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    • 2. 发明申请
    • SELECTIVE LASER SINTERING APPARATUS WITH RADIANT HEATING
    • 选择性激光烧结装置与辐射加热
    • WO1992008566A1
    • 1992-05-29
    • PCT/US1991008338
    • 1991-11-07
    • DTM CORPORATION
    • DTM CORPORATIONGRUBE, Kris, W.BEAMAN, Joseph, J.
    • B23K26/00
    • G05B19/4099B22F3/1055B22F2003/1056B23K26/34B29C35/0288B29C64/153B33Y30/00B33Y40/00C04B35/64G05B2219/49013Y02P10/295
    • A radiant heater (30), and an apparatus for performing selective laser sintering using the same, are disclosed. The radiant heater (30) is ring-shaped with its dimensions and distance from the target surface preferably defined to provide radiant energy to a target surface (4), with the rate of energy received per unit area of the target surface (4) being substantially uniform. A frusto-conical ring-shaped radiant heater (40) is also disclosed, which may be disposed closer to the surface (4) to provide improved efficiency of heat transfer in a uniform fashion. A cooling element similary shaped is also disclosed, which operates in the same manner to uniformly transfer radiant heat from the target surface (4). Zoning of the ring-shaped radiant heaters (30), to allow for non-uniform radiant energy emission to the target surface, is also disclosed. Monitoring of the temperature of the target surface (4) is done by way of infrared sensors (34). For monitoring of cool temperatures, a second infrared sensor (36) is directed at the radiant heater, so that compensation for reflection of the radiant heat from the surface (4) may be accomplished.
    • 公开了一种辐射加热器(30)以及使用其进行选择性激光烧结的设备。 辐射加热器(30)是环形的,其尺寸和距离目标表面的距离优选地被限定为向目标表面(4)提供辐射能,其中目标表面(4)的每单位面积接收的能量为 基本均匀。 还公开了一种截头圆锥形环形辐射加热器(40),其可以设置成更靠近表面(4),以提供均匀方式的改善的热传递效率。 还公开了类似形状的冷却元件,其以相同的方式操作以均匀地传递来自目标表面(4)的辐射热。 还公开了环形辐射加热器(30)的分区,以允许对目标表面发射不均匀的辐射能。 目标表面(4)的温度监测通过红外传感器(34)进行。 为了监测冷却温度,第二红外传感器(36)被引导到辐射加热器,从而可以实现对来自表面(4)的辐射热的反射的补偿。
    • 3. 发明申请
    • CONTROLLED GAS FLOW FOR SELECTIVE LASER SINTERING
    • 用于选择性激光烧结的控制气体流
    • WO1992008592A1
    • 1992-05-29
    • PCT/US1991008351
    • 1991-11-08
    • DTM CORPORATIONGRUBE, Kris, W.FORDERHASE, Paul, F.CARR, Brian, J.DECKARD, Carl, R.ROGGE, William, E.
    • DTM CORPORATION
    • B29C35/08
    • B29C67/04B22F3/1055B22F2003/1056B29C35/16B29C64/153B29C2035/0838B29K2105/251B33Y10/00B33Y30/00Y02P10/295
    • An apparatus for fabricating parts by selective laser sintering is disclosed, which includes a baffle (40) for directing gas at the target surface (4). The gas is preferably controlled in temperature to cool, by convection, a layer of heat-fusible powder after it has been selectively laser sintered, to the temperature of the part formed in prior layers. The cooling preferably occurs prior to the application of the next layer of powder. The baffle (40) directs gas flow towards the center of the target surface (4), and exhaust ports are provided on multiple sides of the target surface (4) so that the gas flow is substantially symmetric at the target surface (4). A ring exhaust hood (54) may be suspended over the target surface, so that uniform gas flow may result and so that powder may be disposed over the target surface by way of a counter-rotating roller (18). The baffle (40) may direct the gas directly at the target surface, or may be constructed so that the gas spirals toward the target surface (4) in cyclonic fashion; further alternative baffles can be used to direct the gas at the target surface in a non-uniform, fashion, including turbulent or arbitrary flow patterns.
    • 公开了一种用于通过选择性激光烧结制造零件的装置,其包括用于在目标表面(4)处引导气体的挡板(40)。 优选将气体控制在温度下,通过对流将一层热熔粉末选择性地激光烧结后冷却到现有层中形成的部件的温度。 冷却优选在施加下一层粉末之前进行。 挡板(40)引导气流朝向目标表面(4)的中心,并且排气口设置在目标表面(4)的多个侧面上,使得气流在目标表面(4)处基本对称。 环形排气罩(54)可以悬挂在目标表面上,使得可能导致均匀的气体流动,使得粉末可以通过反向旋转辊(18)设置在目标表面上。 挡板(40)可以将气体直接引导到目标表面,或者可以被构造成使得气体以气旋方式朝向目标表面(4)螺旋; 可以使用另外的替代挡板来以不均匀的方式引导目标表面处的气体,包括湍流或任意的流动模式。
    • 4. 发明申请
    • METHOD OF FORMING ARTICLES USING THERMOSETTING MATERIALS
    • 使用热成型材料制备文章的方法
    • WO1997013601A1
    • 1997-04-17
    • PCT/US1996016206
    • 1996-10-10
    • DTM CORPORATION
    • DTM CORPORATIONLAKSHMINARAYAN, UdaykumarMCALEA, Kevin, P.BOOTH, Richard, B.
    • B22F03/105
    • C04B35/622B22F3/1055B22F2998/10B22F2999/00B33Y10/00B33Y80/00C04B35/64Y02P10/295B22F1/0059B22F3/26B22F3/1021B22F2202/15B22F1/0077
    • A method of fabricating articles, such as prototype parts and prototype tooling for injection molding, is disclosed. The method begins with the fabrication of the article in a "green" state by the selective laser sintering, or another additive thermal process, applied to a composite powder, preferably a powder of metal particles coated with a thermoplastic polymer. Both the green article and also an aqueous emulsion of a thermosetting material are then preheated to a temperature below the glass transition temperature of the thermoplastic polymer, and the green article is then infiltrated with the aqueous emulsion. The thermosetting material may be a thermosetting polymer with an appropriate cross-linking agent, or may be a cross-linking agent that will react with the thermoplastic binder polymer. After infiltration, the article is dried, and a rigid skeleton of a thermosetting material is now present within the structure of the article. Further processing may now be performed. The article may be heated beyond the decomposition temperature of the polymers so as to drive off the polymer and sinter the metal particles to one another; alternatively, a resin may be added to the article to form a metal-polymer composite article. High strength articles may thus be formed in a manner which preserves the dimensional accuracy of the article relative to its CAD representation.
    • 公开了一种制造诸如原型部件和用于注模的原型模具的制品的方法。 该方法开始于通过选择性激光烧结或另一种添加剂热处理在“绿色”状态下制造的制品,其应用于复合粉末,优选涂覆有热塑性聚合物的金属颗粒的粉末。 然后将绿色制品和热固性材料的水性乳液预热至低于热塑性聚合物的玻璃化转变温度的温度,然后用水性乳液渗透绿色制品。 热固性材料可以是具有合适的交联剂的热固性聚合物,或者可以是将与热塑性粘合剂聚合物反应的交联剂。 渗透后,制品被干燥,热固性材料的刚性骨架现在存在于制品的结构内。 现在可以进行进一步的处理。 可以将物品加热到超过聚合物的分解温度以驱离聚合物并将金属颗粒彼此烧结; 或者,可以向制品中加入树脂以形成金属 - 聚合物复合制品。 因此,可以以保持制品相对于其CAD表示的尺寸精度的方式形成高强度制品。
    • 6. 发明申请
    • METHOD OF RECOVERING RECYCLABLE UNSINTERED POWDER FROM THE &quote;PART&quote; BED OF A SELECTIVE LASER-SINTERING MACHINE
    • 从选择性激光烧结机的“部分”中回收可回收未消化的粉末的方法
    • WO1994012340A1
    • 1994-06-09
    • PCT/US1993004504
    • 1993-05-11
    • DTM CORPORATION
    • DTM CORPORATIONDICKENS, ElmerTAYLOR, GlennMAGISTRO, AngeloWEISSMAN, EricHRADEK, Timothy
    • B29C67/00
    • B29C64/153B33Y10/00B33Y40/00B33Y70/00
    • This method teaches how to recover and reuse a powder of a thermally degradable material which is used in a selective laser sintering (SLS) process. To recycle such a laser-sinterable powder successfully in an SLS machine it is protected against degradation by cooling the hot bed while layer-upon-layer (layer-wise) of powder is being sintered, seriatim, to form successive slices fused together to form an article of arbitrary shape (part). The process requires maintaining the powder which has more than 80 % of the number of particles
    • 该方法教导了如何回收和再利用用于选择性激光烧结(SLS)工艺的可热降解材料的粉末。 为了在SLS机器中成功地回收这样的可激光烧结粉末,通过冷却热床来保护其免受降解,同时层压(层)上的粉末被烧结,形成连续的切片,以形成熔合在一起形成 任意形状的文章(部分)。 该方法需要将具有多于80%的颗粒数量小于53μm的粉末作为静止床保持,其仍然是足够多孔的,以允许冷却气体向下流动通过床而不破坏其表面。 由于每个切片都是在表面形成的,而在其形成的部分被支撑在一个绝缘良好的床上,与切片相邻的粉末的温度比床的其余部分高得多, 对于冷却气体,会过热。 过热粉末不仅会降解,而且会熔化到热部件的表面,形成“成长”,从而使零件不能用于其预定目的。 该方法允许经济地将未使用的粉末从床中回收到灭绝。 如果粉末在热时也对氧气敏感,则使用惰性气体作为冷却气体。
    • 7. 发明申请
    • MULTIPLE POWDER DELIVERY FOR SELECTIVE LASER SINTERING
    • 多种粉末选择性激光烧结
    • WO1993008928A1
    • 1993-05-13
    • PCT/US1992009624
    • 1992-11-05
    • DTM CORPORATION
    • DTM CORPORATIONFORDERHASE, Paul, F.DECKARD, Carl, R.KLEIN, Jack, M.
    • B05D03/06
    • B22F3/004B22F2003/1056B22F2998/00B29C64/153B29K2105/251B33Y10/00B33Y30/00B33Y40/00G05B2219/49013Y02P10/295B22F3/1055
    • An apparatus and method for producing parts by fusing selected portions of a powder layer at a target area, including the systems for delivering the powder to the target area. Multiple powder pistons (20) are included in the apparatus, each lifts a volume of powder above a surface (22) 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 (28) moves across the lifted powder, distributes it over the target area, and rests beyond a second powder lifting location. 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 (6) at the target area in order to accept the next layer of powder.
    • 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,然后在目标区域上降低部分圆筒,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。
    • 8. 发明申请
    • POLYMER POWDER OF CONTROLLED PARTICLE SIZE DISTRIBUTION
    • 聚合物粉末粒子分布
    • WO1997029148A1
    • 1997-08-14
    • PCT/US1997001938
    • 1997-02-06
    • DTM CORPORATION
    • DTM CORPORATIONMCALEA, Kevin, P.FORDERHASE, Paul, F.BOOTH, Richard, B.
    • C08J03/12
    • C08J3/122B29C64/153B33Y10/00B33Y40/00B33Y70/00C08J2325/04C08J2333/06
    • 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 particles 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。 颗粒尺寸(体积)的所得分布优选具有约20至约50μm的平均粒度,优选小于约5%(体积)的其尺寸小于约15μm的颗粒,以及 小于约2%(体积)的尺寸大于约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。
    • 9. 发明申请
    • COMPOSITE PLASTIC MATERIAL FOR SELECTIVE LASER SINTERING
    • 用于选择性激光烧结的复合塑料
    • WO1996030195A1
    • 1996-10-03
    • PCT/US1996004335
    • 1996-03-29
    • DTM CORPORATION
    • DTM CORPORATIONMcALEA, Kevin, P.FORDERHASE, Paul, F.GANNINGER, Mark, E.
    • B29C67/00
    • C08K7/20B29C39/003B29C41/003B29C64/153B33Y10/00B33Y30/00B33Y40/00B33Y70/00
    • 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 near-fully 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 rough breakout 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。 在要形成近乎完全致密的部分的情况下,当在选择性激光烧结中未掺杂时,第一组分粉末优选为适合于形成近乎致密部分的组合物的半结晶粉末,例如尼龙11; 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。 除了提高所制造部件的刚度和耐热性之外,复合粉末可以使工艺窗口比非混合粉末加宽,提高了产品尺寸精度,并且可以使产品的粗切断裂和光滑整理。
    • 10. 发明申请
    • BINDER COMPOSITIONS FOR SELECTIVE LASER SINTERING PROCESSES
    • 选择性激光烧结工艺的焊接组合物
    • WO1995030503A1
    • 1995-11-16
    • PCT/US1995005579
    • 1995-05-05
    • DTM CORPORATION
    • DTM CORPORATIONMcALEA, Kevin, P.BOOTH, RichardLAKSHMINARAYAN, UdayGIROUARD, Dan
    • B22F03/105
    • G05B19/4099B22F1/0059B22F3/1055B22F2001/0066B29C64/153B33Y70/00C04B35/634C04B35/63424C04B35/64G05B2219/49018Y02P10/295Y02P90/265
    • The composition and use of polymeric binders in fabricating parts by selective laser sintering. The binders are amorphous copolymers of methacrylic acid derivatives and may contain styrene and its derivatives, as well as additives, such as film forming agents and adhesion promoters. The binders are used to coat inorganic particulate substrates to create a powder comprised of the substrate and binder. The binders flow to form an interconnecting polymeric matrix upon the application of sufficient energy from the laser beam in a selective laser sintering process. Parts are thus fabricated by directing laser energy onto layers of the powder applied at a target surface (4) in successive fashion to build up a three-dimensional part comprised of a plurality of such layers. The part may then be subjected to a high temperature annealing process in a reducing environment, whereby the binders are virtually completely removed by thermal depolymerization of the copolymer, leaving an insignificantly small amount of residual ash.
    • 通过选择性激光烧结制备部件中聚合物粘合剂的组成和用途。 粘合剂是甲基丙烯酸衍生物的无定形共聚物,并且可以含有苯乙烯及其衍生物,以及添加剂,例如成膜剂和粘合促进剂。 粘合剂用于涂覆无机颗粒基材以产生由基材和粘合剂组成的粉末。 在选择性激光烧结工艺中,从激光束施加足够的能量时,粘结剂流动以形成互连的聚合物基体。 因此通过将激光能量以连续的方式引导到施加在目标表面(4)上的粉末的层上以构建由多个这样的层组成的三维部分来制造部件。 然后可以在还原环境中对该部分进行高温退火处理,由此通过共聚物的热解聚实际上完全除去粘合剂,留下微量少量的残余灰分。