Method for manufacturing three-dimensional structure, and 3D printer filament

Patent metadata

Field	Value
Publication number	US-12162209-B2
Application number	US-202117381027-A
Country	US
Kind code	B2
Filing date	Jul 20, 2021
Priority date	Jan 22, 2016
Publication date	Dec 10, 2024
Grant date	Dec 10, 2024

Abstract

Provided is the method for manufacturing a three-dimensional structure with a less amount of internal voids or bubbles, and also to provide a 3D printer filament used for manufacturing such three-dimensional structure. The method for manufacturing a three-dimensional structure, the method comprises melting and depositing a filament using a 3D printer, the filament comprising a commingled yarn that contains a continuous reinforcing fiber (A) and a continuous thermoplastic resin fiber (B), with a dispersity of the continuous reinforcing fiber (A) in the commingled yarn of 60 to 100%.

First claim

What is claimed is:

1. A 3D printer filament comprising a commingled yarn that contains a continuous reinforcing fiber (A) and a continuous thermoplastic resin fiber (B), with a dispersity of the continuous reinforcing fiber (A) in the commingled yarn of 60 to 100%;
wherein a component derived from a portion of the continuous thermoplastic resin fiber (B) has an impregnation rate in the continuous reinforcing fiber (A) of not less than 10% and less than 80%;
the 3D printer filament further comprises a reinforcing member for the commingled yarn;
the reinforcing member is a thermoplastic resin fiber (C) and a monofilament; and
the thermoplastic resin fiber (C) has a moisture content of 0.17% to 2.0% and a diameter of 0.5 to 2.5 mm.

2. The 3D printer filament of claim 1 , wherein the filament has an elastic modulus of 10 MPa or larger, where the elastic modulus is measured by embedding an end of a 15 mm-long filament up to 10 mm-depth by a resin to form a 25 mm-diameter cylinder shape; by inserting the cylindrical resin part directed downward into a 25 mm-diameter, 20 mm-high cylindrical hole of a jig; by fitting a 25 mm-diameter disk-like weight from above the cylindrical resin part into the jig, to thereby apply load at a testing speed of 0.2 mm/min.

3. The 3D printer filament of claim 1 , wherein the continuous reinforcing fiber (A) is longer than 30 mm.

4. The 3D printer filament of claim 1 , wherein the continuous thermoplastic resin fiber (B) contains thermoplastic resin b as a constituent, which is a polyamide resin.

5. The 3D printer filament of claim 1 , wherein the continuous thermoplastic resin fiber (B) contains thermoplastic resin b as a constituent, which is a polyamide resin that contains a structural unit derived from diamine and a structural unit derived from dicarboxylic acid, and, 50 mol % or more of the structural unit derived from diamine is derived from xylylenediamine.

6. The 3D printer filament of claim 1 , wherein the continuous reinforcing fiber (A) is a carbon fiber or a glass fiber.

7. The 3D printer filament of claim 1 , wherein the commingled yarn is spirally wound around the thermoplastic resin fiber (C).

8. The 3D printer filament of claim 1 , wherein a difference between a melting point of a thermoplastic resin b that composes the thermoplastic resin fiber (B), and a melting point of a thermoplastic resin c that composes the thermoplastic resin fiber (C) is 50° C. or smaller.

9. The 3D printer filament of claim 1 , wherein the continuous reinforcing fiber (A) includes a polyacrylonitrile-based carbon fiber and/or pitch-based carbon fiber.

10. The 3D printer filament of claim 1 , wherein the component derived from a portion of the continuous thermoplastic resin fiber (B) has an impregnation rate in the continuous reinforcing fiber (A) of 10% or larger and smaller than 30%.

11. The 3D printer filament of claim 1 , wherein the continuous reinforcing fiber (A) or the continuous thermoplastic resin fiber (B) accounts for 95% by weight or more of continuous reinforcing fibers that composes the commingled yarn.

12. The 3D printer filament of claim 1 , wherein the commingled yarn includes 100 to 100,000 f of the continuous reinforcing fiber (A) and continuous thermoplastic resin fiber (B) in total, per a single commingled yarn.

13. The 3D printer filament of claim 1 , which has a cross sectional shape of circular.

14. The 3D printer filament of claim 1 , which has a diameter of 0.5 mm to 3.0 mm.

Assignees

• Mitsubishi Gas Chemical Co

Inventors

• Nakai Asami
• Ohtani Akio
• Ito Hiroto
• Hirano Fumiya
• Hirooka Nobuki
• Matsumoto Nobuhiko

Classifications

• D10B2101/12

  Carbon; Pitch · CPC title

• Y10T428/2936

  Wound or wrapped core or coating [i.e., spiral or helical] · CPC title

• D02G3/047

  including aramid fibres · CPC title

• B29K2077/00

  Use of {PA, i.e.} polyamides, e.g. polyesteramides {or derivatives thereof}, as moulding material · CPC title

• B29K2105/08

  of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns · CPC title