FDM PRINTED LUMINAIRES WITH ENHANCED SHINY APPEARANCE
20220410468 · 2022-12-29
Inventors
- Rifat Ata Mustafa Hikmet (Eindhoven, NL)
- Ties Van Bommel (Horst, NL)
- STEFAN WILLI JUKIUS GRUHLKE (BAESWEILER, DE)
Cpc classification
B33Y10/00
PERFORMING OPERATIONS; TRANSPORTING
B29C64/118
PERFORMING OPERATIONS; TRANSPORTING
F21K9/90
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V1/26
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B33Y70/00
PERFORMING OPERATIONS; TRANSPORTING
B33Y80/00
PERFORMING OPERATIONS; TRANSPORTING
F21V1/22
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B33Y70/10
PERFORMING OPERATIONS; TRANSPORTING
International classification
B29C64/118
PERFORMING OPERATIONS; TRANSPORTING
B33Y10/00
PERFORMING OPERATIONS; TRANSPORTING
B33Y70/10
PERFORMING OPERATIONS; TRANSPORTING
B33Y80/00
PERFORMING OPERATIONS; TRANSPORTING
F21V1/22
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
The invention provides a method for producing a 3D item (1) by means of fused deposition modelling, the method comprising a 3D printing stage comprising: layer-wise depositing an extrudate (321) comprising 3D printable material (201), to provide the 3D item (1) comprising 3D printed material (202), wherein the 3D item (1) comprises a plurality of layers (322) of 3D printed material (202), wherein the 3D printable material (201) comprises core-shell 3D printable material (201) comprising (i) a core (221) comprising core material (240) and (ii) a shell (222) comprising shell material (250), wherein the core material (240) comprises a core thermoplastic material (241) and core additive material (242), wherein the shell material (250) comprises a shell thermoplastic material (251) and shell particles (252), wherein the shell material (250) is light transmissive for one or more wavelengths in the visible wavelength range, wherein the shell particles (252) comprise specularly reflective particles, wherein the core additive material (242) comprises one or more of diffuse reflective particles, white particles, black particles, colored particles, and dye molecules, and wherein the core material (240) and shell material (250) differ in one or more optical properties selected from the group of color, reflectivity, type of reflectivity, and absorption of light.
Claims
1. A method for producing a 3D item by means of fused deposition modelling, the method comprising a 3D printing stage comprising: layer-wise depositing an extrudate comprising 3D printable material, to provide the 3D item comprising 3D printed material, wherein the 3D item comprises a plurality of layers of 3D printed material, wherein the 3D printable material comprises core-shell 3D printable material comprising (i) a core comprising core material and (ii) a shell comprising shell material, wherein the core material comprises a core thermoplastic material and core additive material, wherein the shell material comprises a shell thermoplastic material and shell particles, wherein the shell material is light transmissive for one or more wavelengths in the visible wavelength range, wherein the shell particles comprise specularly reflective particles, wherein the core additive material comprises one or more of diffuse reflective particles, white particles, black particles, colored particles, and dye molecules, and wherein the core material and the shell material differ in one or more optical properties selected from the group of color, reflectivity, type of reflectivity, and absorption of light.
2. The method according to claim 1, wherein the shell particles comprise one or more of (i) polymeric flake-like particles having a metal coating or a metal oxide coating, (ii) glass flakes having a metal coating or a metal oxide coating, (iii) metal flakes, (iv) mica particles having a metal coating or a metal oxide coating, (v) holographic glitter particles, and (vi) colored reflective particles, and wherein optionally the shell material further comprises a dye, wherein the method further comprises using a core-shell filament of 3D printable material or using a core-shell nozzle for creating the extrudate.
3. The method according to claim 1, wherein the shell particles comprise polyethylene terephthalate flake-like particles having an aluminum coating.
4. The method according to claim 1, wherein the shell particles have a particle length (L1), a particle height (L2), and a particle width (L3) with an aspect ratio of L1/L2 of at least 5, and L3/L2 of at least 5, and wherein the method comprises printing one or more layers of the 3D printed material having a layer height (H), wherein the layer height (H) is larger than the particle length (L1), and wherein the layers are stacked.
5. The method according to claim 4, wherein the shell particles have one or more dimensions selected from the particle length (L1), the particle height (L2), and the particle width (L3), having a length selected from the range of equal to and larger than 2 μm and equal to or smaller than 5 mm.
6. The method according claim 1, wherein the core additive material comprise one or more of (i) diffusively reflecting particles and (ii) light absorbing particles.
7. The method according to claim 1, wherein the core additive material comprise metal particles, wherein the metal particles are wrinkled, and/or with wherein the metal particles have a diffuse reflecting surface.
8. The method according to claim 1, wherein the 3D printable material and the 3D printed material comprise one or more of polycarbonate (PC), polyethylene (PE), high-density polyethylene (HDPE), polypropylene (PP), polyoxymethylene (POM), polyethylene naphthalate (PEN), styrene-acrylonitrile resin (SAN), polysulfone (PSU), polyphenylene sulfide (PPS), and semi-crystalline polytethylene terephthalate (PET), acrylonitrile butadiene styrene (ABS), poly(methyl methacrylate) (PMMA), polystyrene (PS), and styrene acrylic copolymers (SMMA).
9. A core-shell filament comprising (i) a core comprising core material and (ii) a shell comprising shell material, wherein the core material comprises a core thermoplastic material and core additive material, wherein the shell material comprises a shell thermoplastic material and shell particles, wherein the shell material is light transmissive for one or more wavelengths in the visible wavelength range, wherein the shell particles comprise specularly reflective particles, wherein the core additive material comprises one or more of diffuse reflective particles, white particles, black particles, colored particles, and dye molecules, and wherein the core material and shell material differ in one or more optical properties selected from the group of color, reflectivity, type of reflectivity, and absorption of light.
10. A 3D item comprising 3D printed material, wherein the 3D item comprises a plurality of layers of 3D printed material, wherein the 3D printed material comprises core-shell 3D printed material comprising (i) a core comprising core material and (ii) a shell comprising shell material, wherein the core material comprises a core thermoplastic material and core additive material, wherein the shell material comprises a shell thermoplastic material and shell particles, wherein the shell material is light transmissive for one or more wavelengths in the visible wavelength range, wherein the shell particles comprise specularly reflective particles, wherein the core additive material comprises one or more of diffuse reflective particles, white particles, black particles, colored particles, and dye molecules, and wherein the core material and shell material differ in one or more optical properties selected from the group of color, reflectivity, type of reflectivity, and absorption of light.
11. The 3D item according to claim 10, wherein the shell particles comprise specularly reflective particles.
12. The 3D item according to claim 10, wherein the shell particles comprise polyethylene terephthalate flake-like particles having metal coating or a metal oxide coating, wherein the shell particles have a particle length (L1) and a particle height (L2) with an aspect ratio of L1/L2 of at least 5, and wherein the one or more layers of the 3D printed material have a layer height (H), wherein the layer height (H) is larger than the particle length (L1), and wherein the layers are stacked.
13. The 3D item according to claim 10, wherein the core additive material comprise one or more of (i) diffusively reflecting particles and (ii) light absorbing particles.
14. A lighting device comprising a light and the 3D item according to claims 10, wherein the 3D item is configured as one or more of (i) at least part of a lighting device housing, (ii) at least part of a wall of a lighting chamber, and (iii) an optical element.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0107] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, and in which:
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DETAILED DESCRIPTION OF THE EMBODIMENTS
[0115]
[0116] The 3D printer 500 is configured to generate a 3D item 1 by layer-wise depositing on a receiver item 550, which may in embodiments at least temporarily be cooled, a plurality of layers 322 wherein each layers 322 comprises 3D printable material 201, such as having a melting point T.sub.m. The 3D printable material 201 may be deposited on a substrate 1550 (during the printing stage). By deposition, the 3D printable material 201 has become 3D printed material 202. 3D printable material 201 escaping from the nozzle 502 is also indicated as extrudate 321. Reference 401 indicates thermoplastic material.
[0117] The 3D printer 500 may be configured to heat the filament 320 material upstream of the printer nozzle 502. This may e.g. be done with a device comprising one or more of an extrusion and/or heating function. Such device is indicated with reference 573, and is arranged upstream from the printer nozzle 502 (i.e. in time before the filament material leaves the printer nozzle 502). The printer head 501 may (thus) include a liquefier or heater. Reference 201 indicates printable material. When deposited, this material is indicated as (3D) printed material, which is indicated with reference 202.
[0118] Reference 572 indicates a spool or roller with material, especially in the form of a wire, which may be indicated as filament 320. The 3D printer 500 transforms this in an extrudate 321 downstream of the printer nozzle which becomes a layer 322 on the receiver item or on already deposited printed material. In general, the diameter of the extrudate 321 downstream of the nozzle 502 is reduced relative to the diameter of the filament 322 upstream of the printer head 501. Hence, the printer nozzle is sometimes (also) indicated as extruder nozzle. Arranging layer 322 by layer 322 and/or layer 322t on layer 322, a 3D item 1 may be formed. Reference 575 indicates the filament providing device, which here amongst others include the spool or roller and the driver wheels, indicated with reference 576.
[0119] Reference A indicates a longitudinal axis or filament axis.
[0120] Reference C schematically depicts a control system, such as especially a temperature control system configured to control the temperature of the receiver item 550. The control system C may include a heater which is able to heat the receiver item 550 to at least a temperature of 50° C., but especially up to a range of about 350° C., such as at least 200° C.
[0121] Alternatively or additionally, in embodiments the receiver plate may also be moveable in one or two directions in the x-y plane (horizontal plane). Further, alternatively or additionally, in embodiments the receiver plate may also be rotatable about z axis (vertical). Hence, the control system may move the receiver plate in one or more of the x-direction, y-direction, and z-direction.
[0122] Alternatively, the printer can have a head can also rotate during printing. Such a printer has an advantage that the printed material cannot rotate during printing.
[0123] Layers are indicated with reference 322, and have a layer height H and a layer width W.
[0124] Note that the 3D printable material is not necessarily provided as filament 320 to the printer head. Further, the filament 320 may also be produced in the 3D printer 500 from pieces of 3D printable material.
[0125] Reference D indicates the diameter of the nozzle (through which the 3D printable material 201 is forced).
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[0127] Hence,
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[0129] Referring to
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[0131] The particles comprise a material 411, or may essentially consist of such material 411. The particles 410 have a first dimension or length L1. In the left example, L1 is essentially the diameter of the essentially spherical particle. On the right side a particle is depicted which has non spherical shape, such as an elongated particle 410. Here, by way of example L1 is the particle length. L2 and L3 can be seen as height and width. Of course, the particles may comprise a combination of differently shaped particles.
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[0134] Note that the notations L1, L2, and L3, and A1, A2 and A3 are only used to indicate the axes and their lengths, and that the numbers are only used to distinguish the axis. Further, note that the particles are not essentially oval or rectangular parallelepiped. The particles may have any shape with at least a longest dimension substantially longer than a shortest dimension or minor axes, and which may essentially be flat. Especially, particles are used that are relatively regularly formed, i.e. the remaining volume of the fictive smallest rectangular parallelepiped enclosing the particle is small, such as less than 50%, like less than 25%, of the total volume.
[0135]
[0136]
[0137]
[0138] As shown in
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[0140]
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[0146] Such (core-shell) filament 322 may be extruded to provide core-shell layers, see e.g. also
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[0148] Referring to
[0149] Referring to e.g.
[0150] Such dopant material 410 as depicted in
[0151] For obtaining metallic appearance use of metal flakes have been suggested. Commercially available aluminum flakes are so-called corn flakes with an irregular shape or so-called dollar flakes which are round. However, these flakes have rough surfaces and when printed they look rather gray without any specular reflecting component. In order to obtain more metallic appearance specularly reflecting flake particles with a smooth surface such as metal glitters can be used. Such glitters are particles of precision cut out of metal sheets such as aluminum and have shapes such as hexagon, rectangle etc. As opposed to metal flakes with a dollar and cornflake shaped particles produced by flattening spherical or irregularly shaped metal particles respectively, these pure metal glitters show specular reflection and have a shiny appearance. They differ from glitters where sub-micron thick aluminum layer is deposited on a polymeric carrier as they can be processed at elevated temperatures such that they can be included in polymers such as polycarbonate with ease. Pure metal glitters have a thickness of at least 2 micrometer and length-width dimensions of at least 50×50 micrometer. It is also possible to use glass flakes coated with silver/aluminum. It was observed that when these pure aluminum metal glitters and/or specularly reflecting glass flakes are used in a mixture with flakes which show only diffuse reflection an enhanced metallic look is obtained. In this ID we propose the use of a mixture of diffuse and specularly reflecting particles to obtain surfaces with a shiny appearance. The shiny sparkling appearance is enhanced when polymer carrying the particles are physically separated. For example, they can also be extruded as core jacket configuration where the jacket is made of a transparent polymer comprising pure metal glitters while the core is made of a polymer with diffuse reflecting metal flakes to obtain a further enhanced metallic look. In such a core shell configuration glass flakes or glitters can be used in combination with another reflective or absorbing layers to create decorative effects. The thickness of the jacket with reflective particles is preferably 10-500 μm and the light transmission through this layer is preferably 60-95% where the individual specularly reflecting particles or clusters of such particles are dispersed in the jacket.
[0152] We produced cylindrical objects comprising specularly reflecting metal glitters in the jacket and various materials in the core. In an example, specularly reflecting metal particles in the jacket and diffuse reflecting metallic particles in the core were applied. In another example, specularly reflecting particles in the jacket and diffuse white reflecting polymer in the core. In yet another example, specularly reflecting particles in the jacket and black absorbing polymer in the core.
[0153] Specularly reflecting particles in the jacket gave sparkling decorative appearance to the objects. In combination with diffuse reflecting particles in the core gave more metallic appearance to the printed objects. When black core is combined with diffuse reflecting particles white particles were used in the shell or the other way around decorative and attractive surfaces can be created.
[0154] The term “plurality” refers to two or more.
[0155] The terms “substantially” or “essentially” herein, and similar terms, will be understood by the person skilled in the art. The terms “substantially” or “essentially” may also include embodiments with “entirely”, “completely”, “all”, etc. Hence, in embodiments the adjective substantially or essentially may also be removed. Where applicable, the term “substantially” or the term “essentially” may also relate to 90% or higher, such as 95% or higher, especially 99% or higher, even more especially 99.5% or higher, including 100%.
[0156] The term “comprise” includes also embodiments wherein the term “comprises” means “consists of”.
[0157] The term “and/or” especially relates to one or more of the items mentioned before and after “and/or”. For instance, a phrase “item 1 and/or item 2” and similar phrases may relate to one or more of item 1 and item 2. The term “comprising” may in an embodiment refer to “consisting of” but may in another embodiment also refer to “containing at least the defined species and optionally one or more other species”.
[0158] Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein.
[0159] The devices, apparatus, or systems may herein amongst others be described during operation. As will be clear to the person skilled in the art, the invention is not limited to methods of operation, or devices, apparatus, or systems in operation.
[0160] It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims.
[0161] In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim.
[0162] Use of the verb “to comprise” and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise”, “comprising”, and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”.
[0163] The article “a” or “an” preceding an element does not exclude the presence of a plurality of such elements.
[0164] The invention may be implemented by means of hardware comprising several distinct elements, and by means of a suitably programmed computer. In a device claim, or an apparatus claim, or a system claim, enumerating several means, several of these means may be embodied by one and the same item of hardware. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.
[0165] The invention also provides a control system that may control the device, apparatus, or system, or that may execute the herein described method or process. Yet further, the invention also provides a computer program product, when running on a computer which is functionally coupled to or comprised by the device, apparatus, or system, controls one or more controllable elements of such device, apparatus, or system.
[0166] The invention further applies to a device, apparatus, or system comprising one or more of the characterizing features described in the description and/or shown in the attached drawings. The invention further pertains to a method or process comprising one or more of the characterizing features described in the description and/or shown in the attached drawings.
[0167] The various aspects discussed in this patent can be combined in order to provide additional advantages. Further, the person skilled in the art will understand that embodiments can be combined, and that also more than two embodiments can be combined. Furthermore, some of the features can form the basis for one or more divisional applications.
[0168] It goes without saying that one or more of the first (printable or printed) material and second (printable or printed) material may contain fillers such as glass and fibers which do not have (to have) influence on the on T.sub.g or T.sub.m of the material(s).