Printed article and a feedstock

Patent metadata

Field	Value
Publication number	US-10087309-B2
Application number	US-201515528803-A
Country	US
Kind code	B2
Filing date	Nov 24, 2015
Priority date	Nov 24, 2014
Publication date	Oct 2, 2018
Grant date	Oct 2, 2018

Abstract

The invention relates to a printed article and a feedstock for printing comprising a matrix forming material, in particular a polymeric material, and a filler material dispersed within the matrix forming material, in which the filler material comprises glass flakes. Glass flakes are characterized as having an aspect ratio of average diameter divided by average thickness greater than or equal to three. Selecting aspect ratio of glass flakes controls an orientation of glass flakes angled relative to a printed layer and formation of a depletion layer in a printed article. Technical effects of angled flakes include better adhesion between successive printed layers in 3D printing and a crack-stopping function. In a preferred embodiment the glass flakes comprise a conductive coating such that a printed article functions as a moisture sensor. Technical effects of a depletion layer include high moisture permeability and so a fast rate of change in electrical resistance due to moisture. A process of manufacturing a feedstock and a process of printing comprising a step of providing glass flakes are also disclosed.

First claim

The invention claimed is:

1. A printed article, comprising:
a matrix forming material, and
a filler material, dispersed within the matrix forming material,
wherein the filler material comprises glass flakes, having an aspect ratio of average diameter divided by average thickness greater than or equal to three, and
a proportion of the glass flakes is angled relative to a printed layer.

2. The printed article according to claim 1 , wherein the matrix forming material ( 1 ) is a polymer selected from high density polyethylene (HDPE), polycarbonate (PC), polyphenylene ether (PPE), acrylonitrile butadiene styrene (ABS), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), poly(butylene adipate) (PBA), polypropylene (PP), polyurethane (PU), poly(lactic acid) (PLA), polyamide (PA) and UV-cured resins.

3. The printed article according to claim 2 , wherein the glass flakes are coated with silane.

4. The printed article according to claim 1 , wherein the glass flakes have average diameter in a range from 10 um to 500 um.

5. The printed article according to claim 1 , wherein the glass flakes have average thickness in a range from 0.1 um to 5 um.

6. The printed article according to claim 1 , wherein the glass flakes have an aspect ratio of average diameter divided by average thickness greater than or equal to 10.

7. The printed article according to claim 1 , wherein a proportion of the glass flakes in the printed article is in a range 5 weight % to 30 weight %.

8. The printed article according to claim 1 , comprising a depletion layer having a lower concentration of glass flakes than in the rest of the printed article.

9. The printed article according to claim 1 , wherein a proportion of the filler material is glass flakes coated with an electrically conductive coating.

10. The printed article according to claim 9 , wherein electrical resistance of the printed article is moisture-dependent, so as to function as a moisture sensor.

11. The printed article according to claim 10 , wherein a change in electrical resistance of the printed article due to a change in moisture is faster than 10 seconds.

12. A feedstock for a printing apparatus, comprising:
a matrix forming material, and
a filler material, dispersed within the matrix forming material to provide a mixture,
wherein the filler material comprises glass flakes, having an aspect ratio of average diameter divided by average thickness greater than or equal to three;
wherein the feedstock is configured as a filament, and
glass flakes are mainly oriented parallel with a diameter of the filament.

13. The feedstock according to claim 12 , wherein the matrix forming material is a polymer selected from high density polyethylene (HDPE), polycarbonate (PC), polyphenylene ether (PPE), acrylonitrile butadiene styrene (ABS), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), poly(butylene adipate) (PBA), polypropylene (PP), polyurethane (PU), poly(lactic acid) (PLA), polyamide (PA) and UV-cured resins.

14. The feedstock according to 12 , wherein the glass flakes have average thickness in a range from 0.1 um to 5 um.

15. The feedstock according to claim 12 , wherein the glass flakes have an aspect ratio of average diameter divided by average thickness greater than or equal to 10.

16. The feedstock according to claim 12 , wherein a concentration of glass flakes in the feedstock is in a range from 5 weight % to 30 weight %.

17. A process of manufacturing a feedstock for a printing apparatus, comprising:
providing a matrix forming material,
providing a filler material, and
dispersing the filler material within the matrix forming material to provide a mixture, wherein the filler material comprises glass flakes, having an aspect ratio of average diameter divided by average thickness greater than or equal to three; and
wherein the feedstock is configured as a filament, and
glass flakes are mainly oriented parallel with a diameter of the filament.

18. The process of manufacturing a feedstock according to claim 17 , wherein the glass flakes are provided in granular form.

19. A process of printing, comprising:
providing a feedstock, comprising:
a matrix forming material, and
a filler material, dispersed within the matrix forming material, and feeding the feedstock into a printing apparatus,

wherein the filler material comprises glass flakes, having an aspect ratio of average diameter divided by average thickness greater than or equal to three, and
wherein a proportion of the glass flakes is angled relative to a printed layer.

20. The process of printing according to claim 19 , wherein a depletion layer having a lower concentration of glass flakes than in the rest of the printed article is formed during printing.

Assignees

• Ngf Europe Ltd
• Pilkington Group Ltd

Inventors

• Mason David
• Campbell James Underwood

Classifications

• Y10T428/31725

  Of polyamide · CPC title

• B29K2995/0005

  Conductive · CPC title

• Y10T428/2982

  Particulate matter [e.g., sphere, flake, etc.] · CPC title

• B29K2505/14

  Noble metals, e.g. silver, gold or platinum · CPC title

• Y10T428/31786

  Of polyester [e.g., alkyd, etc.] · CPC title