Block copolymer ink formulation for 3d printing and method of making a 3d printed radiofrequency (rf) device

Patent metadata

Field	Value
Publication number	US-2018320008-A1
Application number	US-201615773282-A
Country	US
Kind code	A1
Filing date	Nov 1, 2016
Priority date	Nov 3, 2015
Publication date	Nov 8, 2018
Grant date	—

Abstract

An ink formulation for 3D printing comprises a triblock copolymer in a solvent, where the triblock copolymer includes end blocks comprising an aromatic or acrylate polymer and a midblock between the end blocks comprising an aliphatic polymer. The ink formulation exhibits a shear thinning threshold of about 0.02 rad/sec or less. A method of making a 3D printed radiofrequency (RF) device comprises extruding an ink formulation from a deposition nozzle moving relative to a substrate, where the ink formulation comprises a triblock copolymer in a solvent and the triblock copolymer includes end blocks comprising an aromatic or acrylate polymer and a midblock between the end blocks comprising an aliphatic polymer. One or more continuous filaments comprising the ink formulation are deposited in a predetermined pattern on the substrate, and the ink formulation is treated to remove or cure the solvent, thereby forming a printed RF device.

First claim

1 . An ink formulation for 3D printing, the ink formulation comprising:
a triblock copolymer in a solvent, the triblock copolymer including end blocks comprising an aromatic or acrylate polymer and a midblock between the end blocks comprising an aliphatic polymer, wherein the ink formulation comprises a shear thinning threshold of about 0.02 rad/sec or less.

2 . (canceled)

3 . The ink formulation of claim 2 , wherein the end blocks comprise polystyrene and/or a derivative of polystyrene;
wherein the midblock comprises polybutadiene, polyisoprene, poly(ethylene-ran-butylene), a polybutadiene derivative, a polyisoprene derivative, or a poly(ethylene-ran-butylene) derivative.

4 . (canceled)

5 . The ink formulation of claim 1 , wherein the triblock copolymer is selected from the group consisting of polystyrene block-polybutadiene block-polystyrene block (SBS), polystyrene block-polyethylene-ran-polybutylene block-polystyrene block (SEBS), and polystyrene block-polyisoprene block-polystyrene block (SIS).

6 . The ink formulation of claim 1 , wherein the triblock copolymer is present at a concentration of at least about 40 wt. %.

7 . The ink formulation of claim 1 , further comprising a plurality of dielectric filler particles;
wherein the dielectric filler particles are present at a concentration of at least about 20 wt. % and the triblock copolymer is present at a concentration of at least about 20 wt. %.

8 . (canceled)

9 . The ink formulation of claim 7 , wherein the dielectric filler particles comprise a dielectric constant of greater than 2.

10 . (canceled)

11 . (canceled)

12 . The ink formulation of claim 1 , wherein the solvent comprises an aromatic solvent, a vinyl-containing monomer or a combination thereof.

13 . (canceled)

14 . (canceled)

15 . (canceled)

16 . (canceled)

17 . The ink formulation of claim 1 , exhibiting a shear thinning region comprising a slope log η/log γ′ of about −0.25 or less.

18 . (canceled)

19 . A method of making a 3D printed radiofrequency (RF) device, the method comprising:
extruding an ink formulation from a deposition nozzle moving relative to a substrate, the ink formulation comprising a triblock copolymer in a solvent, the triblock copolymer including end blocks comprising an aromatic or acrylate polymer and a midblock between the end blocks comprising an aliphatic polymer; and depositing one or more continuous filaments comprising the ink formulation in a predetermined pattern on the substrate; and treating the ink formulation to remove or cure the solvent, thereby forming a printed RF device.

20 . (canceled)

21 . The method of claim 19 , wherein the treating of the ink formulation entails drying, heating and/or exposure to UV radiation.

22 . (canceled)

23 . (canceled)

24 . (canceled)

25 . The method of claim 19 , wherein the end blocks of the triblock copolymer include an aromatic polymer comprising polystyrene and/or a derivative of polystyrene;
wherein the midblock of the triblock copolymer comprises polybutadiene, polyisoprene, poly(ethylene-ran-butylene), a polybutadiene derivative, a polyisoprene derivative, or a poly(ethylene-ran-butylene) derivative.

26 . (canceled)

27 . (canceled)

28 . The method of claim 19 , wherein the triblock copolymer is present at a concentration of at least about 40 wt. %.

29 . The method of claim 19 , wherein the ink formulation further comprises a plurality of dielectric filler particles;
wherein the dielectric filler particles are present at a concentration of at least about 20 wt. % and the triblock copolymer is present at a concentration of at least about 20 wt. %.

30 . (canceled)

31 . The method of claim 19 , wherein the solvent comprises an aromatic solvent, a vinyl-containing monomer, or a combination thereof.

32 . (canceled)

33 . (canceled)

34 . (canceled)

35 . The method of claim 19 , wherein the RF device operates in the K a band and is selected from the group consisting of: filter, antenna, lens, radome, horn, transducer and transition.

36 . A 3D printed radiofrequency (RF) device comprising:
a printed dielectric body comprising a triblock copolymer including end blocks comprising an aromatic or acrylate polymer and a midblock between the end blocks comprising an aliphatic polymer, wherein the printed dielectric body comprises a dielectric loss tangent (ε″/ε′) of less than about 0.005.

37 . The 3D printed RF device of claim 36 , wherein the printed dielectric body comprises at least one of an average surface roughness of about 2 microns or less and a dielectric constant (ε′) greater than 2.

38 . (canceled)

39 . (canceled)

40 . The 3D printed RF device of claim 36 , wherein the end blocks of the triblock copolymer comprise polystyrene and/or a derivative of polystyrene;
wherein the midblock of the triblock copolymer comprises polybutadiene, polyisoprene, poly(ethylene-ran-butylene), a polybutadiene derivative, a polyisoprene derivative, or a poly(ethylene-ran-butylene) derivative.

41 . (canceled)

42 . (canceled)

43 . The 3D printed RF device of claim 36 , wherein the printed dielectric body is a composite body comprising the triblock copolymer as a matrix and further comprising a plurality of dielectric filler particles dispersed therein;
wherein the dielectric filler particles are present at a concentration of at least about 20 wt. %.

44 . (canceled)

45 . (canceled)

46 . (canceled)

47 . The 3D printed RF device of claim 36 , wherein the RF device operates in the K a band and is selected from the group consisting of: filter, antenna, lens, radome, horn, transducer and transition.

Assignees

• Harvard College
• Massachusetts Inst Technology

Inventors

• Fedynyshyn Theodore H
• Lis Michael T
• Lewis Jennifer Ann

Classifications

• B33Y10/00

  Processes of additive manufacturing · CPC title

• C09D11/106 Primary

  containing macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds · CPC title

• B29C64/209

  Heads; Nozzles · CPC title

• C09D11/033

  characterised by the solvent · CPC title

• B29C64/118 Primary

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