Method for preparing and depositing a composition

Abstract

Assembly of suspensions, preferably colloidal, within a channel (1) so as to form aggregates or agglomerates of particles and to expel from this channel (1) a composition comprising these aggregates or agglomerates in order to produce a part by additive manufacturing. Figure for the abbreviation: Fig. 1

Description

Title of the invention: Process for preparing and depositing a composition Technical field

[0001] The invention relates to the field of the preparation and deposition of a composition, in particular with a view to producing a part by additive manufacturing.

[0002] The invention is of particular interest for the manufacture of a ceramic part. State of the prior art

[0003] Conventional additive manufacturing processes by direct writing of ceramic parts implement a step of depositing layers of a viscoelastic composition using a print head.

[0004] This viscoelastic composition typically comprises additives such as plasticizers and / or organic binders giving the composition the rheological properties required to allow its flow in the print head while preventing its spreading during deposition.

[0005] Among other disadvantages, the use of plasticizers and organic binders requires a debinding step to be carried out. Debinding has a cost in terms of time and energy and is likely to damage the part, especially when the wall thicknesses are significant.

[0006] Furthermore, the presence of organic elements in the composition does not promote intimate bonds between the grains of the ceramic powder, nor between the layers successively deposited by the print head, nor between the first layer deposited and the support, which can affect the mechanical strength of the part.

[0007] The invention aims in particular to remedy the drawbacks of conventional additive manufacturing processes by direct writing as well as the drawbacks associated with the compositions used in these processes. Statement of the invention

[0008] The subject of the invention is a process for preparing and depositing a composition, comprising: - a step of introducing into a channel two suspensions each comprising particles, - a step of assembling the suspensions within the channel so as to form said composition and so that this composition comprises aggregates or agglomerates of said particles, - a step of expulsion of the composition of the canal.

[0009] This method can typically be implemented to produce a part by additive manufacturing. In other words, the expulsion step can be carried out so as to produce a part by depositing one or more layers of said composition.

[0010] Unlike conventional direct writing additive manufacturing processes in which the composition is assembled before its introduction into a print head, the method of the invention implements a step of assembling the suspensions directly in the channel at the outlet from which it is deposited. In other words, the assembly step is in this case carried out directly within a print head, just before deposition of the composition formed by this assembly.

[0011] The formation of aggregates or agglomerates of particles in the channel makes it possible to initiate the structuring of the composition in the channel before its deposition and to obtain a cohesive material with mechanical consolidation at the outlet of the channel.

[0012] Such an assembly of suspensions in the channel makes it possible to introduce into the channel fluid suspensions, or more generally suspensions of low viscosity, compared with a conventional rheofluidifying and pseudo-plastic ink.

[0013] The suspensions may therefore be free of organic additives of the plasticizer or binder type, or contain a reduced quantity of organic elements.

[0014] This results in numerous advantages, both economically and environmentally and in terms of the quality of the part thus manufactured.

[0015] In particular, the absence or presence in reduced quantity of organic additives makes it possible to avoid resorting to a debinding step, which makes it possible to preserve the integrity of the part and to reduce the economic and environmental impact linked to its manufacture.

[0016] Concerning the quality of the part, the absence or the presence in reduced quantity of organic elements tends to favor the intimate bonds of the different parts of the composition forming the part as well as its maintenance on the support during deposition. This results in an improvement of the mechanical strength of the part and / or a better adhesion of the part on the support, making for example the process compatible with a sealing or repair application.

[0017] The fluidity of the suspensions also reduces the elastic energy stored during the implementation of the method, which makes it possible to improve the control of the slowdowns and accelerations of the deposition member integrating the channel.

[0018] Furthermore, the assembly in the channel makes it possible, for example by playing on its geometry and / or its outlet, to produce specific particle arrangements, in particular in terms of spatial distribution, internal structuring of the composition, or even concentration gradients.

[0019] The assembly step can in particular be implemented so as to produce a selective localized aggregation / agglomeration between the particles so as to generate a diffuse interface between the two assembled suspensions.

[0020] The invention thus makes it possible to improve the mechanical strength of the part, for example during a subsequent sintering or post-consolidation step at high temperature and / or to generate specific composition gradients.

[0021] In one embodiment, the particles comprise a first type of particles and a second type of particles chosen so as to be able to develop bonds between them during the assembly step, in order to constitute said aggregates or agglomerates.

[0022] Said connections are preferably electrostatic.

[0023] Such combinations of particles make it possible to obtain rapid aggregation / agglomeration reactions.

[0024] This allows the deposition speed to be increased.

[0025] Alternatively, other types of particles can be implemented, by developing bonds of an electrostatic nature or of a different nature.

[0026] In one embodiment, during the introduction step, one of the suspensions comprises the particles of the first type and the other of said suspensions comprises the particles of the second type.

[0027] In one embodiment, the particles of the first type and the particles of the second type have surface electric charges of opposite sign.

[0028] For example, particles of the first type may have positive surface electrical charges and particles of the second type negative surface electrical charges, or vice versa.

[0029] Preferably, the particles of the first type and the particles of the second type have a zeta potential of opposite sign.

[0030] Control of the zeta potential of the different particles can be achieved by any conventional method, for example by functionalizing particles, by modifying the pH of the suspension, etc.

[0031] In a preferred embodiment, said suspensions are colloidal suspensions.

[0032] Preferably, the particles are chosen so that the composition expelled from the channel forms a ceramic element.

[0033] For example, the particles of the first type may comprise silica particles. The particles of the second type may comprise silica particles functionalized with amine functions or deflocculated alumina particles.

[0034] In one embodiment, the introducing step comprises a separate, spatially and / or temporally, introduction of the suspensions.

[0035] Thus, the suspensions can each be introduced through a respective inlet of the channel, simultaneously or one after the other.

[0036] The channel may for this purpose comprise two separate inlets, located for example at one end of the channel opposite the outlet or configured so that the suspensions are introduced into the channel coaxially with respect to each other.

[0037] In one embodiment, the method comprises a step of post-heat treatment of the composition expelled from the channel.

[0038] This thermal post-treatment may include a step of consolidation / drying / selective laser sintering.

[0039] The method can be implemented to manufacture many types of parts in many fields such as health or information and communication technologies.

[0040] For example, the method may be implemented such that the part forms part of an implant or a microelectronic component such as a capacitor.

[0041] The absence or presence in reduced quantity of organic elements is of particular interest in biomedical applications.

[0042] The method of the invention is not limited to the production of a part by additive manufacturing. In a non-limiting manner, this method can also be implemented to bond, assemble and / or repair an object using the composition emerging from the channel, or to encapsulate a component using this composition in order to produce a composite part.

[0043] The invention also relates to a device for preparing and depositing a composition, comprising a channel configured to implement a method as defined above.

[0044] In the context of an additive manufacturing application, this device may for example comprise a print head integrating said channel.

[0045] In one embodiment, the channel is a microchannel, i.e. a channel having at least one dimension, for example a diameter, less than a millimeter.

[0046] In one embodiment, the channel comprises an outlet configured to expel the composition, the outlet having a cross-section having a dimension less than 1.5 mm, preferably less than 1 mm, for example 800 μm.

[0047] In one embodiment, the channel comprises a first inlet capable of introducing one of said suspensions into the channel and a second inlet capable of introducing the other of said suspensions into the channel.

[0048] Other advantages and characteristics of the invention will appear on reading the detailed, non-limiting description which follows. Brief description of the drawings

[0049] The following detailed description refers to the accompanying drawings in which:

[0050] [Fig-1] is a schematic view of a device according to a first embodiment lization of the invention;

[0051] [Fig.2] is a schematic view of a device according to a second embodiment of the invention. Detailed description of embodiments

[0052] [Fig.l] schematically shows a device according to a first embodiment of the invention.

[0053] The device of [Fig.l] comprises a member forming a channel 1, reservoirs 2 and 3, conduits 4 and 5 and a support 6.

[0054] In this example, the device is implemented to produce a part by additive manufacturing, the member forming the channel 1 belonging to a print head of an additive manufacturing tool (not shown).

[0055] In this example, the reservoir 3 contains a first colloidal suspension comprising a first type of particles with a negative surface electrical charge, while the reservoir 2 contains a second colloidal suspension comprising a second type of particles with a positive surface electrical charge.

[0056] Channel 1 comprises two inputs 8 and 9, an output 11 and a portion 12 extending between inputs 8 and 9 on the one hand and output 11 on the other hand.

[0057] In this example, the portion 12 of the channel 1 has a cylindrical shape with a diameter Al approximately equal to 800 pm and a length A2 approximately equal to 9 cm.

[0058] The reservoir 2 is fluidically connected to the inlet 8 of the channel 1 by the conduit 4 so as to be able to introduce into the channel 1, and in particular into the portion 12 of the channel 1, the suspension contained in the reservoir 2.

[0059] Similarly, the reservoir 3 is fluidically connected to the inlet 9 of the channel 1 by the conduit 5 so as to be able to introduce into the channel 1, and in particular into the portion 12 of the channel 1, the suspension contained in the reservoir 3.

[0060] The device comprises displacement means (not shown), such as pressure differential pumps or syringe pumps, configured to introduce into the channel 1 the first suspension and the second suspension, respectively via the inlets 8 and 9, so that these suspensions enter the portion 12 of the channel 1 by flowing towards the outlet 11 in a flow direction B1.

[0061] The particles of the two suspensions having surface electric charges of opposite sign, these develop between them, within the portion 12 of the channel 1, electrostatic bonds constituting aggregates / agglomerates of particles.

[0062] An assembly of the suspensions is thus produced within the portion 12 so as to form, upstream of the outlet 11 relative to the flow direction B1, a composition which comprises these aggregates / agglomerates of particles.

[0063] The movement of the suspensions along the channel 1 in the flow direction B1 causes a progressive expulsion of the composition through the outlet 11.

[0064] The support 6 is arranged opposite the outlet 11 of the channel 1 so that the composition which is expelled from it is deposited on this support 6.

[0065] In this example, the flow direction B1 defines a trajectory comprising a component going vertically from top to bottom, the support 6 being arranged below the outlet 11 of the channel 1. The composition leaving the channel 1 via its outlet 11 thus flows towards the support 6 under the action of the flow.

[0066] In a manner known per se, the device is configured to effect a relative movement of the print head with respect to the support 6 so as to arrange the composition on the support 6 in a previously chosen arrangement.

[0067] Such relative movement makes it possible in particular to form a succession of layers with the composition so as to constitute a three-dimensional part.

[0068] [Fig.2] schematically illustrates a second embodiment of a device according to the invention, which differs from that of [Fig.l] in that it is configured to assemble the two suspensions coaxially.

[0069] The device of [Fig. 2] is described only according to its differences from that of [Fig. 1]. The preceding description applies by analogy to the embodiment of [Fig. 2].

[0070] The device of [Fig.2] is essentially distinguished from that of [Fig.l] in that it comprises a double channel 1, in this case a first channel 21 and a second channel 22 nested within each other.

[0071] The channel 21 has a generally parallelepiped geometry, one end of which forms an inlet 23 and an opposite end forms an outlet 24 of this channel 21.

[0072] The channel 22 has a generally cylindrical geometry, one end of which forms an inlet 26 and an opposite end forms an outlet 27 of this channel 22.

[0073] A lower portion of the channel 21 extends inside an upper portion of the channel 22 in a coaxial manner so that the outlet 24 of the channel 21 opens into the channel 22.

[0074] The channel 22 comprises a lower portion extending longitudinally between the outlet 24 of the channel 21 and the outlet 27 of the channel 22.

[0075] In this example, the lower portion of the channel 22 has a cylindrical shape with a diameter Al approximately equal to 800 μm and a length A2 approximately equal to 9 cm.

[0076] The reservoir 2 is fluidically connected to the inlet 23 of the channel 21 by the conduit 4 so as to be able to introduce into the channel 21 the first suspension contained in the reservoir 2.

[0077] Similarly, the reservoir 3 is fluidically connected to the inlet 26 of the channel 22 by the conduit 5 so as to be able to introduce into the channel 22 the second suspension contained in the reservoir 3.

[0078] The first suspension can thus flow into the channel 21 towards its outlet 24 so as to penetrate into the lower portion of the channel 22, radially in the center of this channel 22.

[0079] The second suspension can flow in the channel 22 towards its outlet 27, firstly radially around the channel 21 then in the lower portion of the channel 22 by penetrating into this lower portion in the form of a ring whose geometry is defined radially on the inside by the section of the channel 21 and radially on the outside by the geometry of the channel 22.

[0080] The two suspensions thus tend to assemble in such a way as to present a core-shell type structure, the core mainly comprising the first suspension, the shell mainly comprising the second suspension.

[0081] First example:

[0082] A first example of implementation of the method of the invention using the device of [Fig.2] will now be described.

[0083] In this first example, the first suspension contained in the reservoir 3 is an aqueous suspension of silica particles and the second suspension contained in the reservoir 2 is an aqueous suspension of silica particles surface-modified by amines.

[0084] In a manner known per se, the silica particles are synthesized according to the method described in the following document: MA Piechowiak, A. Videcoq, F. Rossignol, C. Pagnoux, C. Carrion, M. Cerbelaud and R. Ferrando, Oppositely Charged Model Ceramic Colloids: Numerical Predictions and Experimental Observations by Confocal Laser Scanning Microscopy, Langmuir 2010, 26(15), 12540-12547. The synthesis of these particles is based on a process known as the “Stöber process” which makes it possible to obtain silica core-shell particles with a fluorescent agent incorporated in the center.

[0085] The silica particles thus obtained are spherical and have an average diameter of approximately 600 nm.

[0086] To prepare the first suspension, a powder consisting of silica particles thus obtained is introduced into a volume of deionized water so as to obtain the desired volume fraction of powder. In this example, the volume fraction is 38%.

[0087] Deagglomeration is carried out conventionally by ultrasound, using a sonotrode, imposing the following cycle: 300 W for 30 s with 3 s of pulsation and 1 s of rest.

[0088] The silica particles of the first suspension thus prepared have a negative surface potential over a wide pH range.

[0089] To ensure the stability of the suspension, the pH of the silica is adjusted between 7 and 8 so as to have a zeta potential around -40 mV.

[0090] For the second suspension, silica particles obtained according to the method described above are surface modified with amines. The surface modification of the silica is done by grafting an organosilane, in this example 3-Aminopropyltriethoxysilane (APTES). To do this, a powder consisting of synthesized silica particles is immersed in deionized water and then magnetically stirred. The APTES is then added and stirring is maintained for 24 hours at room temperature. The grafted silica particles are rinsed with water and then centrifuged four times at 3500 rpm for 5 min before being dried at 50 °C overnight.

[0091] The silica particles thus modified immersed in water have a positive surface potential below pH 7.5 and negative above.

[0092] The second suspension is prepared in the same way as the first suspension, except that the pH is adjusted between 4.5 and 5 to have a zeta potential around +40 mV.

[0093] The measurement of the zeta potential can be carried out by zetametry or acoustophorometry.

[0094] When the two suspensions are introduced into channel 1 in equivalent proportions, the pH of the mixture is of the order of 6, knowing that, over the pH range from 2 to 7.5, the silica particles and the modified silica particles have opposite surface potentials and are therefore likely to heteroaggregate.

[0095] In this example, the two suspensions are individually stable and, when mixed in the lower portion of channel 22, the resulting suspension is highly aggregated.

[0096] Second example:

[0097] A second example of implementation of the method of the invention using the device of [Fig.2] will now be described.

[0098] In this second example, the first suspension contained in the reservoir 3 is an aqueous suspension of silica particles marketed by “Alfa Aesar by Thermo Fisher Scientific” under the designation “L16985”, in the form of an amorphous powder of spherical particles with an average diameter of 500 nm. The second suspension contained in the reservoir 2 is an aqueous suspension of alumina particles of the “Alumina ceramic (AKP-30 Series)” type marketed by the company “Sumimoto Chemical advanced technologies” and having an average size of around 400 nm.

[0099] Zeta potential measurements carried out on this commercial silica show a behavior similar to that obtained for particles synthesized by the Stöber route (see above). The zeta potential is negative over the pH range considered.

[0100] Alumina particles in aqueous suspension exhibit a positive zeta potential below pH 9 and negative above it.

[0101] Between pH 2 and 9, the alumina and silica particles used in this second example have surface potentials of opposite sign.

[0102] The suspensions are prepared in the same way as in the first example described above.

[0103] In this second example, the suspensions each have a volume fraction of powder equal to 30 v% and are prepared using osmosis water.

[0104] To ensure the stability of the alumina suspension, the pH is adjusted to around 5-6 by adding hydrochloric acid so that its zeta potential is around 45 mV.

[0105] It has been observed that these suspensions of silica and alumina are stable and that their mixing results in rapid aggregation / agglomeration.

[0106] The description of the first example applies by analogy to this second example.

[0107] Third example:

[0108] A third example of implementation of the method of the invention using the device of [Fig.2] will now be described.

[0109] In this third example, the first suspension contained in the tank 3 is an aqueous suspension of alumina particles surface-modified by a dispersant known as “DARVAN (registered trademark) C” and supplied by “Vanderbilt Minerals, LLC”. This dispersant causes a modification of the surface charge of the alumina which gradually becomes negative without modifying the pH.

[0110] The second suspension contained in the reservoir 2 is an aqueous suspension of silica particles surface-modified by amines, in the same way as in the first example.

[0111] The suspensions are prepared in the same way as in the first example in an aqueous medium with, in this third example, a powder volume concentration of 35%.

[0112] The description of the first and second examples applies by analogy to this third example.

[0113] In these examples, the flow rate of introduction into channel 1 of each of the suspensions is 2 mL / h and the printing speed is 2.2 mm / s.

[0114] The printing speed can be adjusted according to the flow rate of the suspensions and the dimension Al of the outlet 27 of channel 1.

[0115] The examples which have just been described make it possible to manufacture a ceramic part without using an organic additive and without it being necessary to carry out a debinding step.

[0116] The three examples of suspension combinations described above with reference to [Fig.2] apply by analogy to the embodiment of [Fig.l].

[0117] The suspension parameters can of course be adapted to the particularities structural characteristics of their assembly which result from the geometry of the channel 1. For example, in a non-limiting manner, in the context of the first example described above, the volume fraction of powder in each of the suspensions can be 50 v% when the device of [Fig.l] is used.

[0118] The invention is not limited to the particular examples and embodiments described above. For example, the channel(s) 1 and / or 21 and / or 22 may have a geometry and dimensions different from those indicated above. The dimension A1 may be less than 800 pm, for example approximately equal to 400 pm in order to increase the definition of the part, or on the contrary be greater than 800 pm. The dimension A2 may be adjusted according to the suspensions and the time required for the aggregation / agglomeration of the particles they contain.

[0119] Other combinations of suspensions and / or a quantity of suspensions greater than two may be implemented, depending on the desired particle arrangements and composition structure.

[0120] The introduction of the suspensions into channel 1 and their expulsion can be carried out discontinuously.

[0121] For another example, the composition leaving the channel 1 may be subjected to a concomitant drying step, depending for example on the dimension Al of the outlet of the channel 1 and / or the expulsion flow rate.

[0122] Furthermore, the principles described above can be implemented not to produce a part by additive manufacturing but to carry out an operation of bonding, assembly, repair or encapsulation of an object.

Claims

Claims

1. Method for preparing and depositing a composition, comprising: - a step of introducing into a channel (1, 12, 22) two suspensions each comprising particles, - a step of assembling the suspensions within the channel (1, 12, 22) so as to form said composition and so that this composition comprises aggregates or agglomerates of said particles, - a step of expelling the composition from the channel (1, 12, 22).

2. Method according to claim 1, in which the particles comprise a first type of particles and a second type of particles chosen so as to be able to develop bonds between them, preferably electrostatic, during the assembly step, in order to constitute said aggregates or agglomerates.

3. The method of claim 2, wherein, in the introducing step, one of the suspensions comprises particles of the first type and the other of said suspensions comprises particles of the second type.

4. Method according to claim 2 or 3, in which the particles of the first type and the particles of the second type have surface electric charges of opposite sign, preferably a zeta potential of opposite sign.

5. A method according to any one of claims 1 to 4, wherein said suspensions are colloidal suspensions.

6. A method according to any one of claims 1 to 5, wherein the particles are chosen so that the composition expelled from the channel (1, 12, 22) forms a ceramic element.

7. A method according to any one of claims 1 to 6, wherein the expulsion step is carried out so as to manufacture a part by depositing one or more layers of said composition.

Images