EP4735795A1

EP4735795A1 - Fdm printed housings providing improved ingress protection

Info

Publication number: EP4735795A1
Application number: EP24734923.6A
Authority: EP
Inventors: Ties Van Bommel; Rifat Ata Mustafa Hikmet
Original assignee: Signify Holding BV
Current assignee: Signify Holding BV
Priority date: 2023-06-30
Filing date: 2024-06-26
Publication date: 2026-05-06
Also published as: CN121420156A; WO2025003226A1

Abstract

The invention provides a device (1000) comprising a housing that can be reconfigured from a first housing (500) to a second housing (550), each of the first housing (500) and the second housing (550) hosting an electronic device (1010), and being configured to protect the electronic device (1010) against ingress of dust and/or water, wherein: (I) the first housing (500) is a 3D printed monolithic housing (500) comprising (i) a 3D printed first part (600) comprising a first 3D printed material (602) and (ii) a 3D printed second part (700) comprising second 3D printed material (702); wherein the 3D printed first part (600) comprises a first engagement structure (610) and the 3D printed second part (700) comprises a second engagement structure (720); wherein the 3D printed first part (600) and the 3D printed second part (700) are associated via a break-away connection (650) to allow detachment of the 3D printed first part (600) and the 3D printed second part (700) from each other; and (II) the 3D printed first part (600), the 3D printed second part (700), and the break- away connection (650) are configured such that after detachment of the 3D printed first part (600) and the 3D printed second part (700) from each other, the 3D printed first part (600) and the 3D printed second part (700) are configurable into the second housing (550) by associating the 3D printed first part (600) and the 3D printed second part (700) via the first engagement structure (610) and the second engagement structure (720).

Description

FDM PRINTED HOUSINGS PROVIDING IMPROVED INGRESS PROTECTION

FIELD OF THE INVENTION

The invention relates to a device comprising a housing. The invention also relates to a method for producing the device. The invention further relates to a method for reconfiguring the device.

BACKGROUND OF THE INVENTION

US2019081467 (Al), describes a reusable electrical panel cover for protecting an electrical panel box made of a sturdy rectangular box-shaped panel cover with two lengthedge sides and two width-edge sides, a front, a plurality of small openings for attaching the reusable electrical panel cover to an electrical panel box, at least one cutout in the front for access through the reusable electrical panel cover to the electrical panel, and at least one breakaway portion on one width-edge side and at least one breakaway portion on one lengthedge side, with each breakaway portion having a breakaway edge.

SUMMARY OF THE INVENTION

Within the next 10-20 years, digital fabrication will increasingly transform the nature of global manufacturing. One of the aspects of digital fabrication is 3D printing. Currently, many different techniques have been developed in order to produce various 3D printed objects using various materials such as ceramics, metals, and polymers. 3D printing can also be used in producing molds which can then be used for replicating objects.

For the purpose of making molds, the use of polyjet technique has been suggested. This technique makes use of layer by layer deposition of photo-polymerizable material which is cured after each deposition to form a solid structure. While this technique produces smooth surfaces the photo curable materials are not very stable, and they also have relatively low thermal conductivity to be useful for injection molding applications. The most widely used additive manufacturing technology is the process known as Fused Deposition Modeling (FDM). Fused deposition modeling (FDM) is an additive manufacturing technology commonly used for modeling, prototyping, and production applications. FDM works on an "additive" principle by laying down material in layers; a plastic filament or metal wire is unwound from a coil and supplies material to produce a part. Possibly, (for thermoplastics for example) the filament is melted and extruded before being laid down. FDM is a rapid prototyping technology. Other terms for FDM are “fused filament fabrication” (FFF) or “filament 3D printing” (FDP), which are considered to be equivalent to FDM. In general, FDM printers use a thermoplastic filament, which is heated to its melting point and then extruded, layer by layer, (or in fact filament after filament) to create a three- dimensional object. FDM printers are relatively fast, low cost and can be used for printing complicated 3D objects. Such printers are used in printing various shapes using various polymers. The technique is also being further developed in the production of LED luminaires and lighting solutions.

It appears desirable to house an (electronic) device, such as a light generating device (or a light source), within a housing. Especially, it may be desired to prevent the ingress of dirt, dust, smoke, and/or pollutants from the environment into the housing wherein the (electronic) device may be housed. However, it may also be desired to replace, upgrade, or maintain the (electronic) device over the lifetime of operation of the (electronic) device. Hence, a housing that facilitates access to the (electronic) device but simultaneously prevents ingress of contaminants from the environment is much desired. Current solutions may provide housings that may well shield the (electronic) device, but do not allow replace, upgrade, or maintain the (electronic) device. Further, it may be desirable to reduce the complexity of producing such housing.

Hence, it is an aspect of the invention to provide an alternative device which preferably further at least partly obviate(s) one or more of above-described drawbacks. The present invention may have as object to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.

Hence, in a first aspect the invention provides a device comprising a housing that can be reconfigured from a first housing to a second housing. Especially, each of the first housing and/or the second housing may host an electronic device. More especially, the first housing and/or the second housing may be configured to protect the electronic device against the ingress of dust and/or water.

The first housing may be a 3D printed housing, more especially a 3D printed monolithic housing. The first housing may comprise a 3D printed first part further comprising a first 3D printed material. Furthermore, the first housing may comprise a 3D printed second part further comprising second 3D printed material. The 3D printed first part may comprise a first engagement structure. Further, the 3D printed second part may comprise a second engagement structure. Especially, the 3D printed first part and the 3D printed second part may be associated via a break-away connection to allow detachment of the 3D printed first part and the 3D printed second part from each other. The 3D printed first part, the 3D printed second part, and the break-away connection may be configured such that after detachment of the 3D printed first part and the 3D printed second part from each other, the 3D printed first part and the 3D printed second part may be configurable into the second housing by associating the 3D printed first part and the 3D printed second part via the first engagement structure and the second engagement structure.

Hence, the invention provides a device comprising a housing that can be reconfigured from a first housing to a second housing, each of the first housing and the second housing hosting an electronic device, and being configured to protect the electronic device against ingress of dust and/or water, wherein: (I) the first housing is a 3D printed monolithic housing comprising (i) a 3D printed first part comprising a first 3D printed material and (ii) a 3D printed second part comprising second 3D printed material; wherein the 3D printed first part comprises a first engagement structure and the 3D printed second part comprises a second engagement structure; wherein the 3D printed first part and the 3D printed second part are associated via a break-away connection to allow detachment of the 3D printed first part and the 3D printed second part from each other; and (II) the 3D printed first part, the 3D printed second part, and the break-away connection are configured such that after detachment of the 3D printed first part and the 3D printed second part from each other, the 3D printed first part and the 3D printed second part are configurable into the second housing by associating the 3D printed first part and the 3D printed second part via the first engagement structure and the second engagement structure. Especially, the 3D printed (monolithic) housing may be obtainable by a fused deposition modelling method.

Thereby, the invention may provide an (electronic) device with a casing (or “housing” or “enclosure”) that (i.e. the housing) may be made as a monolithic component by means of 3D printing. Especially, the housing may have one or more locations where the 3D printed first part and the 3D printed second part may be separated to create an opening for maintenance, replacement of components, and/or upgrading. The separation may be achieved by the application of a force to a break-away structure at the transition between the two 3D printed parts (i.e., the 3D printed first part and the 3D printed second part). Furthermore, the two 3D printed parts may have mating connection parts (or elements) such that after the separation they may be assembled back together. That is, the first housing may be designed such that although the monolithic component is broken, the two 3D printed parts may still be assembled together by clicking or screwing the two 3D printed parts together using for example click/screw features such as male-female connections.

Furthermore, with such an invention, the first housing may be 3D printed as a monolithic body, thus, facilitating the ease of manufacturing the first housing. For instance, the 3D printed first part and the 3D printed second part may be 3D printed during the same 3D printed cycle. Hence, there may be no need for repositioning the 3D item (i.e., the 3D printed first part, or the 3D printed second part) during the 3D printing stage. Further, the 3D printed first part and the 3D printed second part may be printed together and hence may not require additional assembly to provide the first housing.

Yet further, the first housing may be provided such that it is hermetically sealed i.e., the 3D printed first part and the 3D printed second part may provide an airtight seal and thus protect the electronic device by preventing the ingress of dust, dirt, and/or pollutants, and/or a watertight seal. The first housing may form a hermetic seal for the electronic device. Hence, the invention may provide a FDM printed housing providing improved ingress protection.

The first housing may be configured such that it has an IPxy protection, wherein x indicates the intrusion protection and x indicates the moisture protection, wherein x is at least 5, more especially (at least) 6. The digit y may be at least 2, more especially at least 3, such as at least 4. The protection may be IP65 or higher. The device may be selected such that also the second housing may have such IPxy protection, such as at least IP54, more especially at least IP64, such as at least about IP65.

As mentioned above, the invention may provide a device comprising a housing that can be reconfigured from a first housing into a second housing. Especially, each of the first housing and the second housing may host an electronic device (such as a (solid state) light source). The first housing may be 3D printed. Especially, the 3D printed first part and the 3D printed second part may be 3D printed. The term “3D item” or “3D printed item” refers to items, objects and elements that may be produced by means of 3D printing. Especially, the first housing, the second housing, the 3D printed first part and the 3D printed second part may especially be 3D printed.

The first housing may comprise a 3D printed first part and a 3D printed second part. Especially, the association of the 3D printed first part and the 3D printed second part may form the first housing. Note that the first housing may (also) comprise additional 3D printed parts to facilitate forming the first housing. Features relating to the configuration of the first housing are discussed here below, and the features relating to the configuration of the second housing are discussed following that.

The association between the 3D printed first part and the 3D printed second part may be provided via the break-away connection. Note that the 3D printed first part and the 3D printed second part may be configured to be able to be detached. The break-away connection may especially be limited material connecting the 3D printed first part and the 3D printed second part. The break-away connection may be a region of a smaller width in the first housing. As a result, the break-away connection may be the relatively structurally weaker part of the first housing. Hence, the (for example, smaller width) break-away connection may be susceptible to breaking upon the application of a force or a torque.

Additionally or alternatively, the break-away connection may be a (local) shaped feature susceptible to being broken upon the application of a force or a torque. The advantage of using the break-away connection with (specific) shaped features is that the break-away connection may be structurally weak along a specific direction. Hence, a structurally strong connection between the 3D printed first part and the 3D printed second part may be provided with the exception of a susceptibility to breaking by the application of a force or torque in a specific direction.

Further, the 3D printed first part may comprise the first 3D printed material. Additionally, the 3D printed second part may comprise the second 3D printed material. The first 3D printed material and the second 3D printed material may both be the same 3D printed material. However, the first 3D printed material may also differ from the second 3D printed material. If this is the case, the interface region where two different 3D printing materials meet may be a (relatively structurally weak) region that may be susceptible to being broken upon the application of a force or a torque.

The break-away connection may comprise a stack of 3D printed layers. These 3D printed layers may comprise the same 3D printed material as the 3D printed material of the 3D printed first part and/or 3D printed material of the 3D printed second part. However, the third 3D printed connection part may (also) comprise one or more layers comprising 3D printed material different from the 3D printed material of the 3D printed first part and/or 3D printed material of the 3D printed second part. Such a stack of 3D printed layers may especially be arranged at least partly around a periphery of the first housing (thus providing ingress protection). The stack of 3D printed layers may especially be melted together. Further, the stack of 3D printed layers may (hence) provide a relatively structurally weaker connection susceptible to breaking upon the application of a force or a torque. Hence, the break-away connection may be one or more of (i) a (local) smaller width connection in the first housing, (ii) a (local) special shaped feature in the first housing, (iii) provided by using different polymer materials for the 3D printed first part and the 3D printed second part, and (iv) providing a break-away connection comprising a stack of 3D printed layers melted together.

The term “associated” may refer to two parts that may be connected to one another. In relation to the first housing, when the 3D printed first part is associated with the 3D printed second part, the 3D printed first part may be connected to the 3D printed second part by means of adhesive coupling and/or Van der Waals forces, such as is in general the case between 3D printed layers. The adhesive coupling may be: (i) via direct contact between the 3D printed first part and the 3D printed second part (i.e., the 3D printed first part and the 3D printed second part may be monolithic), or (ii) via an (intermediate) connection part that adheres to both the 3D printed first part and the 3D printed second part.

The 3D printed first part and the 3D printed second part may be associated to one another via a third connection part. That is, the third connection part may especially be a separate connection part (for example a 3D printed break-away connection) connecting the 3D printed first part and the 3D printed second part (see also above). Hence, in this way, the 3D printed first part and the 3D printed second part may especially be associated with each other via the third connection part. Especially, the break-away connection may be broken by the application of a force or a torque. The third connection part may be 3D printed and hence, may provide a 3D printed break-away connection. Furthermore, the 3D printed connection part may be configured to provide the break-away connection (to allow detachment of the 3D printed first part and the 3D printed second part from each other).

Hence, the device may further comprise a 3D printed connection part, wherein the 3D printed connection part is configured to provide the break-away connection. The connection part may especially be a 3D printed connection part.

Hence, the 3D printed connection part may especially comprise a third 3D printed material. The third 3D printed material may be the same as the first 3D printed material. Furthermore, the third 3D printed material may be the same as the second 3D printed material. However, the third 3D printed material may differ from one or more of the first 3D printed material and the second 3D printed material. The 3D printed connection part comprises a third 3D printed material, wherein the third 3D printed material differs from one or more of the first 3D printed material and the second 3D printed material. It may happen that, in specific situations, the first 3D printed material and the second 3D printed material may have a relatively high adhesive strength between the said 3D printed materials. In which case, detaching the 3D printed first part and the 3D printed second part from each other may require excessive force. However, by selecting the third 3D printed material with a relatively low adhesion strength between third 3D printed material and the first 3D printed material (and/or the second 3D printed material), the third 3D printed connection part may be provided such that the third 3D printed connection part may be susceptible to breaking upon the application of a minimal amount of force or a torque. The 3D printed connection part comprises a third 3D printed material, wherein the third 3D printed material differs from both the first 3D printed material and the second 3D printed material. Hence, in this way, the 3D printed connection part (comprising such 3D printed material) may facilitate ease in detachment of the 3D printed first part from the 3D printed second part. Note also that the first 3D printed material and the second 3D printed material may be the same and (both) may be different from the third 3D printed material.

Note that the first housing may be a monolithic first housing. That is, the 3D printed first part, the 3D printed second part (and the optional third connection part) may be associated to each other. Especially, the 3D printed first part, the 3D printed second part and the third 3D printed connection part may be 3D printed during the same stage, hence providing a monolithic first housing. Note that, the device may comprise a 3D printed connection part, wherein the first housing consists of the 3D printed first part, the 3D printed second part, and the 3D printed connection part, wherein the 3D printed first part and the 3D printed second part are detached from one another by breaking away the 3D printed connection part, wherein the 3D printed first part and the 3D printed second part are reconfigured to provide the second housing, wherein the second housing consists of the 3D printed first part and the 3D printed second part (and not the 3D printed connection part).

The device may comprise a 3D printed housing, wherein the first housing consists of the 3D printed first part and the 3D printed second part (associated with each other), wherein the 3D printed first part and the 3D printed second part may be detached from one another and reconfigured to provide the second housing. If this is the case, the second housing may be provided by the association of the first engagement structure and the second engagement structure and may not (necessarily) comprise the 3D printed connection part. Note further that, in the first housing, the 3D printed first part and the 3D printed second part may especially be directly associated with a break-away connection in between the two parts or comprising a third connection part comprising the break-away connection. The break-away connection may be configured in a plurality of different locations. One or more of the 3D printed first part and the 3D printed second part may comprise a recess, wherein the break-away connection may at least partly be configured in the recess. The first engagement structure (or the second engagement structure) may protrude away from the 3D printed first part (or 3D printed second part) and may be configured in the recess of the 3D printed second part (or the 3D printed first part) to provide the second housing. The break-away connection may be provided by the 3D printed connection part, wherein the 3D printed connection part may be configured in the recess of the 3D printed first part (or the 3D printed second part). By providing the break-away connection at least partly in the recess, the first engagement structure (or the second engagement structure) may already be configured at least partly in the recess of the 3D printed second part (or 3D printed first part) when providing the first housing. Such a configuration may limit access to the interior of the first housing and thus provide ingress protection. Alternatively, the break-away connection may also be configured in a part of the 3D printed first part and/or the 3D printed second part not comprising the recess. In dependence of the shape of the engagement structures (for example screw threads which may not protrude (much) away from the 3D printed first part or the 3D printed second part) it may not always be necessary to configure the break-away connection in the recess.

As mentioned above, the device may comprise a housing that may be reconfigured from the first housing to provide the second housing. The 3D printed first part and the 3D printed second part may especially be separated from each other at the breakaway connection and may be reconfigured to provide the second housing. Especially, the second housing may be provided by associating the 3D printed first part and the 3D printed second part. More especially, the 3D printed first part and the 3D printed second part (in the configuration of the second housing) may be associated via the first engagement structure and the second engagement structure, respectively. That is, the first engagement structure (comprised by the 3D printed first part) and the second engagement structure (comprised by the 3D printed second part) may especially be associated with each other to provide the second housing.

Hence, the 3D printed first part, the 3D printed second part, and the breakaway connection may be configured such that after detachment of the 3D printed first part and the 3D printed second part from each other, the 3D printed first part and the 3D printed second part may be configurable into a second housing by associating the 3D printed first part and the 3D printed second part via the first engagement structure and the second engagement structure. Note that the second housing may especially (also) host the electronic device.

Hereinafter, several possibilities relating to the configuration/association of the 3D printed first part and the 3D printed second part to provide the second housing are described.

The 3D printed first part may comprise a main first part and the first engagement structure. Analogously, the 3D printed second part may comprise the second engagement structure. Further, the 3D printed first part may comprise a main first part and the first engagement structure, wherein the main first part and the 3D printed second part may be associated to each other via at least the first engagement structure. Additionally or alternatively, the main first part and the 3D printed second part may be associated to each other via at least the second engagement structure. Note that the first engagement structure and the second engagement structure may especially be associated via a break-away connection. The first engagement structure and the second engagement structure may provide a close tolerance fit between the 3D printed first part and the 3D printed second part, especially in the second housing. Thereby preventing access to the interior of the second housing and hence, protecting the electronic device from the ingress of dust and/or dirt. Aspects related to the engagement structures and their configuration are discussed further below. Note however that the first housing may yet also be provided by the break-away connection and not an association between the first engagement structure and the second engagement structure. That is, the 3D printed first part and the 3D printed second part may comprise the first engagement structure and the second engagement structure but may not yet be engaged (or associated) with one another, especially in the first housing.

The first engagement structure and the main first part form a monolithic body. Alternatively, the first engagement structure and the main first part may not form a monolithic body. Especially, the first engagement structure may be connected to the main first part and may be configured to move relative to the main first part. The first engagement structure and the main first part are movable relative to each other via one or more of bending, rotation, and translation. The first engagement structure and/or the second engagement structure may not be 3D printed as a part of the 3D printed first part (and/or the 3D printed second part). If this is the case, the first engagement structure (and/or the second engagement structure) may be configured in the 3D printed first part (and/or the 3D printed second part) either during or after the 3D printing stage. Further, the 3D printed first part (and/or the 3D printed second part) may comprise recesses, slots, and/or grooves, to accommodate the first engagement structure (and/or the second engagement structure). Furthermore, the first engagement structure (and/or the second engagement structure) may be configured not engaged (but still connected) in the first housing and may be engaged after detachment and reconfiguration to provide the second housing.

The first engagement structure and the second engagement structure may (each) comprise a connection part. Especially, the connection parts may provide a malefemale connector (in the second housing). Male-female connectors are a pair of mating connectors or fasteners, wherein the female connector receives and holds the male connector. The male-female connectors may be selected from one or more of a stud and stopper connector, a jack and plug connector, and rivets. Note that, a connection part also refers to a plurality of connection parts. Note that the connection part may be 3D printed and hence may be provided as part of the 3D printed monolithic housing. However, the connection part may not necessarily be 3D printed. The connection parts may also be conventional connectors which may be configured in the 3D printed first part (and/or 3D printed second part). If this is the case, the 3D printed first part and the 3D printed second part may comprise one or more of grooves, slots, and recesses, to accommodate the connection part. Especially, the connector part may comprise elements that may be movable relative to each other via one or more of bending, rotation, and translation. Such connector parts may improve the stability and structural strength of the second housing upon reconfiguration of the 3D printed first part and 3D printed second part.

The first engagement structure and the second engagement structure may provide a screw-connection type connection (for or in the second housing). Especially, the first engagement structure may comprise screw threads and the second engagement structure may comprise the lining (to accommodate the screw threads), or vice versa. That is, the first engagement structure (or the second engagement structure) may comprise a helical protrusion of a predefined pitch. Analogously, the second engagement structure (or the first engagement structure) may comprise helical indents of the same predefined pitch. Of course, other screw threading contours known in the art may also be applied. In the first housing, the first engagement structure and the second engagement structure may be configured in an unscrewed configuration and may be connected by means of the break-away connection. After detachment, the 3D printed first part and the 3D printed second part may be reconfigured to provide the second housing by screwing together the first engagement structure and the second engagement structure. Thus, providing a close tolerance fit and protecting the electronic device from exposure to the external environment. Furthermore, the first engagement structure and the second engagement structure may provide a pin-hole type connection. The first engagement structure may protrude from the 3D printed first part (i.e., the pin). Additionally or alternatively, the second engagement structure may protrude from the 3D printed second part. Analogously, the second engagement structure may be configured in an (antagonistic) recess. Additionally or alternatively, the first engagement structure may be configured in an (antagonistic) recess. Hence, the (protruding) first engagement structure (or the second engagement structure) may be configured in an antagonistic recess of the 3D printed second part (or the 3D printed first part) to provide the second housing by means of the pin-hole type connection. For instance, the 3D printed first part may comprise a slot wherein a spring loaded pin may be configured, and the 3D printed second part may comprise a hole to accommodate the pin. In the first housing the spring may remain compressed, and the pin may remain withing the slot in the 3D printed first part. Upon detachment and reconfiguration, the slot may be aligned with the hole which may trigger the translation of the spring loaded pin along the slot and into the hole. Thus, associating the 3D printed first part to the 3D printed second part to provide the second housing.

One or more of the 3D printed first part and the 3D printed second part may comprise a flexible material and may undergo (elastic) deformation. Especially, the 3D printed first part and/or the 3D printed second part may undergo (elastic) deformation when associated with each other to provide the second housing. That is, the 3D printed first part may be pushed against the 3D printed second part (or vice versa) to provide the second housing, wherein at least a part of the 3D printed first part and/or at least a part of the 3D printed second part may undergo (some) deformation.

In relation to other features of the device, the device may especially be configured to provide light. The electronic device may especially comprise a light source configured to provide light source light. Furthermore, one or more of the first 3D printed material and the second 3D printed material may comprise a material that is at least partly transmissive for the light source light. Hence, the electronic device comprises a light source configured to provide light source light, and wherein one or more of the first 3D printed material and the second 3D printed material comprise a light transmissive material that is transmissive for the light source light. The light transmissive material may be (substantially) transmissive for light source light, such as 90 % or higher, such as 95 % or higher, especially 99 % or higher, including 100 %. Alternatively, light transmissive material may be partially transmissive for light. Especially, the light transmissive material may scatter incident light and hence, transmit diffuse light. If this is the case, the light transmissive material is at least 50 %, such as at least 60 %, especially at least 70 % transmissive for light source light. The light transmissive (3D printed) material may be selected from the group of PLA (Polylactic Acid), PETG (Polyethylene Terephthalate Glycol), ABS (Acrylonitrile Butadiene Styrene), polymethylmethacrylate (PMMA), and PC (Polycarbonate). Of course, other 3D printable light transmissive materials may also be selected.

The term “light source” may in principle relate to any light source known in the art. It may be a conventional (tungsten) light bulb, a low pressure mercury lamp, a high pressure mercury lamp, a fluorescent lamp, an LED (light emissive diode). The light source may comprise a solid state LED light source (such as an LED or laser diode (or “diode laser”)). The term “light source” may also relate to a plurality of light sources, such as 2-2000 (solid state) LED light sources. Hence, the term LED may also refer to a plurality of LEDs. Further, the term “light source” may also refer to a so-called chip-on-board (COB) light source. The term “light source” may also refer to a chip scaled package (CSP). A CSP may comprise a single solid state die with provided thereon a luminescent material comprising layer. The term “light source” may also refer to a midpower package. The term “light source” may refer to a semiconductor light-emitting device, such as a light emitting diode (LEDs), a laser diode, a resonant cavity light emitting diode (RCLED), a vertical cavity laser diode (VCSELs), an edge emitting laser (EEL), a photonic crystal surface emitting laser (PCSEL), or a vertical external cavity surface emitting laser (VECSEL). The term “light source” may also refer to an organic light-emitting diode (OLED), such as a passive-matrix (PMOLED) or an active-matrix (AMOLED). The light source may comprise a solid-state light source (such as an LED or laser diode). The light source may comprise an LED (light emitting diode). The terms “light source” or “solid state light source” may also refer to a superluminescent diode (SLED). The term “solid state light source”, or “solid state material light source”, and similar terms, may especially refer to semiconductor light sources, such as a light emitting diode (LED), a laser diode, or a superluminescent diode. The term “solid state light source”, and similar terms, may especially refer to semiconductor light sources, such as a light emitting diode (LED), a laser diode, or a superluminescent diode. Instead of the term “solid state light source” also the term “semiconductor-based light source” may be applied. Hence, the term “semiconductor-based light source” may refer to one or more of a light emitting diode (LED), a laser diode, and a superluminescent diode. Hence, the light generating device may comprise one or more of a light emitting diode (LED), a laser diode, and a superluminescent diode. As indicated above, the electronic device may comprise a (solid state) light source. However, the electronic device may also comprise another type of electronic device than a light source.

Hence, the electronic device may selected from the group comprising a (solid state) light source, a driver (for a (solid state) light source), a controller (for a (solid state) light source), an antenna (for a (solid state) light source) and a sensor (for a (solid state) light source). Further, the term “device” may refer to a plurality of the same type of devices but may also refer to a plurality of devices comprising at least two devices that are different type of devices (such as a light source and a sensor; see also above for some different types of devices).

As mentioned above, the 3D printed first part, the 3D printed second part, and the break-away connection may be configured such that after detachment of the 3D printed first part and the 3D printed second part from each other, the 3D printed first part and the 3D printed second part are configurable into a second housing by associating the 3D printed first part and the 3D printed second part via the first engagement structure and the second engagement structure. Here below, a method for reconfiguring the device (or “configuration change method”) to configure the 3D printed first part and the 3D printed second part to form the second housing is described.

In a further aspect, the invention provides a method for reconfiguring the device the first housing into the second housing, wherein the method comprises detaching the 3D printed first part and the 3D printed second part of the first housing enclosing an electronic device from each other. Especially, the connection between the 3D printed first part and the 3D printed second part may be relatively weak. Hence, the application of force to one or more of the 3D printed first part and the 3D printed second part may especially detach the 3D printed first part and the 3D printed second part from each other. Further, the method for reconfiguring the device may comprise configuring the 3D printed first part and the 3D printed second part such that the second housing is formed. Especially, a pin-hole type or screw-connection type connection may be formed between the first engagement structure and the second engagement structure. Hence, the invention provides a method for reconfiguring the device , especially for reconfiguring the first housing into the second housing, wherein the method comprises: detaching the 3D printed first part and the 3D printed second part of the first housing enclosing an electronic device from each other, and configuring the 3D printed first part and the 3D printed second part such that the second housing is formed. The method for reconfiguring the device may further comprise replacing at least part of the electronic device with a replacement part after detaching the 3D printed first part and the 3D printed second part of the first housing and before forming the second housing. Note that, the method for reconfiguring the device may especially also comprise complete replacement of the (electronic) device after detaching the 3D printed first part and the 3D printed second part of the first housing and before forming the second housing. Such a method facilitates access to the (electronic) device and subsequently reconfigures the 3D printed first part and the 3D printed second part to form the second housing. Hence, the (electronic) device may be repaired, upgraded, or maintained.

In a further aspect, the invention provides a second device comprising the second housing (hosting the electronic device) and configured to protect the electronic device for ingress of dust and/or water, obtainable with the (configuration change) method described above.

As derivable from the above, the 3D printed first part and the 3D printed second part (comprised by the first housing) may be produced by means of 3D printing, especially by means of fused deposition modelling. The 3D printing method may especially comprise a 3D printing stage. Basically, the 3D printing stage may comprise feeding 3D printable material, forming an extrudate, and depositing the 3D printable material, to provide a 3D item comprising 3D printed material. The term “3D item” may refer to one or more of the first housing, the second housing, the 3D printed first part and the 3D printed second part. Here below, the method for producing the first housing (or the “3D printing method”) is discussed.

The term “controlling”, and similar terms especially refer at least to determining the behavior or supervising the running of an element. Hence, herein “controlling” and similar terms may refer to imposing behavior to the element (determining the behavior or supervising the running of an element), such as measuring, displaying, actuating, opening, shifting, and changing temperature. Beyond that, the term “controlling”, and similar terms may additionally include monitoring. Hence, the term “controlling”, and similar terms may include imposing behavior on an element and also imposing behavior on an element and monitoring the element. The controlling of the element can be done with a control system, which may also be indicated as “controller”. The control system and the element may thus at least temporarily, or permanently, functionally be coupled. The element may comprise the control system. The control system and element may not be physically coupled. Control can be done via wired and/or wireless control. The term “control system” may also refer to a plurality of different control systems, which especially are functionally coupled, and of which one control system may be a master control system and one or more others may be slave control systems. A control system may comprise or may be functionally coupled to a user interface. The control system may also be configured to receive and execute instructions from a remote control. The control system may be controlled via an App on a device, such as a portable device, like a Smartphone or I-phone, and a tablet. The device is thus not necessarily coupled to the lighting system but may be (temporarily) functionally coupled to the lighting system. Hence, the control system may (also) be configured to be controlled by an App on a remote device. If this is the case, the control system of the lighting system may be a slave control system or control in a slave mode. For instance, the lighting system may be identifiable with a code, especially a unique code for the respective lighting system. The control system of the lighting system may be configured to be controlled by an external control system which has access to the lighting system on the basis of knowledge (input by a user interface or with an optical sensor (for example a QR code reader) of the (unique) code). The lighting system may also comprise means for communicating with other systems or devices, such as on the basis of Bluetooth, WIFI, LiFi, ZigBee, BLE or WiMAX, or another wireless technology.

The system, or apparatus, or device may execute an action in a “mode” or “operation mode” or “mode of operation” or “operational mode”. The term “operational mode may also be indicated as “controlling mode”. Likewise, in a method an action or stage, or step may be executed in a “mode” or “operation mode” or “mode of operation” or “operational mode”. This does not exclude that the system, or apparatus, or device may also be adapted for providing another controlling mode, or a plurality of other controlling modes. Likewise, this may not exclude that before executing the mode and/or after executing the mode one or more other modes may be executed.

However, a control system may be available, that is adapted to provide at least the controlling mode. Would other modes be available, the choice of such modes may especially be executed via a user interface, though other options, like executing a mode in dependence of a sensor signal or a (time) scheme, may also be possible. The operation mode may also refer to a system, or apparatus, or device, which can only operate in a single operation mode (i.e. “on”, without further tunability).

Hence, the control system may control in dependence of one or more of an input signal of a user interface, a sensor signal (of a sensor), and a timer. The term “timer” may refer to a clock and/or a predetermined time scheme. In a further aspect, the invention provides a method for producing the device; wherein the method comprises a 3D printing stage comprising layer-wise depositing 3D printable material, to provide the first housing comprising a plurality of layers of 3D printed material. Hence, in an aspect the first housing, such as described above, may be obtainable with the herein described method for producing the device.

The 3D printing method may comprise layer-wise depositing a first 3D printable material to provide the 3D printed first part. Further, the 3D printing method may comprise layer-wise depositing a second 3D printable material, to provide the 3D printed second part.

Hence, the 3D printing method may comprise layer-wise depositing: (i) a first 3D printable material to provide a 3D printed first part, and (ii) a second 3D printable material to provide a 3D printed second part; wherein the 3D printed first part comprises a first engagement structure and the 3D printed second part comprises a second engagement structure; wherein the 3D printed first part and the 3D printed second part are associated via a break-away connection to allow detachment of the 3D printed first part and the 3D printed second part from each other.

As indicated above, the method may comprise depositing during a printing stage 3D printable material. Herein, the term “3D printable material” may especially refer to the material to be deposited or printed, and the term “3D printed material” may especially refer to the material that is obtained after deposition. These materials may be essentially the same, as the 3D printable material may especially refer to the material in a printer head or extruder at elevated temperature and the 3D printed material refers to the same material, but in a later stage when deposited. The 3D printable material may be provided as a filament to the printer head and deposited as 3D printed material. The 3D printable material may also be provided as pellets to the printer head and may be deposited as 3D printed material. Hence, whatever starting materials are applied, 3D printable material is provided to the printer head and 3D printed. The term “extrudate” may be used to define the 3D printable material downstream of the printer head, but not yet deposited. The latter is indicated as “3D printed material”. In fact, the extrudate may comprise 3D printable material, as the material is not yet deposited. Upon deposition of the 3D printable material or extrudate, the material is thus indicated as 3D printed material. Essentially, the materials are the same material, as the thermoplastic material upstream of the printer head, downstream of the printer head, and when deposited, may essentially be the same material. Herein, the term “3D printable material” may also be indicated as “printable material. The term “polymeric material” may refer to a blend of different polymers but may also refer to essentially a single polymer type with different polymer chain lengths. Hence, the terms “polymeric material” or “polymer” may refer to a single type of polymers but may also refer to a plurality of different polymers. The term “printable material” may refer to a single type of printable material but may also refer to a plurality of different printable materials. The term “printed material” may refer to a single type of printed material but may also refer to a plurality of different printed materials.

As indicated above, the invention thus provides a method comprising providing a filament of 3D printable material and printing during a printing stage said 3D printable material on a substrate, to provide said 3D item.

Materials that may especially qualify as 3D printable materials may be selected from the group consisting of metals, glasses, thermoplastic polymers, and silicones. Especially, the 3D printable material comprises a (thermoplastic) polymer selected from the group consisting of ABS (acrylonitrile butadiene styrene), Nylon (or polyamide), Acetate (or cellulose), PLA (poly lactic acid), terephthalate (such as PET polyethylene terephthalate), Acrylic (polymethylacrylate, Perspex, polymethylmethacrylate, PMMA), Polypropylene (or polypropene), Polycarbonate (PC), Polystyrene (PS), PE (such as expanded- high impact- Polythene (or poly ethene), Low density (LDPE) High density (HDPE)), PVC (polyvinyl chloride) Polychloroethene, such as thermoplastic elastomer based on copolyester elastomers, polyurethane elastomers, polyamide elastomers polyolefin based elastomers, and styrene based elastomers. Optionally, the 3D printable material comprises a 3D printable material selected from the group consisting of Urea formaldehyde, Polyester resin, Epoxy resin, Melamine formaldehyde, and thermoplastic elastomer. Optionally, the 3D printable material comprises a 3D printable material selected from the group consisting of a polysulfone. Elastomers, especially thermoplastic elastomers, are especially interesting as they are flexible and may help obtain relatively more flexible filaments comprising the thermally conductive material. A thermoplastic elastomer may comprise one or more of styrenic block copolymers (TPS (TPE-s)), thermoplastic polyolefin elastomers (TPO (TPE-o)), thermoplastic vulcanizates (TPV (TPE-v or TPV)), thermoplastic polyurethanes (TPU (TPU)), thermoplastic copolyesters (TPC (TPE-E)), and thermoplastic polyamides (TPA (TPE-A)). 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(m ethyl methacrylate) (PMMA), polystyrene (PS), and styrene acrylic copolymers (SMMA).

The term 3D printable material is further also elucidated below, but especially refers to a thermoplastic material, optionally including additives, to a volume percentage of at maximum about 60%, especially at maximum about 30 vol.%, such as at maximum 20 vol.% (of the additives relative to the total volume of the thermoplastic material and additives).

The printable material is printed on a receiver item. Especially, the receiver item can be the building platform or can be comprised by the building platform. The receiver item can also be heated during 3D printing. However, the receiver item may also be cooled during 3D printing.

The phrase “printing on a receiver item” and similar phrases include amongst others directly printing on the receiver item, or printing on a coating on the receiver item, or printing on 3D printed material earlier printed on the receiver item. The term “receiver item” may refer to a printing platform, a print bed, a substrate, a support, a build plate, or a building platform. Instead of the term “receiver item”, the term “substrate” may also be used. The phrase “printing on a receiver item” and similar phrases include amongst others also printing on a separate substrate on or comprised by a printing platform, a print bed, a support, a build plate, or a building platform. Therefore, the phrase “printing on a substrate” and similar phrases include amongst others directly printing on the substrate, or printing on a coating on the substrate or printing on 3D printed material earlier printed on the substrate. Here below, further the term substrate is used, which may refer to a printing platform, a print bed, a substrate, a support, a build plate, or a building platform, or a separate substrate thereon or comprised thereby.

Layer by layer printable material is deposited, by which the 3D printed item is generated (during the printing stage). The 3D printed item may show a characteristic ribbed structures (originating from the deposited filaments).

During or after the 3D printing stage, a component configuration stage may be executed. In addition to a 3D printer head configured for the layer by layer deposition of 3D printed material, the 3D printer may also comprise a controllable mechanism (for example a controllable robotic arm) to position or remove one or more additional components in the device. The electronic device may be configured in the first housing during or after the 3D printing stage. Hence, during the 3D printing stage, the controllable mechanism may be configured to position at least a part of the electronic device within the first housing. Especially, the entire electronic device may also be replaced during this stage. Additionally or alternatively, the controllable mechanism may be configured to replace one or more components comprised by the electronic device. Yet further, the controllable mechanism may also be used to position or configure one or more non-3D printed components in the 3D printed material (for example connector parts).

However, it may also be possible that after a printing stage, a further stage is executed, such as a finalization stage. This stage may include removing the printed item from the receiver item and/or one or more post processing actions. One or more post processing actions may be executed before removing the printed item from the receiver item and/or one more post processing actions may be executed after removing the printed item from the receiver item. Post processing may include one or more of polishing, coating, and adding a functional component. Post-processing may include smoothening the ribbed structures, which may lead to an essentially smooth surface.

Further, the invention relates to a software product that can be used to execute the method described herein. Therefore, in yet a further aspect the invention also provides a computer program product, when running on a computer which is functionally coupled to or comprised by a fused deposition modeling 3D printer, is capable of bringing about the method as described herein.

Hence, in an aspect the invention (thus) provides a software product, which, when running on a computer is capable of bringing about the method for producing a 3D item by means of fused deposition modelling as described herein.

The herein described method provides 3D printed items. Hence, the invention also provides in a further aspect a 3D printed item obtainable with the herein described method.

The 3D printed item may comprise a plurality of layers on top of each other, i.e. stacked layers. The width (thickness) and height of (individually 3D printed) layers may be selected from the range of 100 pm to 5000 pm, such as from the range of 200 pm to 2500 pm, with the height in general being smaller than the width. For instance, the ratio of height and width may be equal to or smaller than 0.8, such as equal to or smaller than 0.6.

Layers may be core-shell layers or may consist of a single material, unless indicated otherwise herein. Within a layer, there may also be a change in composition, for instance when a core-shell printing process was applied and during the printing process it was changed from printing a first material (and not printing a second material) to printing a second material (and not printing the first material). The term “plurality of layers” may especially refer to at least four layers, like at least 5 layers, like at least 10 layers, such as at least 15 layers. The term “plurality of layers” may especially refer to a stack of at least four layers, like a stack of at least 5 layers, such as a stack of at least 10 layers, such as a stack of at least 15 layers. At least part of the 3D printed item may include a coating.

As can also be derived from the above, the 3D printable material may be fed to the printer head as filament and/or as pellets.

The 3D printing method may 3D print one or more of the 3D printed first part and the 3D printed second part in stages. Especially, the electronic device may be configured within the first housing during one of the said stages, or between these stages. For instance, the 3D printing method may comprise 3D printing a part of the 3D printed second part in a first stage, configuring (or positioning) the electronic device within the first housing, and 3D printing the remaining part of the 3D printed second part. This may provide increased accessibility for positioning the electronic device within the first housing. The 3D printing method may comprise 3D printing at least part of the 3D printed second part, positioning the electronic device, 3D printing a remaining part of the 3D printed second part in case the 3D printed second part was not completely 3D printed before positioning the electronic device, and 3D printing the first part, whereby the 3D printed first part and the 3D printed second part are associated via a break-away connection. Note that, in relation to the second housing, the 3D printed first part may be associated with the 3D printed second part by means of physical coupling. Especially, the 3D printed first part and the 3D printed second part may comprise (the herein described) engagement structures that may facilitate the physical coupling (such as engagement structures for a pin-hole type or screw-connection type connection).

As mentioned above, a connection part may be 3D printed and may provide a 3D printed break-away connection. Hence, the 3D printing method may especially provide a 3D printed connection part between the 3D printed first part and the 3D printed second part. The 3D printed connection part may facilitate sealing the 3D printed first part and the 3D printed second part to provide the first housing. Further, the 3D printed connection part may be configured to provide a break-away connection to allow detachment of the 3D printed first part and the 3D printed second part from each other. The 3D printing method comprises 3D printing a third 3D printable material to provide a 3D printed connection part between the 3D printed first part and the 3D printed second part, wherein the 3D printed connection part is configured to provide the break-away connection.

Furthermore, it must be noted that the device may comprise a light source configured to provide light source light. Especially, the device may be configured as a lighting device.

Hence, at least a part of the first housing (and/or the second housing) may be transmissive for light source light.

Hence, the deposited 3D printable material may be transmissive for light source light. The electronic device may comprise a light source configured to provide light source light, and wherein one or more of the first 3D printable material and the second 3D printable material comprise a light transmissive material that is transmissive for the light source light. Electronic devices other than a light source, or additional thereto, may also be possible (see also above).

In a further aspect, the invention provides a lighting device comprising the device as described herein. The device may especially comprise the electronic device comprising a light source. Especially, the light source may comprise a solid state light source. Further, the housing (i.e. the first housing and the second housing) 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. The light source may generate light source light which may propagate via the (light transmissive) first housing and the second housing. Hence, the lighting device may be configured to generate device light (comprising light source light). The lighting device may be a luminaire or a lamp.

Hence, in a further aspect, the invention also provides a lighting device, such as a lamp or a luminaire, comprising the device as defined herein. The luminaire may further comprise one or more of a housing element, an optical element, and a louvre. The lamp or luminaire may comprise a light window in the housing (i.e., the first housing and the second housing) or a housing opening, through which the light source light may escape from the first housing and second housing. In yet a further aspect, the invention also provides a projection device comprising the device as defined herein. Especially, a projection device or “projector” or “image projector” may be an optical device that projects an image (or moving images) onto a surface, such as a projection screen. In an aspect the invention also provides a lighting device selected from the group of a lamp, a luminaire, a projector device, a disinfection device, a photochemical reactor, an automotive lighting device, and an optical wireless communication device, comprising the device as defined herein. The lighting device may comprise a carrier, configured to house or support, one or more elements of the device.

BRIEF DESCRIPTION OF THE DRAWINGS

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:

Fig. la-lc schematically depict some general aspects of a 3D printer and of a 3D printed material;

Figs. 2a-2g schematically depict some general aspects of the device 1000; and Fig. 3 schematically depicts an application.

The schematic drawings are not necessarily to scale.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Fig. la schematically depicts some aspects of the 3D printer. Reference 800 indicates a 3D printer. Reference 830 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 801 indicates the printer head. The 3D printer of the present invention may especially include a plurality of printer heads (see below). Reference 802 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).

Instead of a filament also pellets may be used as 3D printable material. Both can be extruded via the printer nozzle.

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 601, 701).

The 3D printer 800 may be configured to 3D print a 3D item 1, wherein the 3D item 1 may be one or more of the 3D printed first part 600 and the 3D printed second part 700. 3D item 1 may also be any part that may be produced by means of 3D printing method (described further below) The 3D printer 800 is configured to generate a 3D item 1 by layer-wise depositing on a receiver item 850, which may at least temporarily be cooled, a plurality of layers 322 wherein each layer 322 comprises 3D printable material 601, 701, such as having a melting point T_m. The 3D printable material 601, 701 may be deposited on a substrate 1550 (during the printing stage). By deposition, the 3D printable material 601, 701 has become 3D printed material 602, 702. 3D printable material 601, 701 escaping from the nozzle 802 is also indicated as extrudate 321.

The 3D printer 800 may be configured to heat the filament 320 material upstream of the printer nozzle 802. This may be done with a device comprising one or more of an extrusion and/or heating function. Such device is indicated with reference 873 and is arranged upstream from the printer nozzle 802 (i.e. in time before the filament material leaves the printer nozzle 802). The printer head 801 may (thus) include a liquefier or heater. Reference 601, 701 indicates printable material. When deposited, this material is indicated as (3D) printed material, which is indicated with reference 602, 702.

Reference 872 indicates a spool or roller with material, especially in the form of a wire, which may be indicated as filament 320. The 3D printer 800 transforms this into 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 802 is reduced relative to the diameter of the filament 322 upstream of the printer head 801. Hence, the printer nozzle is sometimes (also) indicated as extruder nozzle. Arranging layer 322 by layer 322 and/or layer 322 on layer 322, a 3D item 1 may be formed. Reference 875 indicates the filament providing device, which here amongst others include the spool or roller and the driver wheels, indicated with reference 876.

Reference Ax indicates a longitudinal axis (especially of a layer (or filament) or filament axis (in the case of a filament). A length of a layer 322 may be determined along its longitudinal axis Ax.

Reference 300 schematically depicts a control system. The control system may be configured to control the 3D printer 800. The control system 800 may be comprised or functionally coupled to the 3D printer 800. The control system 300 may further comprise or be functionally coupled to a temperature control system configured to control the temperature of the receiver item 850 and/or of the printer head 801. Such temperature control system may include a heater which is able to heat the receiver item 850 to at least a temperature of 50 °C, but especially up to a range of about 350 °C, such as at least 200 °C. Fig. lb 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 be the case.

Reference H indicates the height of a layer and W indicates the width of a layer. 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). Fig. lb schematically depicts six stacks of each four layers. Hence, Figs, la-lc 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, la-lc, 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.

Fig. 1c schematically depicts a stack of 3D printed layers 322, each having a layer height H and a layer width W. Note that 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).

Referring to Figs, la-lc, 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.

In a further aspect, the invention provides a 3D printing method or method for producing the 3D printed item 1 (i.e., the 3D printed first part 600 and the 3D printed second part 700) using the 3D printer 800 described herein. Hence, the invention may provide a method for producing the device 1000. Especially, the method may comprise a 3D printing stage comprising layer-wise depositing (an extrudate 321 comprising) 3D printable material 601, 701, to provide the first housing 500 comprising a plurality of layers 322 of 3D printed material 602,702.

Further, the 3D printing method may comprise providing the 3D printed first part 600 and the 3D printed second part 700. Hence, the 3D printing method may especially provide the first housing 500. Further, the 3D printing method may provide the 3D printed first part 600 comprising a first engagement structure 610. Additionally, the 3D printing method may provide the 3D printed second part 700 comprising the second engagement structure 720. The method may comprise providing a break-away connection 650 to allow detachment of the 3D printed first part 600 and the 3D printed second part 700. Especially, the first engagement structure 610 and the second engagement structure 720 may be associated via the break-away connection 650.

Note that the electronic device 1010 comprised by the device 1000 may especially be positioned within the first housing 500 prior to completing the 3D printing of the 3D printed second part 700. For instance, a part of the 3D printed second part 720 may be 3D printed, following which the electronic device 1010 may be positioned within the partially completed first housing 500. Subsequently, the remainder of the 3D printed second part 700 may be 3D printed. This may provide access to the first housing 500 to position or configure the electronic device 1010 within.

Hence, the method comprises 3D printing at least part of the 3D printed second part 700, positioning the electronic device 1010, 3D printing a remaining part of the 3D printed second part 700 in case the 3D printed second part 700 was not completely 3D printed before positioning the electronic device 1010, and 3D printing the second part 700, whereby the 3D printed first part 600 and the 3D printed second part 700 are associated via a break-away connection 650.

As mentioned above, the 3D printed first part 600 and the 3D printed second part 700 may especially be separated at the break-away connection 650. The method may comprise 3D printing a third 3D printable material 656 to provide a 3D printed connection part 655 between the 3D printed first part 600 and the 3D printed second part 700. Especially, the 3D printed connection part 655 may be configured to provide the break-away connection 650 to allow detachment of the 3D printed first part 600 and the 3D printed second part 700 from each other.

In a further aspect, the invention also provides a software product when running on a computer may be capable of bringing about the method as described herein.

Figs. 2a-2g schematically depict some aspects of the device 1000. First some general aspects of the device 1000 are described followed by some specific aspects of the device 1000.

The invention provides a device 1000 comprising a housing that can be reconfigured from a first housing 500 to a second housing 550, each of the first housing 500 and the second housing 550 hosting an electronic device 1010. Especially, the first housing 500 and/or the second housing 550 may be configured to protect the electronic device 1010 against the ingress of dust and/or water. Especially, the first housing 500 may comprise a 3D printed first part 600 further comprising a first 3D printed material 602. Further, the first housing 500 may comprise a 3D printed second part 700 further comprising second 3D printed material 702. Especially, the first 3D printed material 602 may have a different material from the second 3D printed material 702. Alternatively, the first 3D printed material 602 and the second 3D printed material 702 may (also) comprise the same 3D printed material. The 3D printed first part 600 may comprise a first engagement structure 610. Analogously, the 3D printed second part 700 may comprise a second engagement structure 720. Especially, the 3D printed first part 600 and the 3D printed second part 700 may be associated via a break-away connection 650 to allow detachment of the 3D printed first part 600 and the 3D printed second part 700 from each other.

Further, the 3D printed first part 600, the 3D printed second part 700, and the break-away connection 650 may be configured such that after detachment of the 3D printed first part 600 and the 3D printed second part 700 from each other, the 3D printed first part 600 and the 3D printed second part 700 are configurable into a second housing 550. Especially, the second housing 550 may be formed by associating the 3D printed first part 600 and the 3D printed second part 700 via the first engagement structure 610 and the second engagement structure 720. For instance, this may be facilitated by means of the pin-hole type or screw-connection type connection between the first engagement structure 610 and the second engagement structure 720.

The break-away connection 650 may especially be a 3D printed break-away connection 650.

Hence, the 3D printed break-away connection 650 may be associated with one or more of the first engagement structure 610 and the second engagement structure 720. Note that the first 3D printed material 602 and the second 3D printed material 702 may comprise the same material. Furthermore, the 3D printed break-away connection 650 may comprise a third 3D printed material 603. The third 3D printed material 603 may comprise the same material as the first 3D printed material 602 and the second 3D printed material 702. Alternatively, the first 3D printed material 602 may differ from the second 3D printed material 702. The third 3D printed material 603 may differ from both the first 3D printed material 602 and the second 3D printed material 702.

The electronic device 1010 may comprise a light source 10 configured to provide light source light 11. Further, one or more of the first 3D printed material 602 and the second 3D printed material 702 may comprise a light transmissive material that is transmissive for the light source light 11. Especially, the light source 10 may comprise a solid state light source. Hence, in a further aspect, the invention provides a lighting device 2000 comprising the device 1000.

In relation to detachment and reconfiguration of the 3D printed first part 600 and the 3D printed second part 700, the invention may provide a method for reconfiguring the device. In a further aspect, the invention provides a method for reconfiguring the device, especially for reconfiguring the first housing to the second housing comprising: detaching the 3D printed first part 600 and the 3D printed second part 700 (of the first housing 500 enclosing an electronic device 1010) from each other, and configuring the 3D printed first part 600 and the 3D printed second part 700 such that the second housing 550 is formed.

Separating the 3D printed first part 600 and the 3D printed second part 700 may provide access to the space within the first housing 500 (which houses the electronic device 1010). Hence, (at least a part of) the electronic device 1010 may be replaced, or modified, or upgraded after the separation of the 3D printed first part 600 and the 3D printed second part 700. Following which, the 3D printed first part 600 and the 3D printed second part 700 may be associated to provide the second housing 550 which (again) provides protection from ingress of pollutants or foreign matter from the environment such as dust and/or water. The method for reconfiguring the device comprises replacing at least part of the electronic device 1010 with a replacement part after detaching the 3D printed first part 600 and the 3D printed second part 700 of the first housing 500 and before forming the second housing 550. Note that the method for reconfiguring the device may especially also comprise replacing the entire electronic device 1010 before forming the second housing 550.

Hence, in a further aspect, the invention provides a second device 1200 comprising the second housing 550 (hosting the electronic device 1010) and configured to protect the electronic device 1010 for ingress of dust and/or water) obtainable with the method for reconfiguring the device described herein.

Figs. 2a-2g schematically depict three configurations of the device 1000, wherein: (i) the figure (left) depicts the first housing 500 wherein the 3D printed first part 600 and the 3D printed second part 700 are associated by means of the breakaway connection 650, (ii) the figure (middle) depicts the 3D printed first part 600 and the 3D printed second part 700 detached from each other, and (iii) the figure (right) depicts the second housing 550 provided (after detachment) by the reconfiguration of the 3D printed first part 600 and the 3D printed second part 700. Fig. 2a depicts the device 1000, wherein the first engagement structure 610 protrudes (away) from the 3D printed first part 600. Further, in the depiction of Fig. 2a, the 3D printed second part 700 comprises a recess 770. Note that the 3D printed first part 600 may comprise a main first part 620 and the first engagement structure 610. In the depiction of Fig. 2a, the first engagement structure 610 and the main first part 620 form a monolithic structure. The second engagement structure 720 may be configured in the recess 770. The first engagement structure 610 may be associated with or connected to the 3D printed second part 700 (but not yet configured in the recess 770). The 3D printed first part 600 may be detached from the 3D printed second part 700 at the break-away connection 650. Especially, the electronic device 1010 may be accessible following the detachment of the 3D printed first part 600 and the 3D printed second part 700. The 3D printed first part 600 and the 3D printed second part 700 may be reconfigured such that the two (protruding) first engagement structures 610 are received by the two recess 770 (comprising the second engagement structure 720). The recess 770 provides the benefit of accommodating the protruding first engagement structure 610. Hence, upon reconfiguring the 3D printed first part 600 and the 3D printed second part 700 to provide the second housing 550, the 3D printed first part may be configured flush with the 3D printed second part 700 i.e., the two parts may be associated in close physical contact without any gaps which prevents the ingress of dust, smoke, and/or pollutants. Moreover, in this way, the main first part 620 and the 3D printed second part 700 may especially be associated to each other via at least the first engagement structure 610.

Fig. 2b depicts the device 1000, wherein the first engagement structure 610 may comprise a recess 670 and the second engagement structure 720 may protrude (away) from the 3D printed second part 700. The first engagement structure 610 may be associated or connected to the 3D printed second part 700 (but not yet configured in the recess 670). Upon detaching the 3D printed first part 600 and the 3D printed second part 700 from each other, the 3D printed first part 600 may be temporarily associated with the 3D printed second part 700 by configuring one of the two (protruding) second engagement structures 720 in the recess 670 of the 3D printed first part 600. This may safely secure the 3D printed first part 600 when the device is in an open configuration, for instance during the replacement of the electronic device 1010. Especially limiting (or preventing) the accumulation of dust or dirt on the engagement structures 610, 720. Further, the second housing 550 may be provided by configuring both (protruding) second engagement structures 720 in the two recesses 670 of the 3D printed first part 600. Note that the main first part 620 and the 3D printed second part 700 may be associated to each other via at least the second engagement structure 720. Fig. 2c depicts the device 1000, wherein the main first part 620 and the first engagement structure 610 do not form a monolithic body. Especially, the first engagement structure 610 may be configured to move relative to the main first part 620. In the depiction of Fig. 2c, the first engagement structure 610 may translate relative to the main first part 620. Alternatively, the first engagement structure 610 may (also) be configured to bend or rotate relative to the main first part 620.

Note that the first engagement structure 610 and the second engagement structure 720 may not necessarily be 3D printed and may not necessarily be provided monolithic with the 3D printed first part 600 and the 3D printed second part 700, respectively. The first engagement structure 610 and the second engagement structure 720 may also be provided separately and configured in the 3D printed first part 600 and the 3D printed second part 700, respectively, during or after the 3D printing stage.

In the depiction of Fig. 2c, the 3D printed first part has a groove or slot to accommodate the first engagement structure 610. For example, a spring loaded pin may be configured in the said groove or slot. In the first housing 500, the spring loaded pin may not be completely engaged. However, upon detachment and reconfiguration, the said groove or slot may be aligned with a hole to receive the spring loaded pin. This alignment may trigger the translation of the pin (i.e., the first engagement structure 610) into the hole (i.e., the second engagement structure 720) to provide the second housing 550. In this way, the first engagement structure 610 and the second engagement structure 720 may be associated (via a pin-hole type connection) to provide the second housing 550.

The 3D printed first part 600 may be associated via the break-away connection 650 to the 3D printed second part 700. Note that in the depiction of Fig. 2c, the first engagement structure 610 is not yet configured in the recess 770 comprising the second engagement structure 720. The 3D printed first part 600 may especially be detached from the 3D printed second part 700 at the break-away connection 650, providing access to the electronic device 1010. Further, the 3D printed first part 600 and the 3D printed second part 700 may be reconfigured to provide the second housing 550. Especially, the first engagement structure 610 may extend and be configured in the recess 770 comprising the second engagement structure 720. Especially, the 3D printed first part 600 may comprise a leverage mechanism (for example a spring or a lever) to manipulate the first engagement structure 610. Such a leverage mechanism may facilitate a close tolerance fit between the 3D printed first part 600 and the 3D printed second part 700. Thus, preventing the ingress of dust, dirt, and pollutants. The first engagement structure 610 and the second engagement structure 720 may be configured to provide a pin-hole type connection.

Fig. 2d schematically depicts the device 1000. In the depiction of Fig. 2d, the 3D printed first part 600 is associated to the 3D printed second part 700 to provide the first housing 500. In the configuration depicted, the 3D printed first part 600 and the 3D printed second part 700 may be 3D printed together as part of the same 3D printing process. Following the detachment of the 3D printed first part 600 and the 3D printed second part 700 from each other, the 3D printed first part 600 may be inverted and reconfigured with the 3D printed second part 700 to provide the second housing 550. In the depiction of Fig. 2d, the second engagement structure 720 is arrow-shaped and the first engagement structure 610 comprises a lip that may be configured over part of the arrow-shaped end of the second engagement structure 720. The arrow-shaped second engagement structure may facilitate the ease of sliding the 3D printed first part 600 towards the 3D printed second part 700. Thus, locking or securing the 3D printed first part 600 to the 3D printed second part 700. Especially, the first engagement structure 610 may be relatively thin and may be flexible. Furthermore, during the application of the method for reconfiguring the device, the first engagement structure 610 may especially undergo elastic deformation when associated with the second engagement structure 720.

Fig. 2e schematically depicts the device 1000. In this depiction, analogous to the depiction of Fig. 2d, the 3D printed first part 600 may be detached, inverted, and reconfigured with the 3D printed second part 700 to provide the second housing 550. In this depiction, the 3D printed first part 600 and the 3D printed second part 700 may be 3D printed together as part of the same 3D printing process. At least part of the 3D printed first part 600 and/or the 3D printed second part 700 may be flexible. In the depiction of Fig. 2e, the 3D printed first part 600 may be pushed against the 3D printed second part 700. Especially, the first engagement structure 610 may undergo (elastic) deformation when being associated with the second engagement structure 720. Especially, the first engagement structure 610 may comprise a shape that may fit in the recess 770. In the depiction of Fig. 2e, the 3D printed second part 700 has an opening with a tapering end. This facilitates the ease of reconfiguring the 3D printed first part 600 and the 3D printed second part 700 to provide the second housing 550.

Fig. 2f schematically depicts the device 1000, wherein the device 1000 comprises a 3D printed break-away connection 650. Especially, the 3D printed connection part 655 may be configured to provide the break-away connection 650 to allow detachment of the 3D printed first part 600 and the 3D printed second part 700 from each other. The 3D printed break-away connection 650 may either be (i) structurally weak, or (ii) comprise a 3D printed material that may have a low adhesive strength to the 3D printed first part 600 and/or the 3D printed second part 700. Thus, the break-away connection 650 may facilitate the ease of detachment of the 3D printed first part 600 and the 3D printed second part 700. In the depiction of Fig. 2f, 3D printed first part 600 comprises a (protruding) first engagement structure 610 and the 3D printed second part 700 comprises the second engagement structure 720 (comprised by the recess 770). Furthermore, the first engagement structure 610 may be connected to the second engagement structure 720 via the 3D printed break-away connection 650. Upon detachment, the 3D printed break-away connection 650 is separated (and removed) from the 3D printed first part 600 and the 3D printed second part 700. Subsequently, the first engagement structure 610 may be configured in the recess 770 of the second engagement structure 720 to provide the second housing 550.

Fig. 2g schematically depicts the device 1000, wherein the device 1000 comprises a 3D printed break-away connection 650. Especially, the 3D printed break-away connection 650 may be configured in the recess 770 (comprised by the second engagement structure 720). Analogous to the depiction of Fig. 2f, the 3D printed break-away connection 650 may be separated and removed upon detachment. Subsequently, the first engagement structure 610 may be configured at least partly in the recess 770 to provide the second housing 550. In this way, the first housing 500 may be provided such that the first engagement structure 610 is at least partly configured in the recess 770. This limits the access to the interior of the first housing 500. Thus, protecting the electronic device 1010 from exposure to dust, dirt, and/or pollutants.

Fig. 3 schematically depicts the lighting device 2000. Especially, the lighting device 2000 may be configured as a lamp or luminaire. The lighting device 2000 may especially comprise an optical element 2 and the device 1000. Especially, the device 1000 may comprise the light source 10 and hence, may provide light source light 11. The optical element 2 (the half sphere in the cross-sectional view) may be selected from the group of a shade, a reflector, and a lens. Especially, the optical element 2 may be configured to beam shape the light source light 11. One or more of the first 3D printable material 601 and the second 3D printable material 701 may comprise a light transmissive material that is transmissive for the light source light 11.

The term “plurality” refers to two or more. 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”, or “all”. 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 %. The term “comprise” also includes embodiments wherein the term “comprises” means “consists of’. 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”.

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.

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.

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.

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

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”.

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

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.

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.

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.

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.

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_g or T_m of the material(s).

Claims

CLAIMS:

1. A device (1000) comprising a housing that can be reconfigured from a first housing (500) to a second housing (550), each of the first housing (500) and the second housing (550) hosting an electronic device (1010), and being configured to protect the electronic device (1010) against ingress of dust and/or water, wherein: the first housing (500) is a 3D printed monolithic housing comprising (i) a 3D printed first part (600) comprising a first 3D printed material (602) and (ii) a 3D printed second part (700) comprising second 3D printed material (702); wherein the 3D printed first part (600) comprises a first engagement structure (610) and the 3D printed second part (700) comprises a second engagement structure (720); wherein the 3D printed first part (600) and the 3D printed second part (700) are associated via a break-away connection (650) to allow detachment of the 3D printed first part (600) and the 3D printed second part (700) from each other; and the 3D printed first part (600), the 3D printed second part (700), and the breakaway connection (650) are configured such that after detachment of the 3D printed first part (600) and the 3D printed second part (700) from each other, the 3D printed first part (600) and the 3D printed second part (700) are configurable into the second housing (550) by associating the 3D printed first part (600) and the 3D printed second part (700) via the first engagement structure (610) and the second engagement structure (720).

2. The device (1000) according to claim 1, wherein the electronic device (1010) comprises a light source (10) configured to provide light source light (11); wherein one or more of the first 3D printed material (602) and the second 3D printed material (702) comprise a light transmissive material that is transmissive for the light source light (11); and wherein the first engagement structure (610) and the second engagement structure (720) are configured to provide a pin-hole type or screw-connection type connection when configured as second housing (550).

3. The device (1000) according to any one of the preceding claims, wherein the first 3D printed material (602) differs from the second 3D printed material (702).

4. The device (1000) according to any one of the preceding claims, further comprising a 3D printed connection part (655), wherein the 3D printed connection part (655) is configured to provide the break-away connection (650).

5. The device (1000) according to claim 4, wherein the 3D printed connection part (655) comprises a third 3D printed material (603), wherein the third 3D printed material (603) differs from one or more of the first 3D printed material (602) and the second 3D printed material (702).

6. The device (1000) according to any one of the preceding claims, wherein the 3D printed first part (600) comprises a main first part (620) and the first engagement structure (610), wherein the main first part (620) and the 3D printed second part (700) are associated to each other via at least the first engagement structure (610) or at least the second engagement structure (720).

7. The device (1000) according to claim 6, wherein the first engagement structure (610) and the main first part (620) form a monolithic body.

8. The device (1000) according to any one of the preceding claims, wherein one or more of the 3D printed first part (600) and the 3D printed second part (700) comprise a recess (670,770), wherein the break-away connection (650) is at least partly configured in the recess (670,770).

9. The device (1000) according to any one of the preceding claims, wherein the first housing (500) forms a hermetic seal for the electronic device (1010).

10. A lighting device (2000) comprising the device (1000) according to any one of the preceding claims, comprising one or more electronic devices (1010), wherein the one or more electronic devices (1010) are selected from the group comprising a light source (10), a driver for a light source (10), a controller for a light source (10), an antenna for a light source (10), and a sensor for a light source (10).

11. A method for producing the device 1000 according to any one of the preceding claims 1-9; wherein the method comprises a 3D printing stage comprising layer-wise depositing 3D printable material (601,701), to provide the first housing (500) comprising a plurality of layers (322) of 3D printed material (602,702).

12. The method according to claim 11, comprising 3D printing at least part of the 3D printed second part (700), positioning the electronic device (1010), 3D printing a remaining part of the 3D printed second part (700) in case the 3D printed second part (700) was not completely 3D printed before positioning the electronic device (1010), and 3D printing the second part (700), whereby the 3D printed first part (600) and the 3D printed second part (700) are associated via a break-away connection (650).

13. The method according to any one of claims 11-12, wherein the method comprises 3D printing a third 3D printable material (656) to provide a 3D printed connection part (655) between the 3D printed first part (600) and the 3D printed second part (700), wherein the 3D printed connection part (655) is configured to provide the break-away connection (650).

14. A method for reconfiguring the device (1000) according to any one of the preceding claims 1-9, comprising: detaching the 3D printed first part (600) and the 3D printed second part (700) of the first housing (500), enclosing the electronic device (1010), from each other, and configuring the 3D printed first part (600) and the 3D printed second part (700) such that the second housing (550) is formed.

15. The method for reconfiguring the device (1000) according to claim 14, further comprising replacing at least part of the electronic device (1010) with a replacement part after detaching the 3D printed first part (600) and the 3D printed second part (700) of the first housing (500) and before forming the second housing (550).