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Patexia Research
Issue Date Dec 2, 2021
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Patent Application - WATER-BASED BINDER SOLUTIONS FOR USE IN ADDITIVE MANUFACTURING PROCESSES > Claims

  • 1. A method of additive manufacturing comprising: depositing a layer of powder on a working surface;selectively depositing a water-based binder solution comprising from greater than or equal to 0.1 wt % to less than or equal to 5 wt % of a non-aqueous solvent having a boiling point of greater than 100° C. and below 175° C. and a thermoplastic binder into the layer of powder in a pattern representative of a structure of a part, wherein: the thermoplastic binder comprises: a first polymer strand having a weight average molecular weight (Mw) of from greater than or equal to 5,000 g/mol to less than or equal to 15,000 g/mol; andat least one of a second polymer strand having a weight average molecular weight (Mw) of from greater than or equal to 10,000 g/mol to less than or equal to 50,000 g/mol and a third polymer strand having a weight average molecular weight (Mw) of from greater than or equal to 1,000 g/mol to less than or equal to 5,000 g/mol;the first polymer strand differs from each of the second polymer strand and the third polymer strand;the second polymer strand differs from the third polymer strand; andcoupling the first polymer strand with the at least one of the second polymer strand and the third polymer strand to form a green body part.
    • 2. The method according to claim 1, wherein the non-aqueous solvent is present in the water-based binder solution in an amount of from greater than or equal to 1 wt % to less than 4 wt %.
    • 3. The method according to claim 1, wherein the non-aqueous solvent comprises 2-methoxy ethanol, butanol, 2-butanol, tert-butanol, 1-methoxy-2-propanol, 2-butoxy ethanol, isoamyl alcohol, isobutyl alcohol, ethylene glycol butyl ether, or combinations thereof.
    • 4. The method according to claim 1, wherein the first polymer strand comprises polyvinyl pyrrolidone (PVP), polyvinyl alcohol (PVA), or combinations thereof.
      • 5. The method according to claim 4, wherein the first polymer strand is present in an amount of from greater than or equal to 5 wt % to less than or equal to 20 wt % based on a total weight of the water-based binder solution.
    • 6. The method according to claim 1, wherein the thermoplastic binder comprises the second polymer strand in an amount of from greater than or equal to 0.5 wt % to less than or equal to 7 wt % based on a total weight of the water-based binder solution.
      • 7. The method according to claim 6, wherein the thermoplastic binder comprises the third polymer strand in an amount of from greater than or equal to 0.1 wt % to less than or equal to 5 wt % based on a total weight of the water-based binder solution.
    • 8. The method according to claim 1, wherein the second polymer strand is selected from the group consisting of polyvinyl alcohol (PVA), polyacryl amide (PAAm), derivatives thereof and combinations thereof.
    • 9. The method according to claim 1, wherein the third polymer strand is selected from the group consisting of polyacrylic acid (PAA), polymethyl methacrylate (PMMA), polyvinyl methyl ether-maleic anhydride (PVME-MA), derivatives thereof, and combinations thereof.
    • 10. The method according to claim 1, wherein the water-based binder solution further comprises from greater than or equal to 0.1 wt % to less than or equal to 2 wt % of a surfactant.
    • 11. The method according to claim 1, wherein a total weight of polymers present in the water-based binder solution is from greater than or equal to 5 wt % to less than or equal to 20 wt % based on a total weight of the water-based binder solution.
    • 12. The method according to claim 1, wherein: the first polymer strand comprises polyvinyl pyrrolidone (PVP);the second polymer strand is selected from the group consisting of polyvinyl alcohol (PVA), polyacryl amide (PAAm), derivatives thereof and combinations thereof; andthe third polymer strand is selected from the group consisting of polyacrylic acid (PAA), polymethyl methacrylate (PMMA), polyvinyl methyl ether-maleic anhydride (PVME-MA), derivatives thereof, and combinations thereof.
  • 13. A green body part comprising: a plurality of layers, at least one layer formed from a powder bound by a water-based binder solution comprising a thermoplastic binder, wherein: the thermoplastic binder comprises: a first polymer strand having a weight average molecular weight (Mw) of from greater than or equal to 5,000 g/mol to less than or equal to 15,000 g/mol; andat least one of a second polymer strand having a weight average molecular weight (Mw) of from greater than or equal to 10,000 g/mol to less than or equal to 50,000 g/mol and a third polymer strand having a weight average molecular weight (Mw) of from greater than or equal to 1,000 g/mol to less than or equal to 5,000 g/mol;the first polymer strand differs from each of the second polymer strand and the third polymer strand;the second polymer strand differs from the third polymer strand; andthe first polymer strand is non-covalently coupled to the at least one of the second polymer strand and the third polymer strand.
    • 14. The green body part according to claim 13, wherein the first polymer strand comprises polyvinyl pyrrolidone (PVP), polyvinyl alcohol (PVA), or combinations thereof.
    • 15. The green body part according to claim 13, wherein the second polymer strand is selected from the group consisting of polyvinyl alcohol (PVA), polyacryl amide (PAAm), derivatives thereof and combinations thereof.
    • 16. The green body part according to claim 13, wherein the third polymer strand is selected from the group consisting of polyacrylic acid (PAA), polymethyl methacrylate (PMMA), polyvinyl methyl ether-maleic anhydride (PVME-MA), derivatives thereof, and combinations thereof.
    • 17. The green body part according to claim 13, wherein the green body part has a green strength of greater than or equal to 10 MPa on x- and y-printed orientations.
  • 18. A water-based binder solution for use in additive manufacturing, comprising: a thermoplastic binder comprising: a first polymer strand having a weight average molecular weight (Mw) of from greater than or equal to 5,000 g/mol to less than or equal to 15,000 g/mol; andat least one of a second polymer strand having a weight average molecular weight (Mw) of from greater than or equal to 10,000 g/mol to less than or equal to 50,000 g/mol and a third polymer strand having a weight average molecular weight (Mw) of from greater than or equal to 1,000 g/mol to less than or equal to 5,000 g/mol;wherein the first polymer strand differs from each of the second polymer strand and the third polymer strand and the second polymer strand differs from the third polymer strand;from greater than or equal to 0.1 wt % to less than or equal to 5 wt % of a non-aqueous solvent having a boiling point of greater than 100° C.; andwater.
    • 19. The water-based binder solution according to claim 18, further comprising from greater than or equal to 0.1 wt % to less than or equal to 2 wt % of a surfactant.
    • 20. The water-based binder solution according to claim 18, wherein: the first polymer strand comprises polyvinyl pyrrolidone (PVP);the second polymer strand is selected from the group consisting of polyvinyl alcohol (PVA), polyacryl amide (PAAm), derivatives thereof and combinations thereof; andthe third polymer strand is selected from the group consisting of polyacrylic acid (PAA), polymethyl methacrylate (PMMA), polyvinyl methyl ether-maleic anhydride (PVME-MA), derivatives thereof, and combinations thereof.
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