Rapid prototype extruded conductive pathways

Patent metadata

Field	Value
Publication number	US-2016295703-A1
Application number	US-201615187836-A
Country	US
Kind code	A1
Filing date	Jun 21, 2016
Priority date	Nov 22, 2011
Publication date	Oct 6, 2016
Grant date	—

Abstract

A process of producing electrically conductive pathways within additively manufactured parts and similar parts made by plastic extrusion nozzles. The process allows for a three-dimensional part having both conductive and non-conductive portions and allows for such parts to be manufactured in a single production step.

First claim

1 . A process of providing a multi-layered object having areas of electrical conductivity and electrical non-conductivity comprising the steps of:
forming a substrate by the deposition of multiple substrate layers; integrating within the multiple substrate layers at least one three-dimensional region of a non-conductive substrate and at least one three-dimensional region of a conductive substrate, the conductive substrate applied by one of the either stereo lithography, laser sintering, ink-jet printing, or fused deposition and having an x-ray density substantially identical to an x-ray density of the non-conducting substrate, the multi-layered object having the substantially identical x-ray density achieved by adding an x-ray density additive to at least one of the conductive substrate or the non-conductive substrate; wherein the multi-layered object has a three dimensional electrical conductive portion within the non-conductive substrate.

2 . The process according to claim 1 wherein the substantially identical x-ray density is achieved by adding an x-ray density additive to both the conductive substrate and the non-conductive substrate.

3 . The process of claim 1 wherein the step of integrating at least one three dimensional region of a conductive binder further comprises providing a conductive substrate comprising a conductive material selected from the group consisting of metal fibers, metal particles, steel wool, carbon, carbon nanostructures, carbon nano tubes, metallic powders, conductive polymers, and combinations thereof.

4 . The process according to claim 1 wherein the integrating step further includes a step of combining a coloring agent to both the electrically conductive and the electrically non-conductive portions so that a color of the electrically conductive and non-conductive portions is essentially uniform.

5 . A process of providing a three dimensional object having a selected area of an electrically conductive portion and a selected area of a non-conducting portion comprising the steps of:
supplying a rapid prototype extrusion machine; producing a three dimensional object wherein a first portion is electrically non-conductive and has an x-ray density, the three dimensional object having a second portion which is electrically conductive, the second portion having an x-ray density substantially equal to the x-ray density of the non-conducting portion and wherein the extrusion step further includes the step of combining a coloring agent to at least one of the electrically conductive or electrically non-conductive portions so that a color of the conductive and non-conductive portions is essentially uniform.

6 . The process according to claim 5 wherein the three dimensional object has a substantially uniform x-ray density achieved by adding an x-ray density additive.

7 . The process according to claim 6 wherein the extrusion step further includes a step of combining a coloring agent to both the electrically conductive and the electrically non-conductive portions so that a color of the conductive and non-conductive portions is essentially uniform.

8 . A multi-layer three-dimensional object having a selected area of an electrically conductive portion in a selected area of a non-conducting portion, the electrically conducting portion having an x-ray density substantially equal to the x-ray density of the non-conducting portion.

9 . The three-dimensional object according to claim 8 wherein at least one of the electrically conductive portions or the non-conducting portions has an x-ray density additive present.

10 . The three-dimensional object according to claim 9 wherein both the electrically conducting portion and the non-electrically conducting portion have an x-ray density additive present.

11 . The three-dimensional object according to claim 8 wherein a coloring agent is added to at least one of the electrically conductive or the electrically non-conductive portions so that a color of the conductive and non-conductive portions is essentially uniform.

12 . The three-dimensional object according to claim 8 wherein both the electrically conductive and the electrically non-conductive portions have a coloring agent present so that the color of the conductive and non-conductive portions is essentially uniform.

13 . The process according to claim 5 wherein the step of producing a three dimensional object further defines using a printer.

Assignees

• Savannah River Nuclear Solutions Llc

Inventors

• Bobbitt Iii John Thomas

Classifications

• H05K2203/107

  Using laser light · CPC title

• B29C64/165

  using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber · CPC title

• H05K3/12

  using {thick film techniques, e.g.} printing techniques to apply the conductive material {or similar techniques for applying conductive paste or ink patterns} · CPC title

• B29C64/153

  using layers of powder being selectively joined, e.g. by selective laser sintering or melting · CPC title

• H05K1/0284

  Details of three-dimensional rigid printed circuit boards (H05K1/119 takes precedence; shaping of the substrate H05K3/0014) · CPC title