Reinforcement system for additive manufacturing, devices and methods using the same

• US 10,369,742 B2
• Filed: 12/28/2015
• Issued: 08/06/2019
• Est. Priority Date: 12/28/2015
• Status: Active Grant

• Current Assignee: Southwest Research Institute
• Original Assignee: Southwest Research Institute
• Inventors: Scribner, Cliff James, Parvin, Jr., Albert Joseph, Barnette, Darrel Ray
• Primary Examiner(s): Del Sole, Joseph S
• Assistant Examiner(s): Leyson, Joseph S
• Application Number:
  US14/981,014
• Publication Number:
  US 20170182712A1
• Time in Patent Office: 1,317 Days
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B29C 64/188 involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• CPC Class Codes: B29C 64/194 during lay-up
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/264 Arrangements for irradiation
• CPC Class Codes: B29C 64/268 using laser beams; using electron beams [EB]
• CPC Class Codes: B29C 64/295 Heating elements
• CPC Class Codes: B29C 64/336 of two or more materials
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29C 70/00 Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 40/00 Auxiliary operations or equipment, e.g. for material handling

Abstract

Reinforcement systems for additive manufacturing are disclosed. In some embodiments, the reinforcement systems include a print head assembly including a print head that is configured to form a plurality of layers of an additively manufactured article, and a reinforcement head. The reinforcement head may be configured to form at least one reinforcement element on or within a working layer of the plurality of layers formed by the print head. Additive manufacturing systems including such reinforcement systems and methods of additive manufacturing using those reinforcement systems are also disclosed.

Claims

1. A print head assembly for additive manufacturing, comprising:

a print head configured to deposit a plurality of layers during the production of an additively manufactured article; and

a reinforcement head configured to form at least one reinforcement element on or within a working layer of said plurality of layers;

wherein;

said at least one reinforcement element comprises a reinforcement structure;

said reinforcement head comprises;

a housing comprising an opening; and

a biasing member;

the biasing member is movable between a retracted position and an extended position;

in the retracted position the biasing member is disposed within said housing; and

in the extended position at least a portion of the biasing member extends out of the opening and is at least partially inserted into the working layer to form said at least one reinforcement element.

2. The print head assembly of claim 1, wherein said reinforcement element is configured such that the coupling of said working layer and another layer of said plurality of layers is enhanced over the coupling between an identical working and said other layer in the absence of said at least one reinforcement element.

3. The print head assembly of claim 1, wherein the reinforcement structure is selected from the group consisting of one or more channels, dimples, holes, grooves, moats, ridges, slots, cross hatched features, or a combination thereof.

4. The print head assembly of claim 1, wherein said at least one reinforcement element comprises a plurality of holes, a plurality of grooves, or a combination thereof.

5. The print head assembly of claim 1, further comprising a solvent store configured to coat the surface of the biasing member with a solvent prior to insertion of the biasing member into the working layer.

6. The print head assembly of claim 1, further comprising a heating element configured to raise a temperature of the biasing member above a glass transition temperature of a material forming said working layer.

7. The print head assembly of claim 1, wherein said reinforcement head comprises:

a housing comprising an opening; and

a

a directed energy source;

wherein;

the directed energy source is configured to emit directed energy through said opening to impinge on said working layer, so as to form said at least on reinforcement element.

8. The print head assembly of claim 7, wherein said directed energy source is selected from the group consisting of:

a light source, a radio frequency transmitter, a microwave transmitter, or a combination thereof.

17. The print head assembly of claim 1, wherein said reinforcement head is coupled to said print head such that said print head and said reinforcement head move in tandem in a machine direction during a formation of said working layer.

18. The print head assembly of claim 1, wherein said reinforcement head and said print head are independently moveable, relative to one another.

9. A print head assembly for additive manufacturing, comprising:

a print head configured to deposit a plurality of layers during the production of an additively manufactured article; and

a reinforcement head configured to form at least one reinforcement element on or within a working layer of said plurality of layers;

wherein;

said at least one reinforcement element comprises at least one reinforcement article;

said reinforcement head comprises;

a housing comprising an opening; and

a biasing member within the housing;

the housing is configured to receive said reinforcement article from a reinforcement store;

the biasing member is movable between a retracted position and an extended position;

in the retracted position the biasing member is disposed within said housing;

in the extended position at least a portion of the biasing member biases at least a portion of the reinforcement article towards a surface of the working layer.

10. The print head assembly of claim 9, wherein said at least one reinforcement article has a shape selected from group consisting of a jack, a tetrapod, a sphere, a rod, an elongated article, or a combination thereof.

11. The print head assembly of claim 9, wherein said at least one reinforcement article comprises an elongated article.

12. The print head assembly of claim 11, wherein in the extended position, at least a portion of the biasing member pierces the surface of the working layer so as to embed at least a portion of the reinforcement article therein.

13. The print head assembly of claim 11, wherein the biasing member is configured to sew the reinforcement article into the working layer.

14. The print head assembly of claim 12, wherein the biasing member is configured to sew the reinforcement article into the working layer such that at least a portion of the reinforcement article forms a loop above or below the surface of the working layer.

15. A print head assembly for additive manufacturing, comprising:

a print head configured to deposit a plurality of layers during the production of an additively manufactured article; and

a reinforcement head configured to form at least one reinforcement element on or within a working layer of said plurality of layers;

wherein;

said at least one reinforcement element comprises at least one discrete reinforcing article;

said reinforcement head comprises;

a housing comprising an opening; and

an install member within the housing, the install member comprising an install surface proximate to said opening;

the install member is movable between upper and lower positions within said housing;

the install member is configured such that when it is moved from said upper position to said lower position, said install surface contacts said at least one discrete reinforcing article to drive the at least one discrete reinforcing article out of said opening, such that at least a portion of the at least one discrete reinforcing article is embedded into a surface of the working layer.

16. The print head assembly of claim 15, wherein said at least one discrete reinforcing article is in the form of a post.