Conductive Polymer Composite for 3D Printing

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Solution Overview

Problem

Current conductive materials used in additive manufacturing have low conductivity and limited mechanical properties, restricting their application in printing functional objects with embedded sensors and electronics.

Innovation Solution

A conductive polymer composite comprising a thermoplastic polymer, carbon nanotubes, and a charge transfer complex formed by electron donor and acceptor molecules, which enhances electrical conductivity while maintaining processability for 3D printing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conductive materials are used in additive manufacturing, then electrical conductivity is improved, but mechanical properties deteriorate (materials are brittle and not flexible)

Engineering Contradiction:

Improveelectrical conductivityVSAvoidmechanical properties

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent uses a composite material system consisting of thermoplastic polymer matrix combined with carbon nanotubes and charge transfer complexes. This composite structure allows the material to simultaneously achieve high electrical conductivity (up to 100 S/cm) while maintaining good mechanical properties and flexibility, resolving the contradiction between conductivity and mechanical strength.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the physical and chemical parameters of the conductive material by incorporating charge transfer complexes and optimizing carbon nanotube concentrations. This transforms the material from brittle and inflexible to flexible and mechanically robust while maintaining high conductivity, thereby resolving the contradiction between electrical performance and mechanical properties.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If conductive materials with high conductivity are used, then electrical performance is improved, but ease of manufacture deteriorates (limited processability for 3D printing)

Engineering Contradiction:

Improveelectrical conductivityVSAvoidprocessability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent modifies the thermal and rheological parameters of the conductive material by selecting appropriate thermoplastic polymers and optimizing the composition of charge transfer complexes. These parameter changes enable the material to be processed using standard FDM 3D printing techniques while maintaining high electrical conductivity, thus resolving the contradiction between electrical performance and manufacturability.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If conventional conductive materials are used, then electrical conductivity is improved, but device complexity increases (require post-assembly for embedded electronics)

Engineering Contradiction:

Improveelectrical conductivityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent creates a multi-functional material that simultaneously provides structural support, electrical conductivity, and flexibility. This universal material can be directly printed into final functional objects with embedded electronic pathways, eliminating the need for separate assembly steps and reducing overall device complexity while maintaining high conductivity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The composite achieves bulk conductivity greater than 0.7 S/cm, enabling improved conductivity and processability for 3D printing applications, such as fused deposition modeling, allowing for the creation of functional objects with integrated electronics.

Implementation Method 1

The composite comprises a thermoplastic polymer, carbon nanotubes, at least one electron donor molecule and at least one electron acceptor molecule

Methodology Applied

Scientific EffectCharge transfer complex formation:

Implementation Method 2

the conductivity is relatively low... electrons have a continuous pathway to flow

Methodology Applied

Scientific EffectElectron delocalization:

Implementation Method 3

The composite is heated and the heated composite is extruded onto a build platform to form a three dimensional object

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 4

The molten polymer can be deposited layer by layer onto a build plate in order to form 3D objects

Methodology Applied

Scientific EffectExtrusion: Extrusion

Data Source

PatentUS10186344B2Conductive polymer composite

Publication Date: 2019.01.22 GENESEE VALLEY INNOVATIONS LLC

AI summary

A conductive polymer composite is disclosed. The composite comprises a thermoplastic polymer; carbon nanotubes; at least one electron donor molecule and at least one electron acceptor molecule. A method of three-dimensional printing using the conductive polymer composite and a conductive polymer composite filament are also disclosed.