LUMINAIRE WITH TEXTURE PERFORATION

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 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 plurality of layers (322) comprises a stack (1300), wherein the stack (1300) comprises a first layer (1322) and a second layer (2322), wherein the method comprises:—3D printing the first layer (1322) and subsequently the second layer (2322) while providing a plurality of modulations (340) in a z-direction in at least one of the first and second layers (1322, 2322), thereby defining a plurality of openings (354) between the first and second layers (1322, 2322).

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 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 plurality of layers comprises a stack wherein the stack comprises a first layer and a second layer, wherein the method comprises: 3D printing the first layer and subsequently the second layer while providing a regular pattern comprising a plurality of modulations in a z-direction in each of the first and second layers, thereby defining a plurality of openings between the first and second layers, the z-direction being the direction in which the layers are 3D printed on top of each other, the regular patterns being identical but translated relative to one another along a stack axis (SA) of one of the first and second layers, wherein the layers have a layer width W and the plurality of modulations have a pitch, wherein the regular patterns are translated relative to one another with a shift S, and wherein 2*W≤P≤20*W and S=x*P, wherein 0.4≤x≤0.6.

2. The method according to claim 1, wherein the layers have a layer width W, wherein the plurality of the modulations have an amplitude value A, wherein 0.5*W<A<10*W, wherein the plurality of the modulations have a modulation width W1 at half amplitude values A, wherein 0.5*W<W1<10*W.

3. The method according to claim 1, comprising 3D printing at least one of the first and second layers with a plurality of the modulations in one or more of a block-shape way, in a zig-zag way, and in a meandering way.

4. The method according to claim 1, wherein the 3D printable material is transmissive for at least part of the visible light.

5. The method according to claim 1, wherein the 3D item comprises an item wall, wherein the item wall comprises the plurality of layers of 3D printed material, wherein the method comprises providing a plurality of layers with the plurality of the openings between both sides of the item wall.

6. The method according to claim 1, wherein the layers have a layer width, wherein the openings have a cross-sectional area having an equivalent circular diameter D, wherein a shortest distance d2 between nearest neighboring openings is selected from the range of W≤d2≤20*D.

7. A 3D item obtainable by the method according to claim 1, wherein the stack comprises a plurality of n stacked layers, wherein n≥10, wherein the stack comprises at least five sets, each set comprising at least two layers with k≥2 openings configured in a regular arrangement.

8. The 3D item according to claim 7, wherein the first and second layers comprise stack axes (SA), configured in a plane, wherein the openings are defined by modulations from the respective layer relative to the respective stack axis (SA), wherein the modulations have an amplitude value A, wherein 0.5*W<A≤10*W, wherein the plurality of the modulations have a modulation width W1 at half amplitude values A, wherein 0.1*W≤W1≤10*W.

9. The 3D item according to claim 8, wherein the plurality of the modulations of at least one of the first and second layers are configured in one or more of a block-shape arrangement, a zig-zag arrangement, and a meandering arrangement.

10. The 3D item according to claims 7, wherein the 3D printed material is transmissive for at least part of the visible light.

11. The 3D item according to claim 7, wherein the 3D item comprises an item wall, wherein the item wall comprises the plurality of layers of 3D printed material comprising the plurality of the openings, wherein the plurality of the openings define openings between both sides of the item wall, wherein the openings have a cross-sectional area having an equivalent circular diameter D, wherein a shortest distance d2 between nearest neighboring openings is selected from the range of W≤d2≤20*D.

12. A lighting device comprising the 3D item according to claim 7, 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

[0113] 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:

[0114] FIGS. 1a-1c schematically depict some general aspects of the 3D printer and of an embodiment of 3D printed material;

[0115] FIGS. 2a-2e show some embodiments;

[0116] FIGS. 3a-3c schematically depict some examples; and

[0117] FIG. 4 schematically depicts applications. The schematic drawings are not necessarily to scale.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0118] FIG. 1a schematically depicts some aspects of the 3D printer. Reference 500 indicates a 3D printer. Reference 530 indicates the functional unit configured to 3D print, especially FDM 3D printing; this reference may also indicate the 3D printing stage unit. Here, only the printer head for providing 3D printed material, such as an FDM 3D printer head is schematically depicted. Reference 501 indicates the printer head. The 3D printer of the present invention may especially include a plurality of printer heads (see below). Reference 502 indicates a printer nozzle. The 3D printer of the present invention may especially include a plurality of printer nozzles, though other embodiments are also possible. Reference 320 indicates a filament of printable 3D printable material (such as indicated above). For the sake of clarity, not all features of the 3D printer have been depicted, only those that are of especial relevance for the present invention (see further also below). Reference 321 indicates extrudate (of 3D printable material 201).

[0119] 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.

[0120] 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.

[0121] 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.

[0122] Reference A indicates a longitudinal axis or filament axis or axis of elongation of a layer of 3D printed material 202.

[0123] 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.

[0124] 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).

[0125] Hence, the control system may move the receiver plate in one or more of the x-direction, y-direction, and z-direction.

[0126] 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.

[0127] Layers are indicated with reference 322, and have a layer height H and a layer width W.

[0128] 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.

[0129] Reference D indicates the diameter of the nozzle (through which the 3D printable material 201 is forced).

[0130] FIG. 1b schematically depicts in 3D in more detail the printing of the 3D item 1 under construction. Here, in this schematic drawing the ends of the filaments 321 in a single plane are not interconnected, though in reality this may in embodiments be the case.

[0131] Reference H indicates the height of a layer. Layers are indicated with reference 203. Here, the layers have an essentially circular cross-section. Often, however, they may be flattened, such as having an outer shape resembling a flat oval tube or flat oval duct (i.e. a circular shaped bar having a diameter that is compressed to have a smaller height than width, wherein the sides (defining the width) are (still) rounded).

[0132] Hence, FIGS. 1a-1b schematically depict some aspects of a fused deposition modeling 3D printer 500, comprising (a) a first printer head 501 comprising a printer nozzle 502, (b) a filament providing device 575 configured to provide a filament 321 comprising 3D printable material 201 to the first printer head 501, and optionally (c) a receiver item 550. In FIGS. 1a-1b, the first or second printable material or the first or second printed material are indicated with the general indications printable material 201 and printed material 202, respectively. Directly downstream of the nozzle 502, the filament 321 with 3D printable material becomes, when deposited, layer 322 with 3D printed material 202.

[0133] FIG. 1c schematically depicts a stack of 3D printed layers 322, each having a layer height H and a layer width W. Note that in embodiments the layer width and/or layer height may differ for two or more layers 322. Reference 252 in FIG. 1c indicates the item surface of the 3D item (schematically depicted in FIG. 1c).

[0134] Referring to FIGS. 1a-1c, the filament of 3D printable material that is deposited leads to a layer having a height H (and width W). Depositing layer 322 after layer 322, the 3D item 1 is generated. FIG. 1c very schematically depicts a single-walled 3D item 1.

[0135] FIG. 2a schematically depicts the layer-wise deposition by 3D printing of layers 322 of 3D printed material 202. A stack 1300 of 2 layers is shown. Here, by way of example first the first layer 1322 may have been provided, and thereon the second layer 2322, with a modulation 340. The layer height is indicated with reference H and the layer width with reference W. Each layer has an axis of elongation A of the layer of 3D printed material 202. Note that these axes may also be curved. Further, reference 323 indicates a respective print path. Note that the stack may provide a face wherein all print paths 323 and/or axes of elongation A are comprised. Reference SA indicates a stack axis of a layer 322; each layer may comprise a stack axis SA. The stack axis may in embodiments be essentially parallel, which is here the case (see also FIG. 2b), though this is not necessarily the case. As can be seen on the right, the stack axes SA may define a cross-sectional plane (see also FIG. 2b). In embodiments, this plane may be planar, but in other embodiments this plane may be non-planer (i.e. a 1D or 2D curve plane). A cross-section is made at two different positions, which are schematically depicted in FIG. 2b. Further, note that in fact it is assumed that for these embodiments the layers are essentially on top of each other and are not curved (in the xy plane).

[0136] Hence, FIGS. 2a-2b schematically depict (a result of) a method for producing a 3D item 1 by means of fused deposition modelling. The method comprises a 3D printing stage comprising layer-wise depositing 3D printable material (see also FIGS. 1a-1c) to provide the 3D item 1 comprising 3D printed material 202. The 3D item 1 comprises a plurality of layers 322 of 3D printed material 202. The plurality of layers 322 comprises a stack 1300. The stack 1300 comprises a first layer 1322 and a second layer 2322 (which are configured adjacent to each other). Especially, the method comprises 3D printing the first layer 1322 and subsequently the second layer 2322 while providing a plurality of modulations 340 (here only one is depicted for the sake of understanding) in a z-direction in at least one of the first and second layers 1322,2322, thereby defining a plurality of openings 354 between the first and second layers 1322,2322 (in a plane comprising the z-axis). Hence, FIGS. 2a-2b schematically depict an embodiment of a 3D item 1 comprising 3D printed material 202, wherein the 3D item 1 comprises a plurality of layers 322 of 3D printed material 202. The plurality of layers 322 comprises a stack 1300 of a first layer 1322 and a second layer 2322 (which are configured adjacent to each other), with a plurality of openings 354 between the first and second layers 1322,2322 (in a plane comprising the z-axis) due to local differences between interlayer distances dl between the first and second layers 1322,2322.

[0137] FIGS. 2c-2e schematically depict some further aspects. Referring to this Figures (but also to FIGS. 2a-2b), the layers 322 have a layer width W. Further, especially the modulations 340 have an amplitude value A (relative to a print path 323). Especially, 0.5*W<A≤10*W. The modulations 340 have a modulation width W1 at half amplitude values A. In embodiments, 0.1*W≤W1≤10*W.

[0138] In the cross-sectional view of FIG. 2b, it can also be seen that the same layers may at one position have a non-zero inter-layer distance d1 and at another positions have a zero inter-layer distance d1.

[0139] FIGS. 2c-2d schematically depicts embodiments of results of a method comprising 3D printing at least one of the first and second layers 1322,2322 with a plurality of the modulations 340 in one or more of a block-shape way, in a zig-zag way, and in a meandering way. Here, for the sake of economy a plurality of different arrangements are shown.

[0140] The modulations 340 having a pitch P, wherein 2*W≤P≤20*W.

[0141] Amongst others, here also embodiments are depicted of a 3D printed item 1 being the result of a method comprising 3D printing two or more layers 322 each with a regular pattern comprising a plurality of the modulations 340, wherein the patterns are identical but translated relative to one another along a stack axis SA of one of the two or more layers 322 (see FIG. 2c (upper two sinusoidal type layers) and FIG. 2d). For instance, the patterns are translated relative to one another with a shift S, wherein S=x*P, wherein 0.4≤x≤0.6. Hence, the inter-layer distance may vary over (the length of) the layers 322.

[0142] In embodiments, the 3D item 1 may comprise an item wall 350. The item wall 350 may comprise the plurality of layers 322 of 3D printed material 202. The plurality of the openings 354 may be configured between both sides of the item wall 350 (see also FIG. 2e).

[0143] Hence, the method may comprise 3D printing the plurality of modulations 340 in a regular arrangement to provide a regular arrangement of the openings 354 between both sides of the item wall 350.

[0144] As schematically depicted in FIG. 2d, the openings 354 (of the plurality of the openings 354) have a cross-sectional area having an equivalent circular diameter D, wherein a shortest distance d2 between nearest neighboring openings 354 is selected from the range of W≤d2≤20*D.

[0145] In embodiments, the 3D printing method may comprise a continuous 3D printing of the plurality of layers 322 with the one or more print path modulations 340. Referring to FIG. 2e, the stack 1300 may comprise a virtual (optionally curved) stack plane 1305 configured parallel to the stacking of the layers 322 comprised by the stack 1300. The plurality of openings 354 (here only 1 is depicted) at least partly coincide with the stack plane 1305.

[0146] Referring to FIGS. 2c and 2b, the stack 1300 may comprise a plurality of n stacked layers 322, wherein n>5. In embodiments, the stack 1300 may comprise two or more sets 5322, each set comprising at least two layers 322 with the openings 354 (between stacked layers 322 of the set 5322), wherein the openings 354 in the stack 1300 form a regular arrangement. Especially, in embodiments the stack 1300 comprises a plurality of n stacked layers 322, wherein n≥10. Especially, the stack 1300 may comprises at least five sets 5322, each set comprising at least two layers 322 with k≥2 openings 354 (between stacked layers 322 of the set 5322), wherein the openings 354 in the stack 1300 form a regular arrangement.

[0147] In embodiments, the 3D item 1 may comprise two or more sets 5322, each set comprising at least two layers 322 with a regular pattern with a plurality of the openings 354 (between adjacent layers). In embodiments, each of the layers 322 comprises a stack axis SA, wherein at least two patterns are identical but translated relative to one another along the stack axis SA of one of the layers 322, wherein the regular patterns have a pitch P. The patterns are translated relative to one another with a shift S, wherein S=x*P, wherein 0.4≤x≤0.6. As indicated above, the modulations 340 of at least one of the first and second layers 1322,2322 have a pitch P, wherein 2*W<P<20*W.

[0148] As indicated above, FIGS. 2c-2d schematically depict embodiments of the 3D item 1 comprising two or more layers 322 with each a regular pattern with a plurality of the modulations 340, wherein each of the layers 322 comprises a stack axis SA, wherein the patterns are identical but translated relative to one another along the stack axis SA of one of the two or more layers 322.

[0149] FIGS. 2c-2d also schematically depicted embodiments of the 3D item 1 comprising an item wall 350, wherein the item wall 350 comprises the plurality of layers 322 of 3D printed material 202 comprising the plurality of the openings 354. The plurality of the openings 354 define openings between both sides of the item wall 350 (see also FIG. 2e). The layers 322 have a layer width W. The openings 354 (of the plurality of the openings 354) have a cross-sectional area having an equivalent circular diameter D. A shortest distance d2 between nearest neighboring openings 354 may selected from the range of W≤d2≤20*D.

[0150] Especially, the plurality of the openings 354 (between both sides of the item wall 350) may be configured in a regular arrangement.

[0151] FIGS. 3a-3c show some examples, with FIG. 3a depicting 3D printed material being white, with FIG. 3b depicting 3D printed material being light transmissive. Hence, the 3D printed material 202 may be transmissive for at least part of the visible light (especially having a wavelength selected from the range of 380-780 nm). FIG. 3b depicts 3D printed material being black. All wall elements comprise a plurality of holes.

[0152] A benefit of printing holes in combination with artificial light inside the structure may be that when looking towards the lamp, the shape of the light beams are broken by the transparent round shape printed lines, in such a way that a ‘a vertical high intensity’ area is visible on the surface of the lamp. The light beams may be broken in an essentially random direction. The light may be spread homogenously over the surface.

[0153] FIG. 4 schematically depicts an embodiment of a lamp or luminaire, indicated with reference 2, which comprises a light source 10 for generating light 11. The lamp may comprise a housing or shade or another element, which may comprise or be the 3D printed item 1 (of which several embodiments are described above). Here, the half sphere (in cross-sectional view) schematically indicates a housing or shade. The lamp or luminaire may be or may comprise a lighting device (which comprises the light source 10). Therefore, the term lighting device may refer to a lamp or a luminaire, and may thus be indicated with reference 2. Hence, in specific embodiments the lighting device comprises the 3D item 1. The 3D item 1 may be 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. Hence, the 3D item may in embodiments be reflective for light source light 11 and/or transmissive for light source light 11. Here, the 3D item may e.g. be a housing or shade. The housing or shade comprises the item part 400. For possible embodiments of the item part 400, see also above. FIG. 4 schematically depict several embodiments, wherein in the first embodiment I, the transmissivity of the 3D item 1 is relatively small, and in the other embodiments II and III, the transmissivity is larger.

[0154] FIG. 4, like e.g. also FIGS. 2c, 2d, and 3a-3c, schematically depict embodiments of possible texture perforations.

[0155] In embodiments, the 3D item may comprise a regular pitch per 3D printed level. In embodiments, the 3D item may comprise a regular pitch for at least 10 3D printed levels, more preferably at least 13, most preferably at least 15.

[0156] In embodiments, the 3D item may comprise a first 3D printed level comprising a first material, and a second 3D printed level comprising a second material different from the first material.

[0157] In embodiments, the 3D item may comprise a first 3D printed level comprising a first color, and a second 3D printed level comprising a second color different from the first color.

[0158] In embodiments, the pitch P may be preferably W<P<3 W, more especially 1.2 W<P<2.7 W, most especially 1.5 W<P<2.5 W such as for example P=2.

[0159] The term “plurality” refers to two or more.

[0160] 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%.

[0161] The term “comprise” includes also embodiments wherein the term “comprises” means “consists of”.

[0162] 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”.

[0163] 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.

[0164] 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.

[0165] 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.

[0166] In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim.

[0167] 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”.

[0168] The article “a” or “an” preceding an element does not exclude the presence of a plurality of such elements.

[0169] 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.

[0170] 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.

[0171] 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.

[0172] 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.

[0173] 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).

[0174] Amongst others, the invention provides in embodiments a method wherein 3D printed layers are stacked, but wherein at one or more positions at least one layer is modulated. Hence, the one layer may deviate in a z-direction from the layer below but may also return back on the layer below. This may be over a relatively small length. The excursions or modulations are chosen such, that there is a (small) opening between the lower layer and the layer in a plane of the layers. In this way, a 3D printed item comprising a stack of layers may have (physical) openings, which allow transmission of light. In general, the layer height of the layers is not adapted. The deviations or excursions may be provided in a regular way. This may provide a 3D printed with a regular arrangement of openings. Note that not each layer of the 3D printed item necessarily includes such deviations or excursions.