IPC分类号：
B29C64/118 | B29C70/66 | B33Y10/00 | B33Y70/00 | B33Y80/00 | D01F1/02 | B33Y70/10
当前申请(专利权)人：
SIGNIFY HOLDING B.V.
原始申请(专利权)人：
SIGNIFY HOLDING B.V.
当前申请(专利权)人地址：
High Tech Campus 48, AE Eindhoven, NL
发明人：
HIKMET, RIFAT, ATA, MUSTAFA | VAN BOMMEL, TIES | GRUHLKE, STEFAN, WILLI, JULIUS
代理机构：
VERWEIJ, PETRONELLA DANIËLLE
摘要：
The invention provides a method for producing a 3D item by means of fused deposition modelling, the method comprising a 3D printing stage comprising layer-wise depositing 3D printable material, to provide the 3D item comprising 3D printed material, wherein the 3D item comprises layers of 3D printed material, wherein the 3D printable material comprises thermoplastic material, wherein during at least part of the 3D printing stage the 3D printable material further comprises porous inorganic particles embedded in the thermoplastic material, wherein the porosity of the inorganic particles is in the range 5-60 vol. %, and wherein the inorganic particles (410) have an open porosity. The invention also comprises the product resulting from above method.
技术问题语段：
While this technique produces smooth surfaces the photo curable materials are not very stable, and they also have relatively low thermal conductivity to be useful for injection molding applications.
技术功效语段：
[0007]The most widely used additive manufacturing technology is the process known as Fused Deposition Modeling (FDM). Fused deposition modeling (FDM) is an additive manufacturing technology commonly used for modeling, prototyping, and production applications. FDM works on an "additive" principle by laying down material in layers; a plastic filament or metal wire is unwound from a coil and supplies material to produce a part. Possibly, (for thermoplastics for example) the filament is melted and extruded before being laid down. FDM is a rapid prototyping technology. Other terms for FDM are "fused filament fabrication" (FFF) or "filament 3D printing" (FDP), which are considered to be equivalent to FDM. In general, FDM printers use a thermoplastic filament, which is heated to its melting point and then extruded, layer by layer, (or in fact filament after filament) to create a three-dimensional object. FDM printers are relatively fast, low cost and can be used for printing complicated 3D objects. Such printers are used in printing various shapes using various polymers. The technique is also being further developed in the production of LED luminaires and lighting solutions.
[0101]In a specific embodiment, the 3D item comprises a plurality of components at least comprising the thermoplastic material and porous inorganic particles, wherein printed material has a material density n m , wherein the printed material has a theoretical material density n mc , defined on the basis of the densities of the components of the 3D printed material, wherein 0.6 ≤ n m /n mc ≤ 0.95, especially wherein 0.7 ≤ n m /n mc ≤ 0.9. Amongst others due to the voids, the density may be lower, and thus the weight of the 3D item may be reduced.
权利要求：
1. A method for producing a 3D item (1) by means of fused deposition modelling, the method comprising a 3D printing stage comprising layer-wise depositing 3D printable material (201), to provide the 3D item (1) comprising 3D printed material (202), wherein the 3D item (1) comprises layers (322) of 3D printed material (202), wherein the 3D printable material (201) comprises thermoplastic material (401), wherein during at least part of the 3D printing stage the 3D printable material (201) further comprises porous inorganic particles (410) embedded in the thermoplastic material (401), wherein the porosity of the inorganic particles (410) is in the range of 5 to 60 vol. %, characterized in that the inorganic particles (410) have an open porosity.
2. The method according to claim 1, wherein the inorganic particles (410) have a length (L1) in the range of 1 to 500 µm, a width (L2) and a height (L3), wherein the aspect ratio AR1=L1/L2 is in the range of 0.5≤AR1≤2, wherein the aspect ratio AR2=L1/L3 is in the range of 0.5≤AR2≤2, and wherein the aspect ratio AR3=L2/L3 is in the range of 0.5≤AR2≤2.
3. The method according to any one of the preceding claims, wherein the concentration of the porous inorganic particles (410) is in the range of 10 to 30 vol. % relative to the 3D printable material (201).
4. The method according to any one of the preceding claims, wherein the porous inorganic particles (410) comprise porous glass particles.
5. The method according to any one of the preceding claims, wherein the porous inorganic particles (410) comprise core-shell particles, comprising a hollow core (415) and a porous shell.
6. The method according to any of the preceding claims, wherein the porous inorganic particles (410) have a first density n1, wherein the thermoplastic material (401) has a second density n2, wherein 0.8≤n1/n2≤1.2.
7. The method according to any of the preceding claims, wherein the layer (322) comprises a core-shell layer (1322) of 3D printed material (202), comprising: (i) a core (330) comprising thermoplastic material (401) further comprising porous inorganic particles (410) embedded in the thermoplastic material (401) at a concentration c1; and (ii) a shell (340) comprising thermoplastic material (401), further comprising porous inorganic particles (410) embedded in the thermoplastic material (401) at a concentration c2; wherein the shell (340) at least partly encloses the core (330); wherein the core (330) has a core height (H1) and a core width (W1), wherein the shell (340) has a shell width (W2); wherein the 3D printing stage comprises 3D printing the core-shell layer (1322) of 3D printed material (202); wherein c2/c1≤0.5.
8. The method according to any of the preceding claims, wherein the porous inorganic particles (410) have pores having an average pore size in the range of 10-100 µm, and wherein the porous inorganic particles (410) are light transmissive and wherein the 3D printable material (201) is light transmissive.
9. A filament (320) for producing a 3D item (1) by means of fused deposition modelling, the filament (320) comprising 3D printable material (201), wherein the 3D printable material (201) comprises components, wherein the components at least comprise (i) thermoplastic material (401) and (ii) porous inorganic particles (410); wherein in at least part of the filament (320) the 3D printable material (201) comprises the porous inorganic particles (410) embedded in the thermoplastic material (401), wherein the porosity of the inorganic particles (410) is in the range of 5 to 60 vol. %, characterized in that the inorganic particles (410) have an open porosity, wherein the concentration of the porous inorganic particles (410) is in the range of 10 to 30 vol. % relative to the 3D printable material (201); wherein the filament (320) has a material density nf, wherein the filament (320) has a theoretical material density nfc, defined on the basis of the densities of the components of the filament (320), wherein 0.6≤nf/nfc≤1.
10. A 3D item (1) comprising 3D printed material (202), wherein the 3D item (1) comprises a plurality of layers (322) of 3D printed material (202), wherein the 3D printed material (202) comprises thermoplastic material (401),wherein at least part of the 3D printed material (202) further comprises porous inorganic particles (410) embedded in the thermoplastic material (401), wherein the porosity of the inorganic particles (410) is in the range of 5 to 60 vol. %, characterized in that the inorganic particles (410) have an open porosity.
11. The 3D item (1) according to claim 10, wherein the inorganic particles (410) have a length (L1) in the range of 1 to 500 µm, a width (L2) and a height (L3), wherein the aspect ratio AR1=L1/L2 is in the range of 0.5≤AR1≤2, wherein the aspect ratio AR2=L1/L3 is in the range of 0.5≤AR2≤2, and wherein the aspect ratio AR3=L2/L3 is in the range of 0.5≤AR2≤2.
12. The 3D item (1) according to any one of the preceding claims 10-11, wherein the concentration of the porous inorganic particles (410) is in the range 10-30 vol. % relative to the 3D printed material (202).
13. The 3D item (1) according to any one of the preceding claims 10-12, wherein the porous inorganic particles (410) comprise porous glass particles.
14. The 3D item (1) according to any one of the preceding claims 10-13, wherein the 3D item (1) comprises a plurality of components (421) at least comprising the thermoplastic material (401) and porous inorganic particles (410), wherein printed material (202) has a material density nm, wherein the printed material (202) has a theoretical material density nmc, defined on the basis of the densities of the components (421) of the 3D printed material (202), wherein 0.6≤nm/nmc≤0.95.
15. A lighting device (1000) comprising the 3D item (1) according to any one of the preceding claims 10-14, wherein the 3D item (1) is configured as one or more of (i) at least part of a lighting device housing, (ii) at least part of a wall of a lighting chamber, and (iii) an optical element.