Material for 3D printing and a 3D printed device

Patent metadata

Field	Value
Publication number	US-11491706-B2
Application number	US-201816647677-A
Country	US
Kind code	B2
Filing date	Sep 3, 2018
Priority date	Sep 20, 2017
Publication date	Nov 8, 2022
Grant date	Nov 8, 2022

Abstract

A material for 3D printing is described. The material comprises a polymeric composition comprising a thermoplastic polymer; and from 50 to 99 wt. % ceramic particles comprising a metal, wherein at least 50% by weight of the particles have a diameter in a range from 10 to 100 μm; wherein the material has a dielectric strength of at least 5 kV/mm and/or a dielectric constant of at least 5.

First claim

The invention claimed is:

1. A material for 3D printing comprising:
a polymeric composition comprising a thermoplastic polymer; and
from 50 to 99 wt. % ceramic particles comprising a metal, wherein at least 50% by weight of the particles have a diameter in a range from 10 to 100 μm;
wherein the material has a dielectric strength of at least 5 kV/mm and/or a dielectric constant of at least 5.

2. The material according to claim 1 , wherein the material has a dielectric strength of at least 8 kV/mm and/or a dielectric constant of at least 10.

3. The material according to claim 1 comprising at most 95 wt. % particles.

4. The material according to claim 1 , wherein at least 50% by weight of the particles have a diameter in a range from 15 to 45 μm.

5. The material according to claim 1 , wherein the particles comprise an oxide of the metal, wherein the metal is a transition metal.

6. The material according to claim 1 , wherein the thermoplastic polymer is selected from a group consisting of poly(methyl methacrylate) (PMMA), acrylonitrile butadiene styrene (ABS), aliphatic or semi-aromatic polyamides, polylactic acid (polylactide) (PLA), polybenzimidazole (PBI), polycarbonate (PC), polyether sulfone (PES), polyetherimide, polyethylene (PE), polypropylene (PP), polymethylpentene (PMP) and polybutene-1 (PB-1), polystyrene (PS), polyvinyl chloride (PVC) thermoplastic polyurethane (TPU), poly(meth)acrylate, polyphenylene sulphone (PPSU), high density polyethylene HDPE, polyetherimide (PEI), polyether ether ketone (PEK, and nylon.

7. A filament for fused filament fabrication (FFF) formed from the material according to claim 1 .

8. A method of providing a material for 3D printing comprising:
sintering ceramic particles comprising a metal;
milling the sintered particles, wherein at least 50% by weight of the milled particles have a diameter in a range from 10 to 100 μm;
mixing the milled particles in an amount of from 50 to 99 wt. % with a polymeric composition comprising a thermoplastic polymer to provide a mixture;
heating the mixture thereby melting the thermoplastic; and
cooling the mixture thereby providing the material;
wherein the material has a dielectric strength of at least 5 kV/mm and/or a dielectric constant of at least 5.

9. The method according to claim 8 , comprising providing a filament of the material by extruding the mixture.

10. An electrical energy storage device formed at least in part by fused filament fabrication (FFF), wherein the at least part of the electrical energy storage device comprises the material according to claim 1 .

11. A method of forming an electrical energy storage device at least in part by fused filament fabrication (FFF), the method comprising:
providing a filament formed from the material according to claim 1 ;
melting at least a part of the filament; and
solidifying the melted part of the filament to form at least a part of the electrical energy storage device, wherein the formed at least part of the electrical energy storage device has a dielectric strength of at least 5 kV/mm and/or a dielectric constant of at least 5.

12. The method according to claim 11 , wherein melting the at least a part of the filament is carried out in an oxygen-free atmosphere, and wherein the oxygen-free atmosphere comprises nitrogen, sulfur hexafluoride (SF 6 ), hydrogen (H 2 ), helium (He), and/or mixtures thereof.

13. The method according to claim 11 , wherein the formed at least part of the electrical energy storage device has a porosity of at most 1% by volume of the formed at least part of the electrical energy storage device and/or wherein at most 50% by volume of pores therein have a diameter of at most 1 μm.

14. An electrical energy storage device comprising the material according to claim 1 .

15. A filament comprising the material according to claim 1 .

16. The method according to claim 11 , wherein melting the at least a part of the filament is carried out using a heated extrusion nozzle, and solidifying the melted part of the filament to form at least a part of the electrical energy storage device occurs after extrusion of the filament from the nozzle.

17. The material according to claim 1 , wherein the material has a porosity of at most 1% by volume of the material and/or wherein at most 50% by volume of pores therein have a diameter of at most 1 μm.

18. A filament material for 3D printing, the material comprising:
a polymeric composition comprising a thermoplastic polymer; and
from 50 to 95 wt. % ceramic particles comprising a metal, wherein at least 50% by weight of the particles have a diameter in a range from 15 to 45 μm;
wherein the material has a dielectric strength of at least 5 kV/mm and/or a dielectric constant of at least 5.

19. The material according to claim 18 , wherein the particles comprise an oxide of the metal, wherein the metal is a transition metal.

20. The material according to claim 18 , wherein the material has a porosity of at most 1% by volume of the material and/or wherein at most 50% by volume of pores therein have a diameter of at most 1 μm.

Assignees

• Bae Systems Plc

Inventors

• Moore Ian Anthony
• Black Daniel Benjamin
• Newman Mark Trevor

Classifications

• C04B2235/96

  Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance · CPC title

• C04B2235/5208

  Fibers · CPC title

• C04B35/6262

  of calcined, sintered clinker or ceramics · CPC title

• C04B35/653

  Processes involving a melting step · CPC title

• C04B2235/77

  Density · CPC title