Search

EP-4737423-A1 - PRINTABLE COMPOSITION FOR ADDITIVE OR SUBTRACTIVE MANUFACTURING, METHOD OF PRODUCTION THEROF AND RESPECTIVE USES

EP4737423A1EP 4737423 A1EP4737423 A1EP 4737423A1EP-4737423-A1

Abstract

The present description relates to a printable composition for additive or subtractive manufacturing, method of obtention and uses thereof. The present description discloses a printable composition for additive manufacturing comprising at least 30% (w/w) of stone powder; at least 10% (w/w) of at least one polymer resin; at least one functional agent selected from a list consisting of colloidal silica, fibers, silanes, titanates, binding agent, thickeners, superplasticizers or combinations thereof; wherein the granulometry of the stone powder is less than 1 mm.

Inventors

  • FARIA PEIXOTO, Miguel Ângelo
  • DE MOURA RODRIGUES, Juliana Patrícia
  • COSTA DELGADO, Samuel
  • RIBEIRO ANICETO, Marco Aurélio

Assignees

  • CENTITVC - Centro de Nanotecnologia e Materiais Tecnicos, Funcionais e Inteligentes
  • Solancis - Sociedade Exploradora de Pedreiras S.A.

Dates

Publication Date
20260506
Application Date
20240701

Claims (20)

  1. Printable composition for additive or subtractive manufacturing comprising at least 30% (w/w) of stone powder; at least 10% (w/w) of at least one polymer resin; at least one functional agent selected from a list consisting of colloidal silica, fibers, silanes, titanates, binding agent, thickeners, superplasticizers or combinations thereof; wherein the granulometry of the stone powder is less than 1 mm.
  2. Printable composition according to any one of the previous claims, wherein the polymer resin is a water-based polymer resin, or epoxy, or mixtures thereof.
  3. Printable composition according to any one of the previous claims, wherein the polymer resin is selected from a list consisting of polyurethane, polypropylene, polyester, epoxy, or combinations thereof; preferably polyurethane.
  4. Printable composition according to any one of the previous claims, comprising at least 20% (w/w) of polymer resin.
  5. Printable composition according to any one of the previous claims, comprising from 20 to 55% (w/w) of polymer resin, preferably from 35 to 50% (w/w) of polymer resin, more preferably from 40 to 45% (w/w) of polymer resin.
  6. Printable composition according to any one of the previous claims, comprising from 30 to 70% (w/w) of stone powder, preferably from 40 to 55% (w/w) of stone powder, more preferably from 40 to 50% (w/w) of stone powder.
  7. Printable composition according to any one of the previous claims, wherein the stone powder is selected from a list consisting of: limestone, granite, basalt, marble or combinations thereof.
  8. Printable composition according to any one of the previous claims, wherein the thickener is selected from a list consisting of: cellulosic organics, associative or non-associative type synthetics, inorganics or combinations thereof.
  9. Printable composition according to any one of the previous claims, wherein the superplasticizer is selected from a list consisting of: modified lignosulfonates, sulfonated synthetic polymers, polyacrylate polymers or combinations thereof.
  10. Printable composition according to the previous claim, wherein the stone powder has a granulometry with a size smaller than 0.5 mm, preferably less than 90 µm.
  11. Printable composition according to any one of the previous claims, wherein the stone powder has a median diameter (D 50 ) comprised between 3 and 90 µm.
  12. Printable composition according to any one of the previous claims, wherein the stone powder has a granulometry with a median diameter (D 50 ) comprised between 3 and 88 µm, preferably between 4 and 86 µm, more preferably between 5 and 85 µm.
  13. Printable composition according to any one of the previous claims, comprising 1 to 20% (w/w) of functional agent, preferably from 5 to 10% (w/w) of functional agent, more preferably from 5 to 8% (w/w) of functional agent.
  14. Printable composition according to any one of the previous claims, wherein the functional agent is selected from a list consisting of colloidal silica; fibers, such as carbon/polymeric fibers; silanes; or combinations thereof.
  15. Printable composition according to any one of the previous claims further comprising an additive; preferably a dye, a surfactant, an anti-corrosive agent, an anti-foaming agent, a flame retardant or other functional agent.
  16. Printable composition according to any one of the previous claims, further comprising at least one fiber, preferably wherein the fiber is selected from a list consisting of: polypropylene, polyester, polyamide, carbon, of natural or regenerated base, or combinations thereof; even more preferably wherein the largest dimension of the fiber is less than 20mm.
  17. Printable composition according to any one of the previous claims, comprising a viscosity above 200 Pa.s at 20°C, preferably between 200-1000 Pa.s at 20°C.
  18. Article comprising the printable composition for additive manufacturing described in any one of the previous claims, preferably a structure of reinforcement of ornamental stones, decorative pieces or furniture.
  19. Article according to the previous claim, comprising a coating.
  20. Method for obtaining a printable composition for additive manufacturing as described in any one of claims 1 to 17, comprising the homogeneous mixture: of at least 30% (w/w) of stone powder with at least 10% (w/w) of at least one polymer resin and at least one functional agent.

Description

TECHNICAL FIELD The present disclosure relates to a printable composition for additive manufacturing (3D printing) or subtractive manufacturing, method of obtention and uses thereof. The composition includes stone powder, a polymer resin, and at least one functional agent, being suitable for creating articles with complex shapes and high mechanical strength. The printable composition for additive or subtractive manufacturing of the present disclosure can be used to manufacture complex articles with a high content of natural stone, such as reinforcement of facade and flooring products, structures for reinforcing ornamental stones, decorative pieces or furniture. BACKGROUND Geological resources are essential for modern society, as they constitute the raw material for a large number of economic activities, including a reasonable number of manufacturing industries. The responsible exploitation of geological resources is an important means of development, being increasingly considered as a catalyst for improving the performance of economies, through the ecosystems of a circular economy, thus integrating economic, social, and environmental aspects. The prevention of waste production and the encouragement of its reuse and recycling in order to extend its life cycle and develop circular economy strategies should increasingly become a priority for the sector, considering that the waste generated in this sector is one of the largest sources of waste within the European Union (EU), which is mainly characterized by material removed from the surface to enable exploitation, rock and mineral waste generated during activity, and the remnants after the end of exploitation. Among the waste generated in the ornamental rocks sector, namely in stone processing, the stone powder, sludges from industrial wastewater treatment plants, landfill and stone scraps/trimmings stand out, which are destined for the construction industry or as filling material in the landscape restoration of quarries, as they are seen as a less noble material. In the case of stone remnants, resulting from cuts of the final products and stone powder, resulting from various dusty activities in extraction and transformation, these residues have an inert inorganic nature, possessing the same composition/characteristics as the final products, having a different final destination. Stone powder is generated during the various processes of extraction and transformation of ornamental rock. In the ornamental rock extraction sector, this dust can be generated in drilling, quarrying, loading, transportation, and material unloading processes. Regarding the processing sector, stone powder is essentially generated in the sawing, polishing, cutting, and finishing processes during the customization of the final product. In the sawing and cutting processes, the generation of this waste would be expected, however high water usage in stone cutting has prevented its formation. This powder is an inert residue considering it constitutes a fine fraction of the marketable product, it has the same composition. However, its most common destination currently is still in a landfill. Document EP1415792B1 describes methods of three-dimensional printing and compositions for three-dimensional printing. The method described in said document includes the construction of cross sections of a three-dimensional article and the assembly of the individual cross sections in layers to form a final article. The individual cross sections are built using an inkjet print head to supply a fluid to a particulate material. Document EP1272334B1 describes a system and method for three-dimensional printing materials that produce models of appearance and a small number of functional parts in an office environment. The method may include the construction of cross sections of a three-dimensional article and the assembly of the individual cross sections in layers to form a final article. Individual cross sections can be built using a printing head of an inkjet printer to apply an aqueous solvent or binding agent to a mixture of adhesive particles, causing the particles in the mixture to adhere to each other and to the previous cross sections. The binding agent may include at least one nonaqueous organic monomeric compound, an ionizable anionic polymer, a cationic polymer, a polymer, an aqueous colloid, or an inorganic solute. Document EP1174471A1 describes a flexible and high hardness composite material consisting of an organic/inorganic composite material with at least 60% by weight of inorganic components, including an aggregate component, and having a Vickers surface hardness of at least 400 and a radius of curvature, in which the material is foldable without breaking, of at least R25 mm based on a plate body of 3 to 15 mm thickness, the organic/inorganic composite material being of high surface hardness, soft and foldable. These facts are described in order to illustrate the technical problem solved by the em