3d printed conductive compositions anticipating or indicating structural compromise

Patent metadata

Field	Value
Publication number	US-2017284876-A1
Application number	US-201615090259-A
Country	US
Kind code	A1
Filing date	Apr 4, 2016
Priority date	Apr 4, 2016
Publication date	Oct 5, 2017
Grant date	—

Abstract

An article includes a body and at least one 3D-printable conductive composite segment in mechanical communication with the body. The body includes a first material and the at least one conductive composite segment includes a matrix material, a plurality of carbon nanotubes, and conductive additives. The conductive additives include a plurality of metallic particulates, a plurality of graphitic particles or a combination thereof.

First claim

What is claimed is:

1 . An article comprising:
a body portion comprising a first material; and at least one 3D-printable conductive composite segment in mechanical communication with the body, the at least one conductive composite segment comprising
a matrix material,
a plurality of carbon nanotubes; and
a plurality of conductive additives comprising metallic particulates, graphitic particles or a combination thereof.

2 . The article of claim 1 , wherein the first material and the matrix material are the same material.

3 . The article of claim 1 , wherein the first material and the matrix material are different materials.

4 . The article of claim 1 , wherein the first material comprises concrete and the matrix material comprises a polymer.

5 . The article of claim 1 , wherein a breaking strain of the conductive composite is equal to or lower than a breaking strain of the body.

6 . The article of claim 1 , wherein the matrix material comprises a thermoplastic polymer,
wherein the thermoplastic polymer is present in an amount ranging from about 10% to about 90% by weight relative to the total weight of the conductive composite, and wherein the thermoplastic polymer comprises at least one polymer selected from the group consisting of polyacrylates, polybenzimidazoles, polycarbonates, polyether sulfones, polyaryl ether ketones, polyethylenes, polyphenylene oxides, polypropylenes, polystyrenes, polyesters, polyurethanes, polyamides, poly(vinylidene fluoride) (PVDF) and polyvinyl chlorides, polyether ether ketone, poly(ethylene-co-vinylacetate), polyetherimide, polypropylene, Poly(vinylidene fluoride-co-hexafluoropropylene), poly(styrene isoprene styrene), acrylonitrile butadiene styrene (ABS), poly(Styrene Ethylene Butylene Styrene) (SEBS), polyethylene terephthalate, polylactic acid (PLA), polycaprolactone and nylon.

7 . The article of claim 1 , wherein the carbon nanotubes comprise multi-walled carbon nanotubes and wherein the carbon nanotubes are present in an amount ranging from about 1% to about 20% by weight, relative to the total weight of the conductive polymer composite.

8 . The article of claim 1 , wherein the plurality of metallic particulates comprise one or more form selected from the group consisting of nanoflakes, nanoparticles and nanowires, and wherein the metallic particulates are present in an amount ranging from about 1% to 50% by weight, relative to the total weight of the conductive polymer composite.

9 . The article of claim 1 , wherein the plurality of the graphitic particles comprise at least one material selected from the group consisting of graphene and graphite, and wherein the plurality of the graphitic particles are present in in an amount ranging from about 1% to about 50% by weight, relative to the total weight of the conductive polymer composite.

10 . A method of forming an article comprising,
forming a body comprising a first material; and forming at least one 3D-printable conductive composite segment in mechanical communication with the body, wherein the at least one conductive composite segment comprises
a matrix material,
a plurality of carbon nanotubes, and
a plurality of conductive additives comprising metallic particulates, graphitic particles or a combination thereof.

11 . The method of claim 10 , wherein the forming of the first material, the forming of the at least one conductive composite, or both, is by 3D printing.

12 . The method of claim 10 , wherein the first material and the matrix material are the same material.

13 . The method of claim 10 , wherein the first material and the matrix material are different materials.

14 . The method of claim 10 , wherein the first material comprises concrete and the matrix material comprises a polymer.

15 . The method of claim 10 , wherein a breaking strain of the conductive composite is equal to or lower than a breaking strain of the body.

16 . The method of claim 10 , wherein the matrix material comprises a thermoplastic polymer,
wherein the thermoplastic polymer is present in an amount ranging from about 10% to about 90% by weight relative to the total weight of the conductive composite, and wherein the thermoplastic polymer comprises at least one polymer selected from the group consisting of polyacrylates, polybenzimidazoles, polycarbonates, polyether sulfones, polyaryl ether ketones, polyethylenes, polyphenylene oxides, polypropylenes, polystyrenes, polyesters, polyurethanes, polyamides, poly(vinylidene fluoride) (PVDF) and polyvinyl chlorides, polyether ether ketone, poly(ethylene-co-vinylacetate), polyetherimide, polypropylene, Poly(vinylidene fluoride-co-hexafluoropropylene), poly(styrene isoprene styrene), acrylonitrile butadiene styrene (ABS), poly(Styrene Ethylene Butylene Styrene) (SEBS), polyethylene terephthalate, polylactic acid (PLA), polycaprolactone and nylon.

17 . The method of claim 10 , wherein the carbon nanotubes comprise multi-walled carbon nanotubes and wherein the carbon nanotubes are present in an amount ranging from about 1% to about 20% by weight, relative to the total weight of the conductive polymer composite.

18 . The method of claim 10 , wherein the plurality of metallic particulates comprise one or more form selected from the group consisting of nanoflakes, nanoparticles and nanowires, and wherein the metallic particulates are present in an amount ranging from about 1% to 50% by weight, relative to the total weight of the conductive polymer composite.

19 . The method of claim 10 , wherein the plurality of the graphitic particles comprise at least one material selected from the group consisting of graphene and graphite, and wherein the plurality of the graphitic particles are present in in an amount ranging from about 1% to about 50% by weight, relative to the total weight of the conductive polymer composite.

20 . A method for monitoring structural integrity of an object, comprising:
measuring a conductivity value of at least one 3D printable conductive composite segment that is in mechanical communication with the body of an article, wherein the at least one conductive composite segment comprises
a matrix material,
a plurality of carbon nanotubes, and
a plurality of conductive additives comprising metallic particulates, graphitic particles or combinations thereof;
comparing the measured conductivity value to a known conductivity value; determining whether a difference between the measured conductivity value and the known conductivity value falls within a predetermined threshold value; and generating an alarm if the difference is within the predetermined threshold value.

Assignees

• Xerox Corp

Inventors

• Moorlag Carolyn
• Prestayko Rachel
• Keoshkerian Barkev
• Vella Sarah J

Classifications

• B33Y70/10 Primary

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title

• H01B1/22

  the conductive material comprising metals or alloys · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B29K2105/167

  Nanotubes · CPC title

• G01L1/2206 Primary

  Special supports with preselected places to mount the resistance strain gauges; Mounting of supports · CPC title