Polymeric Material for Three-Dimensional Printing

Patent metadata

Field	Value
Publication number	US-2016185050-A1
Application number	US-201414909754-A
Country	US
Kind code	A1
Filing date	Jul 9, 2014
Priority date	Aug 9, 2013
Publication date	Jun 30, 2016
Grant date	—

Abstract

A polymeric material that is capable of being employed as a build material and/or support material in a three-dimensional printer system is provided. The polymeric material is formed from a thermoplastic composition containing a continuous phase that includes a matrix polymer. A microinclusion additive and nanoinclusion additive are dispersed within the continuous phase in the form of discrete domains.

First claim

1 . A printer cartridge for use in a three-dimensional printer system, wherein the printer cartridge contains a spool that carries a polymeric material, wherein the polymeric material is formed from a thermoplastic composition containing a continuous phase that includes a matrix polymer, and further wherein a microinclusion additive and nanoinclusion additive are dispersed within the continuous phase in the form of discrete domains.

2 . The printer cartridge of claim 1 , wherein the polymeric material is in the form of a filament.

3 . The printer cartridge of claim 2 , where the filament is wound around a rim of the spool.

4 . The printer cartridge of claim 1 , wherein the density of the polymeric material is about 1.2 g/cm 3 or less.

5 . The printer cartridge of claim 1 , wherein the modulus of elasticity of the polymeric material is about 2500 MPa or less.

6 . The printer cartridge of claim 1 , wherein a porous network is defined in the polymeric material.

7 . The printer cartridge of claim 6 , wherein the porous network includes a plurality of nanopores having an average cross-sectional dimension of about 800 nanometers or less.

8 . The printer cartridge of claim 7 , wherein the nanopores constitute about 20 vol. % or more of the total pore volume of the material.

9 . The printer cartridge of claim 7 , wherein the porous network further includes micropores.

10 . The printer cartridge of claim 1 , wherein the continuous phase constitutes from about 60 wt. % to about 99 wt. % of the thermoplastic composition.

11 . The printer cartridge of claim 1 , wherein the matrix polymer includes a polyester.

12 . The printer cartridge of claim 1 , wherein the microinclusion additive is polymeric, such as a polyolefin.

13 . The printer cartridge of claim 1 , wherein the ratio of the solubility parameter for the matrix polymer to the solubility parameter of the microinclusion additive is from about 0.5 to about 1.5, the ratio of the melt flow rate for the matrix polymer to the melt flow rate of the microinclusion additive is from about 0.2 to about 8, and/or the ratio of the Young's modulus elasticity of the matrix polymer to the Young's modulus of elasticity of the microinclusion additive is from about 1 to about 250.

14 . The printer cartridge of claim 1 , wherein the nanoinclusion additive is polymeric.

15 . The printer cartridge of claim 1 , wherein the microinclusion additive constitutes from about 1 wt. % to about 30 wt. % of the composition, based on the weight of the continuous phase and/or the nanoinclusion additive constitutes from about 0.05 wt. % to about 20 wt. % of the composition, based on the weight of the continuous phase.

16 . The printer cartridge of claim 1 , wherein the thermoplastic composition further comprises an interphase modifier.

17 . The printer cartridge of claim 1 , wherein a generally cylindrical bore is defined within a central region of the spool.

18 . The printer cartridge of claim 1 , further comprising a housing structure that encloses the spool.

19 . A system comprising a three-dimensional printer and the printer cartridge of claim 1 .

20 . A method for forming a three-dimensional object, the method comprising printing a three-dimensional structure as a series of successive layers of a build material and optionally printing a support structure from a support material, wherein the build material, support material, or both contain a polymeric material formed from a thermoplastic composition containing a continuous phase that includes a matrix polymer, and further wherein a microinclusion additive and nanoinclusion additive are dispersed within the continuous phase in the form of discrete domains.

Assignees

• Kimberly Clark Co

Inventors

• Topolkaraev Vasily A
• Mceneany Ryan J
• Scholl Neil T

Classifications

• B29K2995/0077

  Yield strength; Tensile strength · CPC title

• B29C64/40 Primary

  Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof · CPC title

• B29K2105/0085

  Copolymers · CPC title

• B29C64/259

  Interchangeable · CPC title

• B29C64/118 Primary

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