Claims
- 1. A method for forming a part from one or more particulate inorganic materials comprising:
- a) forming a binder composition by admixing a primary binder and a secondary binder; wherein said primary binder comprises a first component selected from the group consisting of trimethylolpropane, di-trimethylolpropane, neopentyl glycol, pentaerythritol, and dipentaerythritol;
- b) forming a feedstock by mixing said binder composition with one or more particulate materials at a temperature above the melting point of said binder composition;
- c) forming a part from said feedstock by injection molding; and
- d) removing said binder composition from said part by heating the part at a rate of from 0.5.degree. C. per minute to 10 .degree. C. per minute.
- 2. The method of claim 1 wherein the step of forming a binder composition further comprises adding one or more materials selected from the group consisting of lubricants and dispersants.
- 3. The method of claim 1 wherein the primary binder further comprises a second component independently selected from the group consisting of: (C.sub.2 -C.sub.20) 1,2-diols; (C.sub.3 -C.sub.20) 1,2-polyols; (C.sub.3 -C.sub.20) 1,3-diols; (C.sub.4 -C.sub.20) 1,3-polyols; (C.sub.2 -C.sub.6) alkylene oxides; polymers comprising as polymerized units (C.sub.2 -C.sub.6) alkylene oxides, (C.sub.2 -C.sub.6) alkylene oxide oligomers; (C.sub.1 -C.sub.4) ethers of polymers comprising as polymerized units (C.sub.2 -C.sub.6) alkylene oxides; (C.sub.1 -C.sub.4) ethers of (C.sub.2 -C.sub.6) alkylene oxide oligomers; poly(hydroxyalkylene carbonate)s; and polyvinyl alcohol.
- 4. The method of claim 1 wherein the primary binder further comprises a second component independently selected from the group consisting of: 1,3-propanediol; 1,3-butanediol; 2-methyl-1,3-propanediol; neopentyl glycol; 2,2-diethylpropanediol; 2-ethyl-2-methylpropanediol; 2-methyl-2-propylpropanediol; 2-ethyl-2-butylpropanediol; 2,4-dimethyl-2,4-butanediol; 2,4,4-trimethyl-3,5-pentanediol; 2-ethyl-1,3-hexanediol; 3,3-dimethyl-1,2-butanediol; pinacol; 1,4-cyclohexanediol; trimethylolpropane; di-trimethylolpropane; pentaerythritol; di-pentaerythritol; cyclic trimethylolpropane formal; trimethylolpropane allyl ethers; dipropylene glycol; dipropylene glycol methyl ether; tripropylene glycol; tripropylene glycol methyl ether; triethylene glycol; triethylene glycol methyl ether; triethylene glycol dimethyl ether; tetraethylene glycol; tetraethylene glycol methyl ether; and tetraethylene glycol dimethyl ether.
- 5. The method of claim 1 wherein the secondary binder is selected from the group consisting of: acrylic and methacrylic homopolymers and copolymers, polystyrene, poly(vinyl acetate), and poly(2-ethyl-2-oxazoline).
- 6. The method of claim 1 wherein the secondary binder is selected from the group consisting of: polymers comprising as polymerized units: methyl methacrylate, ethyl acrylate, isobutyl methacrylate, tertiary butylaminoethyl methacrylate acrylic acid, and methacrylic acid.
- 7. The method of claim 1 wherein the weight ratio of the total primary binder material to the secondary binder material in the binder composition is 10:1 or less.
- 8. The method of claim 1 wherein the amount of particulate material used to form a part in the method of the present material is at least 40 volume percent of the total mixture.
- 9. The method of claim 1 wherein the inorganic particulate material is selected from the group consisting of ceramics, metals and cermets.
- 10. The method of claim 1 wherein the heating in step (d) is carried out within 12 hours.
- 11. The method of claim 1 further comprising in step (d) holding at a maximum temperature of about 250.degree. C. for less than 180 minutes.
- 12. A method for forming an extruded part from inorganic particulate material, comprising:
- a) forming a binder composition by admixing a primary binder and a secondary binder, wherein said primary binder comprises a first component selected from the group consisting of trimethylolpropane, di-trimethylolpropane, neopentyl glycol, pentaerythritol and dipentaerythritol;
- b) forming a feedstock by mixing said binder composition with one or more particulate materials at a temperature above the melting point of said binder composition;
- c) feeding said feedstock into an extruder comprising a screw and a die;
- d) forming an extrudate by heating said feedstock at a temperature sufficient to liquefy said feedstock and forcing said feedstock through the die;
- e) allowing said extrudate to harden at room temperature; and
- f) removing said binder composition from said part by heating the part at a rate of from 1.degree. C. per minute to 10.degree. C. per minute.
- 13. The method of claim 12 wherein the primary binder further comprises a second component independently selected from the group consisting of: (C.sub.2 -C.sub.20) 1,2-diols; (C.sub.3 -C.sub.20) 1,2-polyols; (C.sub.3 -C.sub.20) 1,3-diols; (C.sub.4 -C.sub.20) 1,3-polyols; (C.sub.2 -C.sub.6) alkylene oxides; polymers comprising as polymerized units (C.sub.2 -C.sub.6) alkylene oxides, (C.sub.2 -C.sub.6) alkylene oxide oligomers; C.sub.1 -C.sub.4) ethers of polymers comprising as polymerized units (C.sub.2 -C.sub.6) alkylene oxides; C.sub.1 -C.sub.4) ethers of (C.sub.2 -C.sub.6) alkylene oxide oligomers; poly(hydroxyalkylene carbonate)s; and polyvinyl alcohol.
- 14. The method of claim 12 wherein the primary binder further comprises a second component independently selected from the group consisting of: 1,3-propanediol; 1,3-butanediol; 2-methyl-1,3-propanediol; neopentyl glycol; 2,2-diethylpropanediol; 2-ethyl-2-methylpropanediol; 2-methyl-2-propylpropanediol; 2-ethyl-2-butylpropanediol; 2,4-dimethyl-2,4-butanediol; 2,4,4-trimethyl-3,5-pentanediol; 2-ethyl-1,3-hexanediol; 3,3-dimethyl-1,2-butanediol; pinacol; 1,4-cyclohexanediol; trimethylolpropane; di-trimethylolpropane; pentaerythritol; di-pentaerythritol; cyclic trimethylolpropane formal; trimethylolpropane allyl ethers; dipropylene glycol; dipropylene glycol methyl ether; tripropylene glycol; tripropylene glycol methyl ether; triethylene glycol; triethylene glycol methyl ether; triethylene glycol dimethyl ether; tetraethylene glycol; tetraethylene glycol methyl ether; and tetraethylene glycol dimethyl ether.
Parent Case Info
This is a nonprovisional application of prior pending provisional application Ser. No. 60/004,498, filed Sep. 29, 1995.
US Referenced Citations (9)
Foreign Referenced Citations (4)
Number |
Date |
Country |
688 746 A1 |
May 1995 |
EPX |
5-196201 |
Aug 1993 |
JPX |
5-238601 |
Sep 1993 |
JPX |
WO 9222509 |
Dec 1992 |
WOX |