# US 10,375,765 B2 · 3-dimensional printed load cell parts

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- Number: US 10,375,765 B2
- Document ID: US10375765B2
- Status: Granted
- Kind: B2
- Application number: 16/073,142
- Filed: 2016-04-15
- Published: 2019-01-24
- Granted: 2019-08-06
- Earliest claimed: 2016-04-15
- Assignees: Hewlett-Packard Development Company, L.P.
- Applicants: Hewlett-Packard Development Company, L.P.
- Inventors: Sterling Chaffins; Cassady Roop; Kevin P. DeKam
- Web page: https://patentgrep.com/patent/US10375765B2

## CPC

- H05B 3/146: {Conductive polymers, e.g. polyethylene, thermoplastics}
- B29C 64/165: using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
- B29C 64/209: Heads; Nozzles
- B29C 64/218: Rollers
- G01B 1/00: Measuring instruments characterised by the selection of material therefor
- G01B 7/18: {using change in resistance}
- G01L 1/2293: {of the semi-conductor type}
- H05B 3/145: {Carbon only, e.g. carbon black, graphite}
- H05K 1/16: incorporating printed electric components, e.g. printed resistors, capacitors or inductors
- H05K 3/12: using {thick film techniques, e.g.} printing techniques to apply the conductive material {or similar techniques for applying conductive paste or ink patterns}
- B29K 2101/12: Thermoplastic materials
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B33Y 80/00: Products made by additive manufacturing
- C09D 11/037: characterised by the pigment
- H05B 2203/003: using serpentine layout
- H05B 2203/013: Heaters using resistive films or coatings
- H05B 2203/017: Manufacturing methods or apparatus for heaters
- H05K 3/0014: {Shaping of the substrate, e.g. by moulding}
- H05K 2201/10151: Sensor
- H05B: ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- G01B: MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01L: MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE (weighing G01G)
- H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)

## Abstract

A 3-dimensional printed load cell part can include a part body formed of fused thermoplastic polymer particles, and a plurality of strain sensors separately formed of a matrix of conductive particles interlocked with a matrix of fused thermoplastic polymer particles. The plurality of strain sensors can have a first electrical contact at a first end and a second electrical contact at a second end. The particles of the plurality of strain sensors can be continuously fused to the particles of the part body.

## Claims

### Claim 1

A 3-dimensional printed load cell part, comprising:
a part body formed of fused thermoplastic polymer particles; and
a plurality of strain sensors separately formed of a matrix of fused conductive particles interlocked with a matrix of fused thermoplastic polymer particles, the plurality of strain sensors each having a first electrical contact at a first end and a second electrical contact at a second end,
wherein the particles of the plurality of strain sensors are continuously fused to the particles of the part body.

### Claim 2 (depends on 1)

The 3-dimensional printed load cell part of claim 1, wherein the plurality of strain sensors are formed on a surface of the printed part.

### Claim 3 (depends on 1)

The 3-dimensional printed load cell part of claim 1, wherein the plurality of strain sensors are embedded in the part body and a plurality of electrical contacts of the plurality of strain sensors are formed on a surface of the printed part.

### Claim 4 (depends on 1)

The 3-dimensional printed load cell part of claim 1, wherein each of the strain sensors has a resistance from 1 ohm to 1 megaohm.

### Claim 5 (depends on 1)

The 3-dimensional printed load cell part of claim 1, wherein the conductive particles comprise conductive polymers, metals, carbon allotropes, or a combination thereof.

### Claim 6 (depends on 1)

The 3-dimensional printed load cell part of claim 1, wherein the fused thermoplastic polymer particles comprise a fusing agent selected from carbon black, a near-infrared absorbing dye, a near-infrared absorbing pigment, a tungsten bronze, a molybdenum bronze, metal nanoparticles, a conjugated polymer, or combinations thereof.

### Claim 7 (depends on 1)

The 3-dimensional printed load cell part of claim 1, wherein each of the strain sensors further comprises an activating ink in the matrix of fused conductive particles, the matrix of fused thermoplastic polymer particles, or both.

### Claim 8 (depends on 1)

The 3-dimensional printed load cell part of claim 1, wherein the part body is formed of multiple layers of fused thermoplastic polymer particles stacked in a z-axis direction, wherein each of the plurality of strain sensors is oriented at least partially in the z-axis direction, and wherein each of the plurality of strain sensors extends across a plurality of the layers of fused thermoplastic polymer particles of the part body.

### Claim 9

A method of making a 3-dimensional printed load cell part, comprising:
dispensing a conductive fusing ink onto a plurality of sensor areas of a layer of thermoplastic polymer particles, wherein the conductive fusing ink comprises conductive particles;
dispensing a second fusing ink onto non-sensor areas of the layer of thermoplastic polymer particles, wherein the second fusing ink comprises a fusing agent capable of absorbing electromagnetic radiation to produce heat; and
fusing the plurality of sensor areas and the non-sensor areas with electromagnetic radiation to form a plurality of strain sensors in the plurality of sensor areas and a part body in the non-sensor areas, wherein the plurality of strain sensors comprise a matrix of conductive particles interlocked with a matrix of fused thermoplastic polymer particles and the part body comprises fused thermoplastic polymer particles, and wherein the particles of each of the plurality of strain sensors are continuously fused to the particles of the part body.

### Claim 10 (depends on 9)

The method of claim 9, wherein each of the plurality of strain sensors is formed at least partially oriented in a z-axis direction such that each of the strain sensors extends across multiple layers of the 3-dimensional printed load cell part.

### Claim 11 (depends on 10)

The method of claim 10, wherein the plurality of strain sensors are formed across the same multiple layers.

### Claim 12 (depends on 10)

The method of claim 10, wherein a first set of the plurality of strain sensors are formed across different layers than a second set of the plurality of strain sensors.

### Claim 13

A load cell, comprising:
a first set of strain sensors electrically connected along a first current path, the first set of strain sensors being separately formed of a matrix of fused conductive particles interlocked with a matrix of fused thermoplastic polymer particles; and
a second set of strain sensors electrically connected along a second current path, the second set of strain sensors being separately formed of a matrix of fused conductive particles interlocked with a matrix of fused thermoplastic polymer particles, wherein the first current path and the second current path are parallel current paths in a common electrical circuit.

### Claim 14 (depends on 13)

The load cell of claim 13, wherein the first set of strain sensors and the second set of strain sensors are formed as part of a monolithic body.

### Claim 15 (depends on 14)

The load cell of claim 14, wherein the first set of strain sensors and the second set of strain sensors are interconnected by embedded internal electrical connections formed of a matrix of fused conductive particles interlocked with a matrix of fused thermoplastic polymer particles.

### Claim 16 (depends on 1)

The 3-dimensional printed load cell part of claim 1, wherein the thermoplastic polymer particles fused to form the part body and the thermoplastic polymer particles fused in the plurality of strain sensors have the same composition and average particle size.

### Claim 17 (depends on 16)

The 3-dimensional printed load cell part of claim 16, wherein the average particle size of the thermoplastic polymer particles is from 20 microns to 100 microns.

### Claim 18 (depends on 16)

The 3-dimensional printed load cell part of claim 16, wherein the thermoplastic polymer particles are selected from the group consisting of nylon 6 powder, nylon 9 powder, nylon 11 powder, nylon 12 powder, nylon 66 powder, nylon 612 powder, polyethylene powder, thermoplastic polyurethane powder, polypropylene powder, polyester powder, polycarbonate powder, polyether ketone powder, polyacrylate powder, polystyrene powder, and mixtures thereof.

### Claim 19 (depends on 18)

The 3-dimensional printed load cell part of claim 18, wherein the thermoplastic polymer particles are nylon 12 powder having a melting point from about 175° C. to about 200° C.

### Claim 20 (depends on 13)

The load cell of claim 13, wherein the thermoplastic polymer particles fused to form the part body and the thermoplastic polymer particles fused in the first set of strain sensors and the second set of strain sensors have the same composition and average particle size.