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    • 4. 发明授权
    • Selective laser sintering of polymer powder of controlled particle size
distribution
    • 选择性激光烧结聚合物粉末的受控粒度分布
    • US5817206A
    • 1998-10-06
    • US597805
    • 1996-02-07
    • Kevin P. McAleaPaul F. ForderhaseRichard B. Booth
    • Kevin P. McAleaPaul F. ForderhaseRichard B. Booth
    • B29C67/00C08J3/12B27N3/00B32B31/00
    • C08J3/122B29C67/0077C08J2325/04C08J2333/06
    • A powder for use in selective laser sintering, from which prototype articles and masters for molds may be formed, is disclosed. The powder is formed by spray drying a polymer emulsion to yield a distribution of particles of substantially spherical shape. The powder is then air classified to remove excessively small particles from the distribution; the powder may also be screened to remove large particles therefrom, as well. The resulting distribution of particle sizes, by volume, preferably has a mean particle size of between about 20.mu. and about 50.mu., with preferably less than about 5% (by volume) of its particles with a size of less than about 15.mu. and less than about 2% (by volume) of its particles with a size of greater than about 75.mu.. The powder is subjected to selective laser sintering to produce an article of approximately 55% to 75% of theoretical density. The article may be used as a prototype article or part, or as a pattern or master for a mold.
    • 公开了用于选择性激光烧结的粉末,其中可以形成用于模具的原型制品和主体。 粉末通过喷雾干燥聚合物乳液形成,以产生基本上为球形的颗粒的分布。 然后将粉末进行空气分类,以从分布中去除过小的颗粒; 也可以筛选粉末以从其中除去大颗粒。 所得到的体积分数的体积优选具有约20至约50微米的平均粒度,优选小于约5%(体积)的其尺寸小于约15微米的颗粒,以及 小于约2%(体积)的其尺寸大于约75μm的颗粒。 对粉末进行选择性激光烧结以产生约55%至75%的理论密度的制品。 该物品可以用作原型制品或零件,或用作模具的图案或母版。
    • 5. 发明授权
    • Selective laser sintering with composite plastic material
    • 选择性激光烧结与复合塑料材料
    • US5733497A
    • 1998-03-31
    • US527840
    • 1995-09-13
    • Kevin P. McAleaPaul F. ForderhaseMark E. GanningerFrederic W. KunigAngelo J. Magistro
    • Kevin P. McAleaPaul F. ForderhaseMark E. GanningerFrederic W. KunigAngelo J. Magistro
    • C08J9/24B29C39/00B29C41/00B29C67/00B29C67/20B29K105/04C08J9/32C08K7/20C08L77/00C08L101/00B29C35/08B29C41/02
    • C08K7/20B29C39/003B29C41/003B29C67/0077
    • A composite powder specially adapted for use in selective laser sintering is disclosed. The composite powder includes a polymer powder dry mixed with a reinforcement powder, where the polymer powder has a melting temperature substantially lower than that of the reinforcement powder. In the case where nearfully dense parts are to be formed, the first constituent powder is preferably a semi-crystalline powder, for example nylon 11, of a composition suitable for forming near-fully dense parts when used unblended in selective laser sintering; if porous parts are desired, the polymer powder is an amorphous powder, such as polycarbonate, polystyrene, acrylates, and styrene/acrylate copolymers. The reinforcement powder is preferably microspheres of glass, preferably coated to enhance wetting and adhesion with the polymer powder when selective laser sintering is performed. Besides improving the stiffness and heat resistance of the part produced, the composite powder widens the process window over that provided by unblended powder, provides improved dimensional accuracy in the part produced, and facilitates roughbreakout and smooth finishing of the part produced.
    • 公开了一种特别适用于选择性激光烧结的复合粉末。 复合粉末包括与增强粉末混合的聚合物粉末,其中聚合物粉末的熔融温度基本上低于加强粉末的熔融温度。 在要形成接近密集部分的情况下,第一组分粉末优选为半结晶粉末,例如尼龙11,适合于在选择性激光烧结中未掺杂时形成近乎致密部分的组合物; 如果需要多孔部分,聚合物粉末是无定形粉末,例如聚碳酸酯,聚苯乙烯,丙烯酸酯和苯乙烯/丙烯酸酯共聚物。 增强粉末优选是玻璃微球体,优选涂覆以在选择性激光烧结时增强与聚合物粉末的润湿性和粘合性。 除了提高所生产部件的刚度和耐热性之外,复合材料粉末使工艺窗口比非混合粉末提高了加工窗口的尺寸,提高了产品尺寸精度,并促进了生产部件的破裂和光滑整理。
    • 7. 发明授权
    • Apparatus and method for producing parts with multi-directional powder
delivery
    • 用于生产多方向粉末输送部件的设备和方法
    • US5252264A
    • 1993-10-12
    • US789358
    • 1991-11-08
    • Paul F. ForderhaseCarl R. DeckardJack M. Klein
    • Paul F. ForderhaseCarl R. DeckardJack M. Klein
    • B23K26/00B22F3/00B22F3/02B22F3/035B22F3/10B22F3/105B23K26/34B29C35/08B29C67/00C04B35/64
    • B29C67/0077B22F3/004B22F2003/1056B22F2998/00B29K2105/251G05B2219/49013Y02P10/295
    • An apparatus and method for producing parts by fusing selected portions of a layer of powder at a target area, including the systems for delivering the powder to the target area, is disclosed. Multiple powder pistons are included in the apparatus, each of which lift a volume of powder above a surface in an alternating manner relative to one another. Powder delivery begins by the lifting of a volume of powder at a first location on one side of the target area. A counter-rotating roller moves across the lifted powder, distributes it over the target area, and rests beyond a second powder lifting location on the other side of the target area. Portions of the powder layer are then fused at the target area according to a cross-section of the part to be produced, and is followed by lowering a part cylinder at the target area in order to accept the next layer of powder. A second volume of powder is lifted at the second location, and the counter-rotating roller moves across the second location and the target area to deliver the next layer of powder to the target area. The multiple powder piston system reduces the excess powder in the chamber, speeds the delivery of powder, and facilitates the installation of powder during the process.
    • 公开了一种用于通过将目标区域上的粉末层的选定部分熔合而制造零件的装置和方法,包括用于将粉末输送到目标区域的系统。 装置中包括多个粉末活塞,每个粉末活塞相对于彼此以交替的方式提升一个表面上方的体积的粉末。 通过在目标区域一侧的第一位置提升一定体积的粉末开始粉末递送。 反转辊移动穿过提升的粉末,将其分配在目标区域上,并且在目标区域的另一侧上放置在第二粉末提升位置之外。 然后根据要制造的部件的横截面将粉末层的部分熔合在目标区域,然后在目标区域处降低部分圆筒,以接受下一层粉末。 第二体积的粉末在第二位置被提升,并且反向旋转辊移动穿过第二位置和目标区域,以将下一层粉末输送到目标区域。 多粉末活塞系统减少了室中的多余粉末,加速了粉末的输送,并且在该过程中容易安装粉末。