US 12,139,638 B2
Sinterable metal paste for use in additive manufacturing
Stephen T. Connor, San Francisco, CA (US); James R. Groves, Sunnyvale, CA (US); and Theodore C. Sorom, San Rafael, CA (US)
Assigned to MANTLE INC., San Francisco, CA (US)
Filed by MANTLE INC., San Francisco, CA (US)
Filed on Sep. 18, 2018, as Appl. No. 16/134,343.
Application 16/134,343 is a continuation of application No. 15/594,472, filed on May 12, 2017, granted, now 10,087,332.
Claims priority of provisional application 62/421,707, filed on Nov. 14, 2016.
Claims priority of provisional application 62/335,679, filed on May 13, 2016.
Prior Publication US 2019/0016904 A1, Jan. 17, 2019
This patent is subject to a terminal disclaimer.
Int. Cl. C22C 38/02 (2006.01); B22F 1/052 (2022.01); B22F 1/0545 (2022.01); B22F 1/107 (2022.01); B22F 3/10 (2006.01); B22F 3/24 (2006.01); B22F 7/00 (2006.01); B22F 7/02 (2006.01); B22F 10/16 (2021.01); B33Y 10/00 (2015.01); B33Y 70/00 (2020.01); C08K 3/08 (2006.01); C09D 5/38 (2006.01); C09D 7/40 (2018.01); C09D 133/02 (2006.01); C09D 169/00 (2006.01); C21D 6/00 (2006.01); C22C 9/02 (2006.01); C22C 9/08 (2006.01); C22C 11/06 (2006.01); C22C 19/05 (2006.01); C22C 27/06 (2006.01); C22C 38/34 (2006.01); C22C 38/44 (2006.01); C22C 38/58 (2006.01); C22F 1/08 (2006.01); C22F 1/10 (2006.01)
CPC C09D 5/38 (2013.01) [B22F 1/052 (2022.01); B22F 1/0545 (2022.01); B22F 1/107 (2022.01); B22F 3/1017 (2013.01); B22F 3/24 (2013.01); B22F 7/008 (2013.01); B22F 7/02 (2013.01); B22F 10/16 (2021.01); B33Y 10/00 (2014.12); B33Y 70/00 (2014.12); C09D 7/67 (2018.01); C09D 7/68 (2018.01); C09D 7/69 (2018.01); C09D 133/02 (2013.01); C09D 169/00 (2013.01); C21D 6/004 (2013.01); C21D 6/005 (2013.01); C21D 6/007 (2013.01); C21D 6/008 (2013.01); C22C 9/02 (2013.01); C22C 9/08 (2013.01); C22C 11/06 (2013.01); C22C 19/056 (2013.01); C22C 19/058 (2013.01); C22C 27/06 (2013.01); C22C 38/02 (2013.01); C22C 38/34 (2013.01); C22C 38/44 (2013.01); C22C 38/58 (2013.01); C22F 1/08 (2013.01); C22F 1/10 (2013.01); B22F 2003/1042 (2013.01); B22F 2003/248 (2013.01); B22F 2301/10 (2013.01); B22F 2301/15 (2013.01); B22F 2301/35 (2013.01); B22F 2998/10 (2013.01); C08K 3/08 (2013.01); Y02P 10/25 (2015.11)] 32 Claims
OG exemplary drawing
 
1. A metal paste for use in a layerwise growth of metal structures, comprising:
a vehicle comprising at least one solvent and a polymeric binder, the at least one solvent being selected from the group consisting of ethylene glycol, diethylene glycol, diethylene glycol monobutyl ether, triethylene glycol monobutyl ether, methanol, ethanol, propanol, butanol, pentanol, hexanol, heptanol, octanol, terpineol, texanol butyl ester, mineral spirits, propylene carbonate, pentane, hexane, cyclohexane, heptane, octane, nonane, decane, undecane, dodecane, tridecane, tetradecane, toluene, benzene, xylene, mesitylene, tetrahydrofuran, ethanolamine N-methylpyrrolidone, dichloromethane, dimethylacetamide, cyclohexanone, methyl acetate and n-butyl acetate, the polymeric binder comprising hydroxyethyl cellulose;
metal scaffold particles comprising a population of large particles comprising iron at a concentration of 90% to 100% by weight with a first D50 and a population of small particles comprising iron at a concentration of 70% to 100% by weight with a second D50 that is smaller than the first D50; and
infiltrant particles with a D50 particle size such that the infiltrant particles primarily position in interstitial spaces between the metal scaffold particles, the melting point of the infiltrant particles being higher than the melting point of the scaffold particles but not more than 400° C. higher than the melting point of the scaffold particles.