ELECTRICAL COMMUNICATION WITH 3D-PRINTED OBJECTS

• US 20160197417A1
• Filed: 12/30/2015
• Published: 07/07/2016
• Est. Priority Date: 01/02/2015
• Status: Abandoned Application

• Current Assignee: Voxel8 Inc. (Kornit Digital Ltd)
• Original Assignee: Voxel8 Inc. (Kornit Digital Ltd)
• Inventors: Busbee, Travis Alexander
• Application Number:
  US14/984,664
• Publication Number:
  US 20160197417A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: H01R 13/03 characterised by the material, e.g. plating, or coating materials
• CPC Class Codes: H01R 13/22 Contacts for co-operating by abutting
• CPC Class Codes: H01R 13/40 Securing contact members in or to a base or case; Insulating of contact members
• CPC Class Codes: H01R 13/6205 Two-part coupling devices held in engagement by a magnet
• CPC Class Codes: H01R 43/18 for manufacturing bases or cases for contact members
• CPC Class Codes: H01R 43/20 for assembling or disassembling contact members with insulating base, case or sleeve
• CPC Class Codes: H01R 9/2416 Means for guiding or retaining wires or cables connected to terminal blocks
• CPC Class Codes: H05K 2201/083 Magnetic materials
• CPC Class Codes: H05K 2201/10234 Metallic balls
• CPC Class Codes: H05K 3/325 by abutting or pinching, i.e. without alloying process; mechanical auxiliary parts therefor adaptations of leads inserted in holes for press-fit connections H05K3/308
• CPC Class Codes: H05K 3/4015 using auxiliary conductive elements, e.g. pieces of metal foil, metallic spheres

Abstract

Electrical signal and power transmission between two or more 3D-printed parts, 3D-printed parts and printed circuit boards, and/or 3D-printed parts and standard wire harnesses are facilitated by inserting electrically conductive magnets in sockets formed in each of the 3D-printed parts during 3D printing; by inserting electrically conductive magnets in sockets formed in a first part and inserting a biasable, electrically conductive object in the sockets formed in a second part during 3D printing; by 3D printing an electrically conductive feature having a biasable face in a first part and forming an electrically conductive pad/socket on a second part; or by affixing a printed circuit board in a first part and connecting the first part to a second part having contact pins and contact pads formed in the second part.

Claims

1. A method of making an electrical connection to a three-dimensionally printed object, the method comprising the steps of:

forming the printed object by three-dimensional printing, wherein the printed object defines a socket disposed proximate a printed electrically conductive lead in the printed object; and

inserting a magnet into the socket to form an electrical contact between the magnet and the electrically conductive lead.

2. The method of claim 1, wherein the forming step comprises three-dimensionally printing a portion of the object with a structural material and printing the electrically conductive lead with a functional material.

6. The method of claim 1, wherein the inserting step occurs prior to at least one of curing and drying of the electrically conductive lead.

8. The method of claim 1 further comprising, after inserting the magnet in the socket, printing a rim over a top edge of the magnet to retain the magnet.

9. The method of claim 1, further comprising the step of contacting the magnet with an external wire.

12. The method of claim 1, wherein the printed object defines a plurality of additional sockets proximate a plurality of additional electrical leads embedded in the printed object, the method further comprising the step of inserting additional magnets into the additional sockets to form additional electrical contacts.

22. The method of claim 1, further comprising using an electromagnetic head to automate the process of picking and placing magnets or ferromagnetic materials into three-dimensionally printed parts.

26. The method of claim 1, further comprising the step of using the magnet to actuate mechanical interlocking with a second printed object.

3-5. -5. (canceled)

7. (canceled)

10-11. -11. (canceled)

13-21. -21. (canceled)

23-25. -25. (canceled)

27. (canceled)

28. An article comprising:

a three-dimensionally printed object defining a socket disposed proximate an electrical lead embedded in the printed object; and

a magnet disposed in the socket, forming an electrical contact between the magnet and the electrical lead.

29. The article of claim 28, wherein the three-dimensionally printed object comprises a structural material and the electrical lead comprises a functional material.

30. The article of claim 28, wherein the magnet and the socket are dimensioned to provide an interference fit.

31. The article of claim 28, wherein an external wire contacts the magnet.

34. The article of claim 28, wherein the printed object defines a plurality of additional sockets proximate a plurality of additional electrical leads embedded in the printed object, and additional magnets are inserted into the additional sockets to form additional electrical contacts.

42. The article of claim 28, wherein the magnet comprises a conductive coating.

44. The article of claim 28, wherein the socket and magnet define complementary shapes.

46. The article of claim 28, wherein the magnet is fully embedded in the socket, and attracts a contact pin into the socket to form an electrical contact between the contact pin and a conductive pad in the socket.

32-33. -33. (canceled)

35-41. -41. (canceled)

43. (canceled)

45. (canceled)

47. (canceled)

48. The article of claim 47, wherein the socket defines a slot and the second printed object defines a printed protrusion that fits into the slot.

49. A method of making an electrical connection to a multi-part, three-dimensionally (3D) printed object, the method comprising the steps of:

forming a first part of the printed object by three-dimensional printing, wherein a socket is formed in the first part proximate a first electrically conductive lead, the first part further comprising at least one press-fit part;

inserting an electrically conductive material into the socket in the first part to form an electrical contact between the material and the first electrically conductive lead;

forming a second part of the printed object by three-dimensional printing, wherein a socket is formed in the second part proximate a second electrically conductive lead, the second part further comprising at least one press-fit part;

inserting a biasable, electrically conductive object into the socket in the second part to form an electrical contact between the electrically conductive object and the second electrically conductive lead; and

press-fitting the first part to the second part to mechanically connect the first part to the second part and to form an electrical communication between the first electrically conductive lead and the second electrically conductive lead.

50. The method of claim 49, wherein the biasable, electrically conductive object comprises a metallic sphere electrically coupled to a spring.

51. The method of claim 49, wherein the biasable, electrically conductive object comprises a spring-loaded electrically conductive pin.

52. The method of claim 49, wherein the wherein the biasable, electrically conductive object holds the three-dimensionally printed object in an electrically coupled position and orientation via a three-dimensionally printed mechanical interlocking feature.

53-61. -61. (canceled)