PROCESS FOR 3D PRINTING AN ARTICLE INCORPORATING A CONDUCTIVE CIRCUIT COMMUNICATING WITH A SEPARATELY INSTALLABLE ELECTRICAL COMPONENT AND AN ARTICLE PRODUCED THEREBY

Abstract

An improved process combining a first insulating filament (ABS/TPE/TPG) material with a second conductive filament (Graphite PLA) material during a 3D printing operation in order to produce a part (not limited to head/tail lamp bezels, hearing aids and cardio monitors incorporating circuitry for providing power, lighting and enhanced heat removal. The process includes the step of modifying the additive process programming at determined intermediate points to allow for installation of non-3D printable electrical components (resistors, diodes, etc.), such as in a lay-in press-fit technique in order to communicate with the conductive pathways incorporated in the printed circuit board article.

Claims

1. A 3D printing process for creating an article having conductive pathways, comprising the steps of: providing a three dimensional printing machine having each of a support platen located within a printing enclosure and a multi-directional printing head actuated by a separate controller; communicating a plurality of successive commands of a software program to the controller to cause timed and directed actuations of the printing head in response to each of the commands, the printing head being caused to issue each of a first insulating base material and a second conductive material integrated within the base material; interrupting operation of the printing head at least once prior to completion of the programmed commands; installing at least one electrical component into the base material so that the component is also in communication with at least one pathway associated with the conductive material; and resuming operation of the printing head and, following completion of all of the commands, removing the article from the printing enclosure.

2. The 3D printing process as described in claim 1, further comprising the step of configuring the printing head with each of a first nozzle for issuing said insulating material and a second nozzle for issuing said conductive material.

3. The 3D printing process as described in claim 2, the step of the software program issuing commands to the printer head further comprising the step of issuing subset commands to each of the first and second nozzles.

4. The 3D printing process as described in claim 1, the step of issuing a first insulating base material further comprising any of an ABS, TPE or TPG material.

5. The 3D printing process as described in claim 1, the step of issuing a second conductive material further comprising a graphite material.

6. The 3D printing process as described in claim 1, further comprising the step of providing at least one of power, lighting and enhanced heat removal (sinking) capabilities to the printed article.

7. A 3D printing article having conductive pathways, comprising: a first insulating base material and a second conductive material integrated within the base material; and at least one electrical component press fit into the base material during at least one pause in the additive forming of the article, said component also being in communication with at least one pathway associated with said conductive material prior to completion of additive printing of at least an additional volume of said insulating material.

8. The article of claim 7, the article including at least one of a headlamp or tail lamp bezel, a hearing aid and a cardio monitor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Reference will now be made to the attached illustrations, when read in combination with the following detailed description, wherein like reference numerals refer to like parts throughout the several views, and in which:

[0017] FIGS. 1-3 present a series of perspective, side and top views of a 3D printed component incorporating a first base material in combination with a second conductive filament material, as well as the use of electrical components applied in an intermediate press fit fashion according to one non-limiting embodiment of the present invention;

[0018] FIG. 4 is an illustration of a 3D printing machine such as which is utilized with the formation of the component with conductive pathways according to the present invention;

[0019] FIGS. 5-6 are top and bottom perspective views of a 3D printed component similar to that shown in FIGS. 1-3 and utilizing the 3D printing machine of FIG. 4; and

[0020] FIG. 7 is an illustration of a further example of a 3D additive printed article produced according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] As previously described the present invention discloses an improved 3D printing process which combines each of an insulating (ABS/TPE/TPG) material with a conductive (Graphite PLA) for printing a highly conductive graphene filament (such as is by itself known in general use in 3D printing applications). In this fashion, the present invention utilizes improved techniques for producing an article having integrated circuit board functionality for providing power, lighting and enhanced heat removal (sinking) capabilities. In this fashion, the present invention makes possible the creation of various parts, including head/tail lamp bezels, hearing aids and cardio monitors, which are beyond the capabilities of existing 3D printing or additive material (AM) technologies.

[0022] The present invention additionally discloses and functionality incorporated into the 3D additive process, and additionally provides the ability to pause the additive process at a determined intermediate position in order to insert suitable electrical components (resistors, diodes, etc.) in a lay-in press-fit technique for the purpose of integrating such componentry at an intermediate stage of the 3D or additive forming process and prior to completing the finished article.

[0023] With reference to FIGS. 1-3, presented are a series of perspective, side and top views of a 3D printed and circuit supporting component, generally at 10, and which incorporates a first base insulating material (generally referenced at 11), again including (ABS/TPE/TPG), in combination with a second conductive material (referencing integrated pathways 12, 14, 16, 18 and 20 in FIGS. 5-6, which are not limited to a graphene fed filament and such as is sold under the name BlackMagic3D by Graphene Lab Inc. Given further that graphene is mechanically strong and a good conductor of electricity and heat, it is useful in 3D printing applications in which basic circuitry functions are desired to be integrated into the insulated and printed material matrix 11 of the created article, and as further configured according to the present description.

[0024] FIGS. 5-6 further depict top and bottom perspective views of a 3D printed component, similar to that depicted in FIGS. 1-3, which is produced utilizing the 3D printing machine of FIG. 4 (generally at 2) and which further better illustrates conductive circuit pathways or traces, these shown at 12, 14, 16, et seq. in FIG. 5, with additional 3D printed pathways further at 18 and 20 in the rotated view of FIG. 6. As previously described, the simultaneous print feed addition of the conductive filament, along with the insulating base or stock material, is integrated into the operating program for creating the desired conductive enabled component.

[0025] Additional electrical components are provided and are shown at 22, 23, 24, 26, 28 and 30 arranged at locations throughout the circuit integrated article depicted in each of FIGS. 1-3 and 5-6. These are not limited to any specific type of electrically conducting component (such as which cannot typically be 3D printed) and can include but are not limited to any of diodes (such as at 23), resistors, conductive posts (at 24, 26, 28 and 30), capacitors, and L.E.D. components (at 22) and connected by a pair of wires 25 and 27 to the posts 24 and 26 in FIG. 5. The electrically conducting components are understood to be provided as separate stock components and which, as will be subsequently described, are intended to be integrated (such as through press fit installation) into the additive printed/developing conductive graphene circuit pathways 3D printed within the article body.

[0026] In operation, and upon the print head 4 in FIG. 4 executing a given number of passes as determined by the operating program associated with the additive (AM) or 3D printer head 4 of the 3D printer 2 depicted in the example of FIG. 4, the printed article 2 is printed to a thickness or depth typically partial to that shown in the completed perspective of FIG. 1 in a manner supported upon the platen or support surface, at 6. At this point, the 3D additive material including both the insulated component (issued through selected injection nozzle 7 defined in the printer head 4) and the conductive graphene component (further issued through proximally located injection nozzle 8), are each in a typically softened or semi-set state such that desired components may be press fit into the setting/solidifying material at a paused and intermediate process step of the part creation operation.

[0027] Following the integration/embedding of the conventional electrical component into the semi-additive formed part, the 3D printing process is resumed for the remaining steps/passes as dictated by the operating program and in order to complete the part in such a fashion as to integrate the conventional electrical component into the matrix of the 3D part. In this manner, the various press fit components can be either partially or (as shown by diode 23) encapsulated within the additive material and in such a fashion that they interact in the desired fashion with the conductive traces (see again 12, 14, 16, 18 and 20) established by the conductive additive (graphene applied) material combined with the insulated material matrix, and further in order to provide the completed article with the desired structural, electrical and heat dissipating/sinking characteristics.

[0028] Finally, FIG. 7 is an illustration, generally at 100, of a further example of a 3D additive printed article produced according to the present invention. In comparison to that shown at 10 in FIG. 1, the additive printed article 100 can exhibited any variable thickness (such as depicted at 102) and which is created through the successive additive printing of the desired insulating material. Concurrently, the conductive graphene or other print-applied material is likewise issued according to the desired numerically controlled operating program through the second multi-directional adjustable feed nozzle and which is further shown as axial elongated conductive pathways 104 and 106, in combination with lateral or crosswise and depth offset pathways 108 and 110.

[0029] The operator attached components are again depicted at 24, 24, 26 and 30 similar to those shown in the embodiment of FIG. 1, with a further extended modified component 28 modified from that shown in FIG. 1 at 28 also being provided for communicating a selected axial conductive trace or pathway (again 104) with a surface exposed location of the component 28. Without limitation, the operational protocol for the additive creation of the circuit supporting 3D printed article contemplates the separate components being installed either during a single interrupted point during the program (such as near the end in which the components are at least partially exposed as shown) or, alternatively, can be installed at multiple points as the article is progressively being created (this further shown by selected components 24, 26 and 28 which are installed at earlier interrupted locations to allow for succeeding additive passes of insulating material 102 to flow over and build up around the lengthened components (as well as to embed other components such as the diode 23 depicted in FIG. 1).

[0030] Without limitation, the material additive process employed can be utilized with a suitable 3D printing machine 2 and variable collection of installable electrical (stock) components, this in order to quickly create custom shaped circuit pathway enabled articles which can include unique shapes and functionality. By virtue of the present process, the operator is provided with the ability to more efficiently produce a considerable number of 3D printed articles with less input than that required in the installation and soldering assembly of typical printed circuit board technology.

[0031] The time and effort savings realized include the operator's attention being limited to one or more brief install points occurring during an interrupted portion of the 3D printing protocol (such as which can be associated with the 3D printer issuing a suitable alarm for notifying the operator to press-fit install the desired components at the intermediate interrupted position). Given that the press fit attachment of the desired electrical components according to the present invention can be accomplished very quickly (and again as opposed to the alternative of time intensive printed circuit board production and soldering), this provides a single operator the ability to stagger an operational program cycle for each of a plurality of 3D printing machines so that adequate attention can be paid to each machine during its interrupted interval and as the printed article develops (or grows) until completed by the final pass. The present invention also contemplates the press fit installation of the separate electrical components can be automated within a redesign of the 3D printing machine architecture, such as which can also be directed by the supporting controller operating program and in order to time and direct the placement of such components as an alternative to the operator installing in a manual press fit fashion.

[0032] Having described our invention, other and additional preferred embodiments will become apparent to those skilled in the art to which it pertains, and without deviating from the scope of the appended claims. The detailed description and drawings are further understood to be supportive of the disclosure, the scope of which being defined by the claims. While some of the best modes and other embodiments for carrying out the claimed teachings have been described in detail, various alternative designs and embodiments exist for practicing the disclosure defined in the appended claims.