Materials for 3d multi-stage method

Abstract

The present invention relates to materials for a multi-stage method for producing one or multiple molded bodies. The materials may be used in a method including constructing one or multiple molded bodies in layers by repeatedly applying particulate material by the 3D printing method; pre-solidifying the molded body; unpacking the pre-solidified molded body and removing unsolidified particulate material, and final solidification of the molded body for achieving a final strength due to the action of thermal energy. The invention also relates to a device which may be used for this method.

What is claimed is: 
     
         1 . A material system for producing one or more molded bodies, comprising:
 i) a particulate material having a casing or a coating including a soluble polymer:   ii) a printable liquid capable of being selectively printed with an ink jet print head and including a solvent capable of liquefying the soluble polymer for forming bridges between adjacent particles;   wherein the particulate material and/or the printable liquid includes a reactive component that reacts at an elevated temperature for achieving a final strength of the molded body.   
     
     
         2 . The material system of  claim 1 , wherein the casing or coating comprises or includes thermoplastic polymers, soluble polymers, waxes, synthetic and natural resins, sugars, salts, inorganic network formers or water glasses. 
     
     
         3 . The material system of  claim 1 , wherein the reactive component chemically reacts at temperature of 110° C. to 200° C. to achieve a final strength of the molded body. 
     
     
         4 . The material system of  claim 1 , wherein the solvent includes water, a hydrocarbon, an alcohol, an ester, an ether, a ketone, an aldehyde, an acetate, a succinate, a monomer, a formaldehyde, a phenol, or any combination thereof. 
     
     
         5 . The material system of  claim 1 , wherein the casing or coating includes a binder. 
     
     
         6 . The material system of  claim 5 , wherein the binder includes some or all the reactive component including a polymerizable monomer. 
     
     
         7 . The material system of  claim 6 , wherein the coating or casing includes an activator for starting a polymerization reaction. 
     
     
         8 . The material system of  claim 1 , wherein the particulate material includes a core component containing natural silica sand, kephalite, cera beads, zircon sand, chromite sand, olivine sand, chamotte, corundum, or glass spheres. 
     
     
         9 . The material system of  claim 8 , wherein the core component has a grain size of about 140 μm. 
     
     
         10 . The material system of  claim 1 , wherein the material system includes an inert material for supporting the molded bodies during a reaction at an elevated temperature occurring after formation of bridges between adjacent particles. 
     
     
         11 . The material system of  claim 1 , wherein the solvent reacts and solidifies with the polymer of the casing or coating. 
     
     
         12 . The material system of  claim 6 , wherein
 the particulate material includes a base containing natural silica sand, kephalite, cera beads, zircon sand, chromite sand, olivine sand, chamotte, corundum, or glass spheres;   the solvent includes water, a hydrocarbon, an alcohol, an ester, an ether, a ketone, an aldehyde, an acetate, a succinate, a monomer, a formaldehyde, a phenol, or any combination thereof; and   the casing or coating comprises or includes thermoplastic polymers, soluble polymers, waxes, synthetic and natural resins, sugars, salts, inorganic network formers or water glasses.   
     
     
         13 . The material system of  claim 12 , wherein the binder includes a phenol resin, a furan, urea or amino resin, a novolak or resol, a urea formaldehyde resin, a furfuryl alcohol urea formaldehyde resin, a phenol modified furan resin, a phenol formaldehyde resin, a furfuryl alcohol phenol formaldehyde resin, or an epoxy. 
     
     
         14 . The material system of  claim 12 , wherein a viscosity of the polymer of the casing or coating in the melt state is about is about 10 to about 1,000 Pas, and the viscosity of the polymer in the solvent is 0.002 to 0.1 Pas. 
     
     
         15 . The material system of  claim 1 , wherein
 the particulate material has a core of silica sand having a grain size of about 140 μm;   the casing or coating includes a resol resin; and   the solvent includes isopropyle alcohol, ethanol, or a mixture of ethanol and isopropyl alcohol.   
     
     
         16 . The material system of  claim 15 , wherein the printable liquid includes a dioxolane additive. 
     
     
         17 . The material system of  claim 1 , wherein all of the components of the material system are in the particulate material or the printable liquid. 
     
     
         18 . The material system of  claim 1 , wherein the concentration of the printable liquid is about 10 weight percent, based on the total weight of the particulate material and the printable liquid in the regions printed by the liquid. 
     
     
         19 . The material system of  claim 1 , wherein the printable liquid includes a dye for identifying the locations that have been printed. 
     
     
         20 . The material system of  claim 1 , wherein the polymer of the casing or coating includes a polyamide, a polyethylene, an amorphous poly alpha-olefin, an ethylene vinyl acetate copolymer, a polyester elastomer, a polyurethane elastomer, a copolyamide elastomer, or a vinyl pyrrolidone/vinyl acetate copolymer. 
     
     
         21 . The material system of  claim 1 , wherein the casing or coating includes Corrodur, dioxolane, or both. 
     
     
         22 . The material system of  claim 1 , wherein the coating or casing contains materials for starting a polymerization with the binder 
     
     
         23 . The material system of  claim 1 , wherein the coating or casing contains a color indicator which is activated by a binder. 
     
     
         24 . The material system of  claim 1 , wherein the material system includes a nucleating agent.