Process for forming a consumable filament

Patent metadata

Field	Value
Publication number	US-10385478-B2
Application number	US-201716094647-A
Country	US
Kind code	B2
Filing date	Mar 20, 2017
Priority date	Apr 22, 2016
Publication date	Aug 20, 2019
Grant date	Aug 20, 2019

Abstract

The present disclosure provides a filament for use in an extrusion-based additive manufacturing system made from or containing a propylene ethylene copolymer having: ethylene derived units content ranging from about 3.0 wt % to about 12.0 wt %, based upon the weight of the propylene ethylene copolymer; MFR L (Melt Flow Rate according to ISO 1133, condition L, at 230° C. and 2.16 kg load) from about 4 to about 20 g/10 min; and xylene solubles measured at 25° C. from about 3 wt % to about 30 wt %, based upon the weight of the propylene ethylene copolymer. The disclosure further provides an extrusion-based additive manufacturing system made from or containing the filament as well as 3D printed articles prepared from the system.

First claim

What is claimed is:

1. A process for forming a consumable filament comprising:
forming a filament, wherein the filament comprises:
a propylene ethylene copolymer having:
an ethylene derived units content ranging from 3.0 wt % to 12.0 wt %, based upon the weight of the propylene ethylene copolymer;
a MFR L (Melt Flow Rate according to ISO 1133, condition L, at 230° C. and 2.16 kg load) from 4 to 20 g/10 min; and
a xylene solubles content, measured at 25° C., from 3 wt % to 30 wt %, based upon the weight of the propylene ethylene copolymer, and

wherein the filament is formed within an extrusion-based additive manufacturing system.

2. The process according to claim 1 , wherein the propylene copolymer has an ethylene derived units content from 3.5 wt % to 10.0 wt %, based upon the weight of the propylene ethylene copolymer.

3. The process according to claim 1 , wherein the propylene copolymer has a MFR L from 5 to 10 g/10 min.

4. The process according to claim 1 , wherein the propylene copolymer has a xylene solubles content, measured at 25° C., from 4 wt % to 25 wt %, based upon the weight of the propylene ethylene copolymer.

5. The process according to claim 1 , wherein the propylene copolymer has an ethylene derived units content from 3.8 wt % to 8.0 wt %, based upon the weight of the propylene ethylene copolymer.

6. The process according to claim 1 , wherein the propylene copolymer has a MFR L ranging from 6 to 8 g/10 min.

7. The process according to claim 1 , wherein the filament has a constant diameter having a variation of +/−0.05 mm.

8. The process according to claim 1 , wherein the filament has a constant diameter having a variation of +/−0.03 mm.

9. The process according to claim 1 , wherein the filament has a diameter selected from the group consisting of: (a) 1.75 mm+/−0.05 mm; and (b) 3 mm+/−0.05 mm.

10. The process according to claim 1 , wherein the filament has a diameter selected from the group consisting of (a) 1.75 mm+/−0.03 mm; and (b) 3 mm+/−0.03 mm.

11. The process of claim 1 comprising the step of forming a 3D printed article with the filament.

Assignees

• Basell Poliolefine Italia Srl

Inventors

• De Palo Roberto
• Cavalieri Claudio

Classifications

• C08F210/16

  Copolymers of ethene with alpha-alkenes, e.g. EP rubbers · CPC title

• C08F210/06

  Propene · CPC title

• B29C64/118

  using filamentary material being melted, e.g. fused deposition modelling [FDM] · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• C08F2500/12

  Melt flow index or melt flow ratio · CPC title