MULTIPLE LAYER FILAMENT AND METHOD OF MANUFACTURING

Abstract

A system for manufacturing a multiple layer filament produces a multiple layer filament including a continuous core, a first layer and a second layer. The continuous core includes one of a continuous fiber, a braided strand, a metal wire and a narrow gauge filament. The materials for the first and second layers of the multiple layer filament are chosen from a plurality of materials with each of the plurality of materials providing a specific function or multiple functions that are required for the particular application of the three-dimensional object manufactured using the multiple layer filament.

Claims

1-20. (canceled)

21. A multiple layer filament comprising: a core material having an outer surface, wherein the core material includes at least one of a thermoplastic filament, a continuous fiber, a braided strand, and a metal wire; and a first layer material disposed on the outer surface of the core material, wherein the first layer provides at least one functionality to the multiple layer filament.

22. The multiple layer filament of claim 21, wherein first layer material disposed on the outer surface of the core material improves printability of the multiple layer filament as compared to the printability of the core material without the first layer.

23. The multiple layer filament of claim 21, wherein the core material includes at least one of a chopped carbon fiber, glass fiber, aramid fiber, cellulosic fibrils, cellulosic crystals, cellulosic nanoparticles, cellulosic microparticles, micro crystalline cellulose, carbon nanotubes, boron nitride nanotubes, titania nanotubes, silicane nanotubes, halloysite nanotubes, graphene, boron, nitride sheets, natural silicates, carbon black, colorants, ultra violet reactive agents, crosslinkers, oxygen scavengers, active functional groups including thiols, carbonyls, amines, nitriles, alcohols, anhydrides, diamond nanoparticles, metal nanoparticles, carbon based nanoparticles, graphene nanoparticles, boron nanoparticles, nitride sheet nanoparticles, and natural silicate nanoparticles.

24. The multiple layer filament of claim 21, wherein the first layer material comprises at least one of polylactic acid, polyester, polyamide, polycarbonate, polyarylether ketone, polyether imide, thermoplastic elastomer, polyarylethersulfone, acrylonitrile butadiene styrene, polyamide-imide, polyurethane, and polyolefin.

25. The multiple layer filament of claim 21, wherein the first layer is a moisture vapor barrier layer.

26. The multiple layer filament of claim 21, wherein the first layer incorporates at least one of a scavenger, an oxygen barrier, and a UV radiation barrier.

27. The multiple layer filament of claim 21, wherein the first layer provides at least one of the following functionalities to the multiple layer filament: antimicrobial, mechanical strength, electric conductivity, anti-static, dielectric, ferro-magnetic, thermal conductivity, electrically insulating, bio-friendly, chemical resistance, reduced friction, corrosion resistance, CO2 barrier, flame retardant, thermal insulation, mechanophore or mechanochromic, interlayer adhesion promotion, chemically active, UV crosslinking responsive, buffer layer, stacked layers, bi-component polymer multiple layer filament, catalytic behavior, abrasion resistance, self-lubrication, photoluminescent, photochromic, hydrophilicity, oleophobic, and oleophilic properties.

28. The multiple layer filament of claim 21, wherein the first layer includes at least one of a chopped carbon fiber, glass fiber, aramid fiber, cellulosic fibrils, cellulosic crystals, cellulosic nanoparticles, cellulosic microparticles, micro crystalline cellulose, carbon nanotubes, boron nitride nanotubes, titania nanotubes, silicane nanotubes, halloysite nanotubes, graphene, boron, nitride sheets, natural silicates, carbon black, colorants, ultra violet reactive agents, crosslinkers, oxygen scavengers, active functional groups including thiols, carbonyls, amines, nitriles, alcohols, anhydrides, diamond nanoparticles, metal nanoparticles, carbon based nanoparticles, graphene nanoparticles, boron nanoparticles, nitride sheet nanoparticles, and natural silicate nanoparticles.

29. The multiple layer filament of claim 21, further comprising a second layer, wherein the second layer provides at least one of the following functionalities to the multiple layer filament: antimicrobial, mechanical strength, electric conductivity, anti-static, dielectric, ferro-magnetic, thermal conductivity, electrically insulating, bio-friendly, chemical resistance, reduced friction, corrosion resistance, CO2 barrier, flame retardant, thermal insulation, mechanophore or mechanochromic, interlayer adhesion promotion, chemically active, UV crosslinking responsive, buffer layer, stacked layers, bi-component polymer multiple layer filament, catalytic behavior, abrasion resistance, self-lubrication, photoluminescent, photochromic, hydrophilicity, oleophobic, and oleophilic properties.

30. The multiple layer filament of claim 21, further comprising a second layer material, wherein the second layer material comprises at least one of polylactic acid, polyester, polyamide, polycarbonate, polyarylether ketone, polyether imide, thermoplastic elastomer, polyarylethersulfone, acrylonitrile butadiene styrene, polyamide-imide, polyurethane, polyolefin, copolymer, composites of a single polymer and composites of a combination of polymers.

31. The multiple layer filament of claim 30, wherein the second layer includes at least one of a chopped carbon fiber, glass fiber, aramid fiber, cellulosic fibrils, cellulosic crystals, cellulosic nanoparticles, cellulosic microparticles, micro crystalline cellulose, carbon nanotubes, boron nitride nanotubes, titania nanotubes, silicane nanotubes, halloysite nanotubes, graphene, boron, nitride sheets, natural silicates, carbon black, colorants, ultra violet reactive agents, crosslinkers, oxygen scavengers, active functional groups including thiols, carbonyls, amines, nitriles, alcohols, anhydrides, diamond nanoparticles, metal nanoparticles, carbon based nanoparticles, graphene nanoparticles, boron nanoparticles, nitride sheet nanoparticles, and natural silicate nanoparticles.

32. The multiple layer filament of claim 30, wherein the second layer is a moisture vapor barrier layer.

33. The multiple layer filament of claim 30, wherein the second layer is an oxidation, UV, or oxidation and UV barrier layer.

34. The multiple layer filament of claim 30, further comprising a primer layer between the first layer and the second layer, wherein the primer includes an active species that is one of charged, activated by electromagnetic waves, photo-active or heat active.

35. The multiple layer filament of claim 30, further comprising a primer layer that provides a compatibilizer between the first and second layers.

36. A manufacturing system for making a multiple layer filament for use in three-dimensional printing, the manufacturing system comprising: a core spool comprising a core material, wherein the core material includes at least one of a thermoplastic filament, a continuous fiber, a braided strand, and a metal wire; and a first layer applicator apparatus comprising a first layer applicator and a first layer material, wherein the first layer material provides at least one functionality to the multiple layer material and wherein the first layer applicator apparatus is disposed to receive the core material from the core spool and dispose the first layer material onto a first outer surface of the core material to form the multiple layer filament.

37. The manufacturing system of claim 36, wherein the first layer applicator apparatus comprises at least one of a co-extruder, a laminator, a liquid depositor, a spray depositor, an ink jet printer, and a primer.

38. The manufacturing system of claim 36, wherein the first layer applicator apparatus comprises a co-extruder and the second layer applicator apparatus comprises a liquid depositor.

39. A method of manufacturing a multiple layer filament for use in three-dimensional printing, the method comprising: providing a core spool comprising a core material, wherein the core material includes at least one of a thermoplastic filament, a continuous fiber, a braided strand, and a metal wire; providing a first layer applicator apparatus comprising a first layer applicator and a first layer material, wherein the first layer material provides at least one functionality to the core material and wherein the first layer applicator apparatus comprises at least one of a co-extruder, a laminator, a liquid depositor, a spray depositor, an ink jet printer; and disposing a first layer onto a first outer surface of the core material to form the multiple layer filament with the first layer applicator apparatus.

40. The method of manufacturing of claim 39 wherein providing a first layer applicator apparatus comprising a first layer applicator and a first layer material further comprises providing the first layer applicator apparatus comprising at least one of a laminator and a spray depositor.

Description

DRAWINGS

[0027] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

[0028] FIG. 1 is a schematic depiction of a manufacturing process for producing a multiple layer filament according to the principles of the present disclosure; and

[0029] FIG. 2 illustrates a multiple layer filament according to the principles of the present disclosure.

DETAILED DESCRIPTION

[0030] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses,

[0031] Referring to FIG. 1, a schematic of a multiple layer filament system for manufacturing and a method of manufacturing a multiple layer filament is illustrated and will now be described. A multiple layer filament system 10 includes a core spool 12, a first layer applicator apparatus 14, a second layer applicator apparatus 16, a third layer applicator apparatus 18, and several pluralities of layer materials 20, 22, 24. More specifically, the core spool 12 includes a continuous core 26 that is fed from the core spool 12 into the first layer applicator 14. The core 26 includes material that may be in one of many forms including but not limited to a continuous fiber, a braided strand, a metal wire or a narrow gauge filament. For example, the continuous fiber and braided strand may be formed from a carbon fiber, a glass fiber, a Kevlar® fiber, an aramid fiber, cellulose based natural fiber, mineral fiber, synthetic polymer fibers, or silicon carbide fiber.

[0032] The first layer applicator apparatus 14 includes a first of the plurality of layer materials 20 and a first layer applicator 28. The first of the plurality of layer materials 20 includes a number of materials that each provides a specific function or series of functions for a first layer 30 that is disposed on the surface of the core 26. For example, the plurality of layer materials 20 includes materials that provide functions including radiation absorption, UV protection, oxidation protection, hydrophobicity, antimicrobial, mechanical strength, electric conductivity, anti-static, dielectric, ferro-magnetic, thermal conductivity, electrically insulating, bio-friendly, chemical resistance, reduced friction, corrosion resistance, moisture, oxygen, or CO.sub.2 barrier, flame retardant, thermal insulation, mechanophore or mechanichromic, interlayer adhesion promotion, chemically active, UV crosslinking responsive, buffer layer, stacked layers, bi-component polymer multiple layer filament, catalytic behavior, abrasion resistance, self-lubrication, photoluminescent, photochromic, hydrophilicity, oleophobic, and oleophilic.

[0033] The plurality of layer materials 20 that provide the functional layers given above include polylactic acid (PLA), polyesters (PET, PETG, PCTG, PBT), polyamides (PA), polycarbonates (PC), polyarylether ketones (PEK, PEEK, PEAK, PEKK, PEEKK), polyether imides(PEI), Thermoplastic elastomers (TPS, TPO, TPV, TPU, TPC, TPA, TPZ), polyarylethersulfones (PSU, PES, PAS, PESU, PPSU), acrylonitrile butadiene styrene (ABS), polyamide-imide (PAI, Torlon), polyurethanes, polyolefins, copolymers, composites made of a single polymer or combinations of polymers, functional and non-functional fillers, and functional moieties including monomers and modified polymers, and any combinations of these materials.

[0034] As stated above, composites may include functional and non-functional fillers. The fillers included may be chosen from the group of carbon fiber (chopped, short, long), glass fiber (short, long), Aramid fiber (short, long), cellulosic materials (fibrils, crystals, nanoparticles, micro crystalline cellulose), nanotubes (carbon, boron nitride, titanic, silicates, halloysite), two-dimensional fillers (graphene, boron nitride sheets, natural silicates such as clay or mica), carbon black, colorant, reactive agents (Ultraviolet activated, cross-linkers, O.sub.2 scavengers), organic chemicals with active functional groups (thiols, carbonyls, amines, nitriles, alcohols, anhydrides), and nanoparticles (diamond, metal, carbon-based, two-dimensional materials).

[0035] The first lay applicator apparatus 14 deposits the first layer material in one of a number of processes. The processes of layer deposition may include co-extrusion, lamination, deposition from liquid, spray depositing, and ink jet printing. A primer step may also be included in the deposition process. For example, co-extrusion allows for the extrusion of multiple layers in a single 3D printing filament during an extrusion process. The inner layer could be filled or unfilled material. Additional layers could comprise of some type of functional formulation made up in part of the same or similar base polymer or at least a compatible polymer resin. These two (or more) layers would be extruded together using a co-extrusion process.

[0036] Layers may also be applied through a lamination process. This would involve adding the desired properties to a thin film of the material, then laminating onto the 3D filament in a line process, or onto the filament post production during a re-winding event.

[0037] Deposition from liquid requires the core 26 or multiple layer filament to be drawn through one or more bath cycles for the deposition of a thin layer. The bath may contain a mixture of the functional component such as acid, base, water-soluble polymer, and a solvent.

[0038] Spray depositing can apply a layer, or layers, via dilute suspensions of material onto the filament shortly after extrusion in a single process, or in a separate step.

[0039] Another process includes inkjet printing layers via liquid dispersions after filament production.

[0040] The primer step may be necessary when layers may require an initial surface priming step to prepare the surface to accept additional layer(s). Possible priming steps could include deposition of an active species (charged, electromagnetic wave active, photo-active, heat active, etc.), or a charge inducing pass through a plasma treatment. Multiple co-extrusion passes could also solve compatibility issues by adding a primer layer that acts as a compatibilizer between the layers.

[0041] The second layer applicator apparatus 16 includes a second of the plurality of layer materials 22 and a second layer applicator 32. The second of the plurality of layer materials 22 may include the same materials as stated above as included in the first of the plurality of layer materials 20. The second layer applicator 32 deposits a second layer 34 on the surface of the first layer 30. Again, each of the second of the plurality of layer materials 22 performs a specific function as it pertains to the material or combination of materials used for the second layer 34.

[0042] In some embodiments, the third layer applicator apparatus 18 may be employed to deposit a third layer 36 on the surface of the second layer 34. The third layer applicator apparatus 18 includes a third of the plurality of layer materials 24 and a third layer applicator 38. The third of the plurality of layer materials 24 may include the same materials as stated above as included in the first and second of the plurality of layer materials 20, 22. Again, each of the third of the plurality of layer materials 24 performs a specific function as it pertains to the material or combination of materials used for the third layer 38.

[0043] The multiple layer filament system 10 can be used to manufacture a multiple layer filament 40 for storage and use at a later time or it can be fed directly to a three dimensional printer 42 for manufacturing a rapidly produced three dimensional object 44. In either application, the multiple layer filament system 10 produces a project specific multiple layer filament 40 that has tailored functional layers 26, 30, 34.

[0044] Turning now to FIG. 2 with continuing reference to FIG. 1, the multiple layer filament 40 is illustrated and will now be described. The multiple layer filament 40 includes the continuous core 26, the first layer 30, and the second layer 34. As described above, the continuous core 26 may be one of a continuous fiber, a braided strand, a metal wire or a narrow gauge filament. For example, the continuous fiber and braided strand may be formed from carbon fiber, glass fiber, Kevlar® fiber, aramid fiber, cellulose based natural fiber, mineral fiber, synthetic polymer fibers, or silicon carbide fiber.

[0045] The first and second layers 30, 34 may each be made from one or a combination of materials. The selection of materials is largely based on the desired function of that particular layer 30, 34 of the multiple layer filament. As stated above, the desired function may include radiation absorption, UV protection, oxidation protection, hydrophobicity, antimicrobial, mechanical strength, electric conductivity, anti-static, dielectric, ferro-magnetic, thermal conductivity, electrically insulating, bio-friendly, chemical resistance, reduced friction, corrosion resistance, moisture, oxygen, or CO.sub.2 barrier, flame retardant, thermal insulation, mechanophore or mechanichromic, interlayer adhesion promotion, chemically active, UV crosslinking responsive, buffer layer, stacked layers, bi-component polymer multiple layer filament, catalytic behavior, abrasion resistance, self-lubrication, photoluminescent, photochromic, hydrophilicity, oleophobic, and oleophilic. The desired function may be the desired function of the particular layer of the multiple layer filament 40 or it may be one of the desired function of the three-dimensional object 44 that is manufactured using the multiple layer filament 40.

[0046] The first and second layers 30, 34 may be made from polylactic acid (PLA), polyesters (PET, PETG, PCTG, PBT), polyamides (PA), polycarbonates (PC), polyarylether ketones (PEK, PEEK, PEAK, PEKK, PEEKK), polyether imides(PEI), Thermoplastic elastomers (TPS, TPO, TPI, TPU, TPC, TPA, TPZ), polyarylethersulfones (PSU, PES, PAS, PESU, PPSU), acrylonitrile butadiene styrene (ABS), polyamide-imide (PAI, Torlon), polyurethanes, polyolefins, copolymers, composites made of a single polymer or combinations of polymers, functional and non-functional fillers, and functional moieties including monomers and modified polymers, and any combinations of these materials.

[0047] The first and second layers 30, 34 may also include one of a continuous fiber, a braided strand, a metal wire or a narrow gauge filament.

[0048] As stated above, composites may include functional and non-functional fillers. The fillers included may be chosen from the group of carbon fiber (chopped, short, long), glass fiber (short, long), Aramid fiber (short, long), cellulosic materials (fibrils, crystals, nanoparticles, micro crystalline cellulose), nanotubes (carbon, boron nitride, titanic, silicates, halloysite), two-dimensional fillers (graphene, boron nitride sheets, natural silicates such as clay or mica), carbon black, colorant, reactive agents (Ultraviolet activated, cross-linkers, O.sub.2 scavengers), organic chemicals with active functional groups (thiols, carbonyls, amines, nitriles, alcohols, anhydrides), and nanoparticles (diamond, metal, carbon-based, two-dimensional materials).

[0049] The description of the disclosure is merely exemplary in nature and variations that do not depart from the gist of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.