from the group consisting of ethanol, isopropyl alcohol, propylene glycol, glycerol, polyethylene glycol, polyoxyethylene, polyvinyl alcohol and mixtures thereof.

4. The composition according to claim 1, wherein the metal-based powders are selected from the group consisting of fine metal powders, fine metal oxide powders and mixtures thereof.

5. The composition according to claim 4, wherein the fine metal powders are selected from the group consisting of fine metal powders, the oxides of which can be reduced by carbon monoxide, such as copper, bismuth, nickel, cobalt, molybdenum, germanium, tungsten, tin, iron, vanadium, alloys of these metals and mixtures thereof.

6. The composition according to claim 4, wherein the fine metal powders are selected from the group consisting of fine metal powders, the oxides of which cannot be reduced by carbon monoxide, such as titanium, aluminum, alloys of these metals with copper, bismuth, nickel, cobalt, molybdenum, germanium, tungsten, tin, iron, vanadium and mixtures thereof.

7. The composition according to claim 4, wherein the fine metal oxide powders are selected from the group consisting of fine metal oxide powders which can be reduced by carbon monoxide, such as copper oxide, bismuth oxide, nickel oxide, cobalt oxide, molybdenum oxide, germanium oxide, tungsten oxide, tin oxide, iron oxide, vanadium oxide and mixtures thereof.

8. The composition according to claim 4, wherein the fine metal oxide powders are selected from the group consisting of fine metal oxide powders which cannot be reduced by carbon monoxide, such as titanium oxide, aluminum oxide and mixtures thereof.

9. The composition according to claim 1, wherein the metal-based powders are about 325 mesh.

10. The composition according to claim 9, wherein the metal-based powders are less than about 325 mesh.

11. The composition according to claim 1, wherein the water dispersible binder is selected from the group consisting of xanthan gum, carboxymethyl-cellulose, methyl cellulose, polyvinyl alcohol, guar gum, sodium alginate, starch, polyvinyl alcohol and mixtures thereof.

12. The composition according to claim 1, wherein said extruded composition is adapted for extrusion through a fine nozzle.

13. The composition according to claim 12, wherein said extruded composition is adapted for extrusion through a fine nozzle having a diameter of about ½

mm.

14. The composition according to claim 12, wherein said extruded composition is adapted for extrusion through a fine nozzle having a diameter of between about ½

mm and about 1½

mm.

15. The composition according to claim 1, wherein said extruded composition is adapted for extrusion by a 3D printer.

16. An extruded composition for use in machine forming an article, said extruded composition comprising:

(a) at least 78 wt. % of one fine metal-based powder;

(b) between about 0.2 wt. % and less than about 1.5 wt. % of a water dispersible binder; and

(c) between about 2 wt. % and about 20 wt. % water, wherein the extrusion rate of said extruded composition through about a 1½

mm nozzle is between about 18,000 Pascal seconds and about 1,800,000 Pascal seconds at a pressure of 120 PSI.

17. The composition according to claim 16, wherein the proportion of the fine metal-based powders is between about 78 wt % and about 90 wt. % when the shape of the powder particles is irregular such as metal powder made by reduction.

18. The composition according to claim 16, wherein the proportion of the fine metal-based powders is between about 83 wt. % and about 95 wt. % when the shape of the powder particles is roughly spherical such as metal powder made by spraying or atomization.

19. An extruded composition for use in machine forming an article, said extruded composition comprising:

(a) at least 78 wt. % of one fine metal-based powder;

(b) between about 0.2 wt. % and less than about 1.5 wt. % of a water dispersible binder;

(c) up to about 2 wt. % of molding additives to improve the stability of said extruded composition by reducing the rate of oxidation of the metal-based powder during storage and forming and to improve the physical properties of the article after forming and drying by remaining hand carvable prior to sintering; and

(d) between about 2 wt. % and about 20 wt. % water, wherein the extrusion rate of said extruded composition through about a 1½

mm nozzle is between about 18,000 Pascal seconds and about 1,800,000 Pascal seconds at a pressure of 120 PSI.

20. The composition according to claim 19, wherein the molding additives are selected from the group consisting of ethanol, isopropyl alcohol, propylene glycol, glycerol, polyethylene glycol, polyoxyethylene, polyvinyl alcohol and mixtures thereof.

21. The composition according to claim 19, wherein the metal-based powders are selected from the group consisting of fine metal powders, fine metal oxide powders and mixtures thereof.

22. The composition according to claim 21, wherein the fine metal powders are selected from the group consisting of fine metal powders, the oxides of which can be reduced by carbon monoxide, such as copper, bismuth, nickel, cobalt, molybdenum, germanium, tungsten, tin, iron, vanadium, alloys of these metals and mixtures thereof.

23. The composition according to claim 21, wherein the fine metal powders are selected from the group consisting of fine metal powders, the oxides of which cannot be reduced by carbon monoxide, such as titanium, aluminum, alloys of these metals with copper, bismuth, nickel, cobalt, molybdenum, germanium, tungsten, tin, iron, vanadium and mixtures thereof.

24. The composition according to claim 21, wherein the fine metal oxide powders are selected from the group consisting of fine metal oxide powders which can be reduced by carbon monoxide, such as copper oxide, bismuth oxide, nickel oxide, cobalt oxide, molybdenum oxide, germanium oxide, tungsten oxide, tin oxide, iron oxide, vanadium oxide and mixtures thereof.

25. The composition according to claim 21, wherein the fine metal oxide powders are selected from the group consisting of fine metal oxide powders which cannot be reduced by carbon monoxide, such as titanium oxide, aluminum oxide and mixtures thereof.

26. The composition according to claim 19, wherein the metal-based powders are about 325 mesh.

27. The composition according to claim 26, wherein the metal-based powders are less than about 325 mesh.

28. The composition according to claim 19, wherein the water dispersible binder is selected from the group consisting of xanthan gum, carboxymethyl-cellulose, methyl cellulose, polyvinyl alcohol, guar gum, sodium alginate, starch, polyvinyl alcohol and mixtures thereof.

29. The composition according to claim 19, wherein said extruded composition is adapted for extrusion through a fine nozzle.

30. The composition according to claim 29, wherein said extruded composition is adapted for extrusion through a fine nozzle having a diameter of about ½

mm.

31. The composition according to claim 29, wherein said extruded composition is adapted for extrusion through a fine nozzle having a diameter of between about ½

mm and about 1½

mm.

32. The composition according to claim 19, wherein said extruded composition is adapted for extrusion by a 3D printer.

33. The composition according to claim 19, wherein the proportion of the fine metal-based powders is between about 78 wt. % and about 90 wt. % when the shape of the powder particles is irregular such as metal powder made by reduction.

34. The composition according to claim 19, wherein the proportion of the fine metal-based powders is between about 83 wt. % and about 95 wt. % when the shape of the powder particles is roughly spherical such as metal powder made by spraying or atomization.