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Title:
3D PRINTING USING CERAMIC TAPES
Document Type and Number:
WIPO Patent Application WO/2017/123250
Kind Code:
A1
Abstract:
In example implementations, an apparatus includes a reel of a ceramic tape on a release liner, a bed, a lamination roller and a liner reel. The bed receives a ceramic tape layer cut from the reel of the ceramic tape, wherein a portion of ceramic tape layer is digitally printed with a liquid functional material (LFM). The ceramic tape layer is laminated onto the bed and the release liner is removed from the ceramic tape layer that is cut from the reel by the lamination roller. The liner reel collects the release liner that is removed from the ceramic tape.

Inventors:
CHOY SILAM J (US)
Application Number:
PCT/US2016/013665
Publication Date:
July 20, 2017
Filing Date:
January 15, 2016
Export Citation:
Click for automatic bibliography generation   Help
Assignee:
HEWLETT PACKARD DEVELOPMENT CO LP (US)
International Classes:
B32B18/00; B32B38/18; B32B37/00; B32B39/00
Foreign References:
US20160009069A12016-01-14
US20110222081A12011-09-15
CN203805323U2014-09-03
US6169605B12001-01-02
US6702918B22004-03-09
Attorney, Agent or Firm:
TONG, Kin-Wah et al. (US)
Download PDF:
Claims:
CLAIMS

1 . An apparatus, comprising:

a ceramic tape on a release liner;

a bed to receive a ceramic tape layer cut from the ceramic tape, wherein a portion of the ceramic tape layer is digitally printed with a liquid functional material (LFM);

a lamination roller to laminate the ceramic tape layer onto the bed and to remove the release liner from the ceramic tape layer that is cut from the ceramic tape; and

a controller to control cutting of the ceramic tape, the bed and the lamination roller.

2. The apparatus of claim 1 , wherein the ceramic tape has a thickness of at least 50 microns.

3. The apparatus of claim 1 , wherein the ceramic tape comprises at least one of: alumina, zirconia, silicon nitride, mullite, or a bioglass.

4. The apparatus of claim 1 , comprising:

a print zone coupled adjacent to the bed, wherein the print zone comprises an LFM dispenser to dispense the LFM onto the portion of the ceramic tape layer.

5. The apparatus of claim 4, wherein the bed moves laterally from underneath the ceramic tape to the print zone.

6. The apparatus of claim 1 , comprising:

a fusing zone comprising a furnace to sinter the portion of the ceramic tape layer that is digitally printed with the LFM.

7. A method, comprising:

unrolling a ceramic tape on a release liner from a roll of the ceramic tape on the release liner;

cutting a ceramic tape layer from the roll of the ceramic tape on the release liner;

moving the ceramic tape layer that is cut over a bed;

laminating the ceramic tape layer onto the bed;

removing the release liner from the ceramic tape layer; and

applying a liquid functional material (LFM) onto portions of the ceramic tape layer to digitally print a layer of a three dimensional structure.

8. The method of claim 7, wherein the ceramic tape layer is cut from the roll of the ceramic tape on the release liner to have dimensions that match dimensions of the bed.

9. The method of claim 7, wherein the ceramic tape has a thickness of at least 50 microns.

10. The method of claim 7, wherein the ceramic tape comprises at least one of: alumina, zirconia, silicon nitride, mullite, or a bioglass.

1 1 . The method of claim 7, wherein the applying comprises:

moving the bed laterally into a print zone under a LFM dispenser.

12. The method of claim 7, wherein the unrolling, the cutting, the moving, the laminating, the removing and the applying are repeated until portions of a plurality of ceramic tape layers are digitally printed with the LFM to define the three dimensional structure.

13. The method of claim 12, comprising:

applying energy to the plurality of ceramic tape layers to sinter the portions of the plurality of ceramic tape layers that are digitally printed with the LFM to form the three dimensional structure.

14. A non-transitory computer readable storage medium encoded with instructions executable by a processor of, the non-transitory computer-readable storage medium comprising:

instructions to cut a ceramic tape layer from a roll of a ceramic tape on a release liner;

instructions to laminate the ceramic tape layer onto a bed and remove the release liner from the ceramic tape layer; and

instructions to applying a liquid functional material (LFM) onto portions of the ceramic tape layer to digitally print a layer of a three dimensional structure.

15. The non-transitory computer readable storage medium of claim 14, wherein the ceramic tape layer is cut from the roll of the ceramic tape on the release liner to have dimensions that match dimensions of the bed.

Description:
3D PRINTING USING CERAMIC TAPES

BACKGROUND

[0001] Three dimensional (3D) printers are becoming more ubiquitous as costs for the printers come down. 3D printers, also referred to as additive manufacturing machines, typically operate by using a material to generate a 3D object layer-by-layer. In some systems, a three dimensional computer aided drawing (CAD) model may be created. Then, an object may be generated in accordance with the model.

BRIEF DESCRIPTION OF THE DRAWINGS

[0002] FIG. 1 is a block diagram of a side view of an example apparatus of the present disclosure;

[0003] FIG. 2 is a block diagram of a top view of an example apparatus of the present disclosure;

[0004] FIG. 3 is a flow diagram of an example method for digitally printing on a ceramic tape;

[0005] FIG. 4 is a block diagram of an example controller of the present disclosure; and

[0006] FIG. 5 is a flow diagram of another example method for digitally printing on a ceramic tape.

DETAILED DESCRIPTION

[0007] The present disclosure discloses a method and apparatus for digitally printing on a ceramic tape. A roll of ceramic tape on a release liner may be cut and laminated onto a bed or previously cut and laminated layers of the green ceramic tape. In the present example, portions of each layer of the green ceramic tape may be digitally printed with a liquid functional material. The liquid functional material "outlines" the portions of each layer of the ceramic tape that will form a portion of the three dimensional object after the layers of ceramic tape are sintered. Notably, in the present disclosure, each layer of ceramic tape is not sintered, cured or fused after each layer is processed and printed with the liquid functional material. The layers of the ceramic tape that remain unbound or uncured may be transported in a carrier to a furnace to be sintered.

[0008] In contrast, some current 3D printing processes that use ceramics use layers of a loose powder of ceramics. The small diameter of the ceramics used for 3D printing processes can lead to challenges due to spreading and moving ceramic powder. Some current 3D printing processes use large diameters of aggregated ceramic granules for spreading that are then broken into submicron sizes for each layer. Other 3D printing processes spread a slurry of the ceramic powder for each layer and then dry each layer in situ. By eliminating the additional processing steps used in the previous methods (e.g., the breaking of granules, drying each layer of the slurry, and the like), the efficiency of the 3D printing process may be improved, as described herein.

[0009] Rather, the present disclosure allows layers of ceramic tape that are digitally printed, but unbound, to be placed into a carrier and placed into a furnace (e.g., a microwave furnace, a heating furnace, a fusing chamber exposing the objects to electromagnetic radiation outside the range designated as microwave radiation, and the like). The furnace provides heat or energy that sinters the ceramic particles within the layers of ceramic tape to each other and between the layers via the liquid functional material. The digitally printed portions of each layer of the layers of ceramic tape may be sintered

simultaneously, or at the same time, within the carrier in a single step.

[0010] FIG. 1 illustrates a side view of a block diagram of an example 3D printer 100 of the present disclosure. In one example, the 3D printer 100 may include a roll of ceramic tape 102, a cutting device 106, a carrier 120 having a bed 108, a heatable lamination roller 1 10 and a controller 1 14. In one implementation, the bed 108 may be coupled to a motor to move the bed 108 up and down. [0011] In one example, the ceramic tape 102 may be fabricated from a ceramic granular material including a powder, a gel, a slurry, and the like, that is predominately microwave transparent. The granular material may have a diameter of approximately 3-30 microns (μιη). For slurries and gels, the diameter may be as small as 1 nanometer (nm).

[0012] The ceramic granules of the ceramic tape 102 may be a microwave transparent material. Examples of microwave transparent materials that can be used as the ceramic tape 102 may include alumina (AI2O3), silicon nitride (SiN), a ceramic, a glass ceramic, a glass, polytetrafluoroetheylen (PTFE), zirconium dioxide (Zr02), silicon dioxide (S1O2), yttrium oxide (Y2O3), magnesium oxide (MgO), aluminum oxide (AI2O3), boron nitride (BN), calcium fluoride (CaF2), tantalum pentoxide (Ta20s), niobium pentoxide (Nb20s), titanium oxide (T1O2), quartz, fused silica, mullite, and the like.

[0013] In one example, the ceramic tape 102 may be "green." In other words, the ceramic granules that comprise the ceramic tape 102 are uncured or unsintered. The ceramic tape 102 may be uncured or unsintered, but may have structural integrity. In other words, the ceramic tape 102 may have a texture or flexibility similar to clay.

[0014] In one example, the ceramic tape 102 may have a thickness of greater than 10 μιη. In another example, the ceramic tape 102 may have a thickness of approximately 50-100 μιη.

[0015] In some implementations, the ceramic tape 102 may be placed on a release liner. The release liner may be a polymer backing. The release liner provides a non-stick backing for the ceramic tape 102 that allows for efficient handling of the ceramic tape 102 within the 3D printer 100. For example, as the ceramic tape 102 becomes less dense (e.g., more porous) to allow a liquid functional material (LFM) or a polymer binder liquid to infiltrate the ceramic tape 102, handling the ceramic tape 102 may become more difficult without the aid of the release liner.

[0016] In one implementation, the controller 1 14 may be in communication with the cutting device 106, the bed 108 and the heated lamination roller 1 10. In addition, the controller 1 14 may be in communication with a reel that is connected to the roll of the ceramic tape 102. The controller 1 14 may unroll a portion 104 of the roll of ceramic tape 102 from the reel.

[0017] The controller 1 14 may then control the cutting device 106 to cut the portion 104 of the ceramic tape 102. In one example, the size or dimensions of the portion 104 of the ceramic tape 102 may be equivalent to the size or dimensions of the bed 108. For example, the portion 104 of the ceramic tape 102 may be cut to have a same length and width as the bed 108.

[0018] In one example, the ceramic tape 102 is cut, but the release liner is not cut. As a result, the release liner may be pulled by a release liner (illustrated in FIG. 2) to move the portion 104 of the ceramic tape 102 that is cut over the bed 108. The heated lamination roller 1 10 may press the portion 104 of the ceramic tape 102 onto the bed 108 to remove the release liner from the portion 104 of the ceramic tape 102.

[0019] In one example, the portion 104 of the ceramic tape 102 may form a layer 1 12i on the bed 108 in a carrier 120. Additional portions 104 of the ceramic tape 102 may be cut from the roll of ceramic tape 102 and laminated onto the bed 108 to form layers 1 12i to 1 12 n (herein referred to individually as a layer 1 12 or collectively as layers 1 12) in the carrier 120.

[0020] FIG. 2 illustrates a block diagram of a top view of the example 3D printer 100. FIG. 2 illustrates a reel-to-reel lamination zone 202 within the 3D printer 100. As discussed above, the 3D printer 100 may include a liner reel 210 to collect the release liner removed from the portion 104 of the ceramic tape 102. The liner reel 210 may pull the portion 104 of the ceramic tape 102 that is cut to be positioned over the bed 108 and released from the release liner by the heated lamination roller 1 10.

[0021] In one implementation, FIG. 2 illustrates how the carrier 120 may be moved laterally under an LFM dispenser 212 in a print zone 204. The LFM dispenser 212 may "digitally print" on selected areas of the layer 1 12 of the ceramic tape 102 by applying an LFM. In another implementation, a polymer binder liquid may be used.

[0022] The LFM may be a susceptor that absorbs microwave energy selectively better than the ceramic tape 102. The LFM may also be a material designed to decrease the local fusing temperature or otherwise locally modify the material properties of the digitally defined object. The layer 1 12 of the ceramic tape 102 is digitally printed by applying the LFM to the selected areas of the layer 1 12 of the ceramic tape 102 to create a susceptor pattern that corresponds to a respective layer of a structure 214. In one example, the LFMs may also be used to modify the local electrical or other fundamental properties of the ceramic tape 102 to create a benefit to the final structure 214.

[0023] An example of the LFM may include any type of material that is conducting, semi-conducting or have a magnetic dipole that can be used as microwave, or radio frequency (RF) susceptors at ambient temperature. Some examples may include carbon black, graphite, carbon nano tubes, silicon carbide (SiC), zinc oxide (ZnO), indium tin oxide (ITO), titanium nitride (ΤΊΝ), ferrite inks, ferromagnetic materials, ferroelectric materials, and the like.

[0024] In addition, the LFMs may include materials designed to react with a base material to enable fusing with less fusing energy delivered. This may include silicon oxide (S1O2) nano-particles, combinations of oxides to form glass in the interstitial regions between particles, and the like.

[0025] In one example, the structure 214 may be designed using, for example, a computer aided design (CAD) program and uploaded to the controller 1 14. In some implementations, bitmap slices of each layer or raster slices of each layer of a design of the structure 214 may be uploaded to the controller 1 14. The controller 1 14 may then control the LFM dispenser 212 to digitally print the structure 214 on the selected areas of the layers 1 12 of the ceramic tape 102 without applying energy between each one of the layers 1 12 of ceramic tape 102.

[0026] Notably, no energy is applied to the LFM and the ceramic tape 102 after each layer 1 12 of the ceramic tape 102 is laminated onto the bed 108. In addition, no additional processing is applied to the ceramic tape 102 (e.g., breaking down the size of the ceramic granules into smaller submicron sized granules, an in-situ drying, and the like). Rather, the plurality of layers 1 12 of the digitally printed, but unsintered ceramic tape 102, is transported into a furnace as part of a fusing zone 206. The plurality of layers 1 12 may be transported to a separate furnace via the carrier 120. In another example, the furnace may be part of the 3D printer 100. In one example, the furnace may be a microwave furnace, a heating furnace, a fusing chamber exposing the objects to electromagnetic radiation outside the range designated as microwave radiation, and the like to sinter the digitally printed areas of each layer 1 12 at the same time.

[0027] In one implementation, microwave energy may be used to selectively "bind" portions within the plurality of layers 1 12 that have been digitally defined with the LFM. The portions within the plurality of layers 1 12 that are digitally printed may be partly densified or moderately bonded together and excavated (e.g., with a wash, brushing away unbound portions, and the like). The excavated portions of the plurality of layers 1 12 that are digitally printed may then be placed in a second furnace that is a traditional heating furnace for a final sintering process.

[0028] After the selected areas of the layers 1 12 of ceramic tape 102 having the LFM is sintered together in the furnace, the carrier 120 may be transported to an excavation zone 208. The structure 214 may be removed from the unsintered areas (e.g., the areas of each layer of the ceramic tape 102 that did not receive the LFM) of the ceramic tape 102. In one example, the structure 214 may be removed by removing the unsintered areas of the ceramic tape 102 via an aqueous wash, via brushing, via vacuuming, and the like.

[0029] FIG. 3 illustrates a flow diagram of an example method 300 for digitally printing on a ceramic tape. In one example, the blocks of the method 300 may be performed by the controller 1 14 or using the 3D printer 100.

[0030] At block 302, the method 300 begins. At block 304, the method 300 cuts a ceramic tape layer from a roll of a ceramic tape on a release liner. In one example, the ceramic tape layer may be cut to have dimensions that are similar to dimensions of a bed of the 3D printer. In other words, the dimensions of the ceramic tape layer may have a length and a width that is the same as the length and the width of the bed.

[0031] At block 306, the method 300 laminates the ceramic tape layer onto a bed and removes the release liner from the ceramic tape layer. For example, heat and/or pressure may be applied to the ceramic tape layer to laminate the ceramic tape layer onto the bed or a previously laminated ceramic tape layer. Laminating may help the ceramic tape layer "stick" to the previously laminated ceramic tape layer and remove the ceramic tape layer from the release liner.

[0032] At block 308, the method 300 applies a liquid functional material (LFM) onto portions of the ceramic tape layer to digitally print a layer of a three dimensional structure. For example, a carrier holding the ceramic tape layers may be laterally moved to a print zone under an LFM dispenser. The LFM dispenser may apply LFM onto select areas of the ceramic tape layer to define parts of the three dimensional structure that are being printed.

[0033] In one example, the blocks 304 to 308 may be repeated. After portions of the ceramic tape layers are digitally printed, the ceramic tape layers may be transported to a furnace to sinter the portions of the ceramic tape layers that received the LFM. The sintered portions of the ceramic tape layers form the three dimensional structure and can be excavated in an excavation zone as described above. At block 310, the method 300 ends.

[0034] FIG. 4 illustrates another example of an apparatus 400. In one example, the apparatus 400 may also be the controller 1 14. In one example, the apparatus 400 may include a processor 402 and a non-transitory computer readable storage medium 404. The non-transitory computer readable storage medium 404 may include instructions 406, 408 and 410 that when executed by the processor 402, cause the processor 402 to perform various functions.

[0035] In one example, the instructions 406 may include instructions to cut a ceramic tape layer from a roll of a ceramic tape on a release liner. The instructions 408 may include instructions to laminate the ceramic tape layer onto a bed and remove the release liner from the ceramic tape layer. The instructions 410 may include instructions to apply a liquid functional material (LFM) onto portions of the ceramic tape layer to digitally print a layer of a three dimensional structure.

[0036] FIG. 5 illustrates a flow diagram of an example method 500 for digitally printing on a ceramic tape. In one example, the blocks of the method 500 may be performed by the controller 1 14 or using the 3D printer 100. [0037] At block 502, the method 500 begins. At block 504, the method 500 unrolls a ceramic tape on a release liner from a roll of the ceramic tape on the release liner. For example, the ceramic tape is rolled onto a reel that is mechanically controlled. The reel may be rotated to unroll a portion of the roll of the ceramic tape.

[0038] At block 506, the method 500 cuts a ceramic tape layer from the roll of the ceramic tape on the release liner. For example, the ceramic tape layer may be cut to have dimensions that are similar to dimensions of a bed of the 3D printer. In other words, the dimensions of the ceramic tape layer may have a length and a width that is the same as the length and the width of the bed.

[0039] In one example, the ceramic tape layer may be cut without cutting the release liner. As a result, a liner reel that collects the release liner that is located opposite the reel of the roll of ceramic tape may pull the ceramic tape layer into position over the bed.

[0040] At block 508, the method 500 moves the ceramic tape layer that is cut over a bed. For example, the liner reel may be mechanically rotated to pull the ceramic tape layer towards the bed and away from the reel of the roll of ceramic tape.

[0041] At block 510, the method 500 laminates the ceramic tape layer onto the bed. For example, a heated lamination roller may apply heat and/or pressure to laminate the ceramic tape layer onto the bed or a previously laminated ceramic tape layer. The heat and/or pressure applied by the heated lamination roller may help the ceramic tape layer to "stick" to the bed or a previously laminated ceramic tape layer.

[0042] At block 512, the method 500 removes the release liner from the ceramic tape layer. For example, the heat and/or pressure applied by the heated lamination roller may remove the ceramic tape layer from the release liner.

[0043] At block 514, the method 500 applies a liquid functional material (LFM) onto portions of the ceramic tape layer to digitally print a layer of a three dimensional structure. For example, the carrier may be laterally moved to a print zone under an LFM dispenser. The LFM dispenser may apply LFM onto select areas of the ceramic tape layer to define parts of a structure that are being printed.

[0044] Notably, no energy is applied to the ceramic tape layer after the LFM is applied and no additional processing is applied to the ceramic tape 102 (e.g., breaking down the size of the ceramic granules into smaller submicron sized granules, an in-situ drying, and the like). Rather, blocks 504 to 514 may be repeated until a plurality of ceramic tape layers are laminated onto the bed and in the carrier. The unsintered ceramic tape layers may then be transported to a furnace to sinter the areas of the plurality of ceramic tape layers that received the LFM. At block 516, the method 500 ends.

[0045] It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.