Tack and bond adhesive system and method for layered object manufacture

Abstract

Provided is an adhesive dispensing device for use in a Layered Object Manufacturing (LOM) system for forming a three-dimensional (3D) object, the device configured to apply adhesive to a plurality of object media layers each comprising a temporary region ( 1 ) and a permanent region ( 2 ). A first adhesive is applied to the temporary regions ( 1 ) and a second adhesive is applied to the permanent regions ( 2 ). Further provided are first and second adhesive formulations, a bonding module for bonding a plurality of individual object media layers using the first and second adhesives, and a LOM system comprising the bonding module. Also provided is a method for self-weeding of a LOM object.

1 . An adhesive dispensing device for use in a Layered Object Manufacturing (LOM) system for forming a three-dimensional (3D) object by application of adhesive to a plurality of object media layers, each object media layer comprising a temporary region and a permanent region, wherein the device is configured to apply a first adhesive to the temporary region of an object media layer and a second bonding adhesive to the permanent region of the object media layer. 
     
     
         2 . The device of  claim 1 , comprising one or more printheads. 
     
     
         3 . The device of  claim 2 , wherein the one or more printheads are configured to co-print the first and second adhesives simultaneously. 
     
     
         4 . (canceled) 
     
     
         5 . (canceled) 
     
     
         6 . (canceled) 
     
     
         7 . The device of  claim 2 , wherein each of the printheads comprises a printhead carriage that is configured to scan across the width of an object media layer when printing the adhesive. 
     
     
         8 . The device of  claim 2 , wherein each of the printheads comprises a page-wide array print head. 
     
     
         9 . The device of  claim 1 , being configured to print predefined volumes of the first adhesive and the second adhesive at specific locations on the object media layer. 
     
     
         10 . A Layered Object Manufacturing (LOM) system for forming a three-dimensional (3D) object, the system comprising an adhesive dispensing device for applying adhesive to object media layers of an object, each object media layer comprising a temporary region and a permanent region, wherein the adhesive dispensing device is configured to apply first and second adhesives to different regions of the object media layers. 
     
     
         11 . The LOM system of  claim 10 , wherein the first adhesive is a temporary tack adhesive and the adhesive dispensing device is configured to apply the first adhesive to the temporary regions of the object media layers. 
     
     
         12 . The LOM system of  claim 10 , wherein the second adhesive is a permanent bond adhesive and the adhesive dispensing device is configured to apply the second adhesive to the permanent regions of the object media layers. 
     
     
         13 . The LOM system of  claim 10 , wherein the first adhesive is applied for temporarily bonding the temporary regions of the object media layers during bonding and profiling. 
     
     
         14 . The LOM system of  claim 10 , wherein the first adhesive is configured to melt and flow out of an interface between the temporary regions of the object media layers when the plurality of object media layers to which adhesive has been applied are heated above a predetermined temperature. 
     
     
         15 . The LOM system of  claim 11 , wherein the tack adhesive comprises a single solid wax and wherein the wax comprises paraffin wax, beeswax or Carnauba wax. 
     
     
         16 . (canceled) 
     
     
         17 . The LOM system of  claim 11 , wherein the tack adhesive comprises one or more of: a microemulsion of wax particles in deionised water and stearic acid. 
     
     
         18 . (canceled) 
     
     
         19 . (canceled) 
     
     
         20 . The LOM system of  claim 11 , wherein the tack adhesive has a pH of between  10  and  11 . 
     
     
         21 . The LOM system of  claim 11 , wherein the tack adhesive is a temporary adhesive configured to be releasable and/or de-activatable and/or removable. 
     
     
         22 . The LOM system of  claim 10 , wherein the second adhesive comprises a bond adhesive for permanently bonding the permanent regions of the object media layers to one another. 
     
     
         23 . The LOM system of  claim 22 , wherein the bond adhesive comprises a microemulsion of ethylene vinyl acetate (EVA) co-polymer glue emulsion particles in deionised water. 
     
     
         24 . The LOM system of  claim 22 , wherein the bond adhesive comprises approximately 5% EVA solids in deionised water. 
     
     
         25 . The LOM system of  claim 22 , wherein the bond adhesive has a viscosity of about 1.66 mPa·s. 
     
     
         26 . The LOM system of  claim 22 , wherein the bond adhesive has a surface tension of about 53.65 mN·m −1 . 
     
     
         27 . The LOM system of  claim 10 , wherein each of the first and second adhesives has one or more of a viscosity of less than 50 mPa·s, a viscosity in the range of 1 to 10 mPa·s, and a surface tension greater than 34 mN·m −1 . 
     
     
         28 . (canceled) 
     
     
         29 . (canceled) 
     
     
         30 . The LOM system of  claim 10 , wherein the first and second adhesives are configured to be inkjet printed. 
     
     
         31 . A bonding module for bonding a plurality of individual object media layers to form a three-dimensional (3D) object in a Layered Object Manufacturing (LOM) system, each object media layer comprising temporary regions to which a first tack adhesive is applied and permanent regions to which a second bond adhesive is applied, wherein the bonding module comprises a heating element for heating the plurality of adhesive applieded applied object media layers. 
     
     
         32 . The bonding module of  claim 31 , wherein the heating element is configured to heat the plurality of adhesive applied object media layers above a predetermined temperature, causing the first adhesive to melt and flow out of an interface between the temporary regions, and causing the second bond adhesive to permanently bond together the bond regions. 
     
     
         33 . The bonding module of  claim 31 , wherein the bonding module comprises a build table for stacking the plurality of object media layers thereon, the build table being configured to be movable to bring the object media layers into contact with the heating element. 
     
     
         34 . The bonding module of  claim 31 , wherein the heating element comprises a hotplate. 
     
     
         35 . The bonding module of  claim 32 , wherein the predetermined temperature is at least 80° C. 
     
     
         36 . (canceled) 
     
     
         37 . A Layered Object Manufacturing (LOM) system configured to assemble a plurality of individual printed media layers to form a three-dimensional (3D) object, the system comprising:
 a collator configured to assemble the plurality of the individual printed media layers to form the 3D object,   the collator comprising the adhesive dispensing device of  claim 1  and a bonding module, the bonding module for bonding a plurality of individual object media layers to form the three-dimensional (3D) object in the Layered Object Manufacturing (LOM) system, each object media layer comprising temporary regions to which a first tack adhesive is applied and permanent regions to which a second bond adhesive is applied, wherein the bonding module comprises a heating element for heating the plurality of adhesive applied object media layers.   
     
     
         38 . The system of  claim 37 , comprising a ink printing module for printing each of the plurality of object media layers prior to collation. 
     
     
         39 . The system of  claim 37 , wherein the collator comprises a profiling module configured to effect a profiling of individual ones of the plurality of media layers to effect a desired 3D shape within the 3D object. 
     
     
         40 . A method of bonding a plurality of individual object media layers to form a three-dimensional (3D) object in in a Layered Object Manufacturing (LOM) system, each object media layer comprising temporary regions and permanent regions, the method comprising:
 applying a first tack adhesive to the temporary regions of each of a plurality of object media layers;   applying a second bond adhesive to the permanent regions of each of the plurality of object media layers;   positioning the object media layers on top of each other to form the object;   heating the object media layers above a predetermined temperature causing the first adhesive to melt, and on cooling re-solidify to form a temporary bond region;   heating the object media layers above the melting point of the tack adhesive, causing the tack adhesive to migrate away from the interlayer bonding region by capillary action; and   separating the temporary regions from the LOM object.   
     
     
         41 . The method of  claim 40 , wherein heating the object media layers above a predetermined temperature causes the second bond adhesive to bond the permanent regions permanently to form a completed LOM object. 
     
     
         42 . The method of  claim 40 , comprising heating the object media layers to a temperature above the melting point of a wax used in the first adhesive. 
     
     
         43 . The method of  claim 40 , comprising heating the heating the object media layers to a temperature above 80° C. and retaining the temperature at this level for a period that ensures sufficient time for the tack adhesive to migrate away. 
     
     
         44 . The method of  claim 40 , wherein heating of the first adhesive causes capillary flow of the first adhesive leading to debonding of the temporary regions of the object media layers. 
     
     
         45 . The method of  claim 40 , wherein the object media layers comprise sheets of paper. 
     
     
         46 . (canceled)