System for feeding filament to a nozzle in an additive manufacturing machine

• US 10,449,719 B2
• Filed: 12/01/2017
• Issued: 10/22/2019
• Est. Priority Date: 12/01/2017
• Status: Active Grant

• Current Assignee: Bulent Besim, Stephen Weatherly
• Original Assignee: Bulent Besim, Stephen Weatherly
• Inventors: Besim, Bulent, Weatherly, Stephen
• Primary Examiner(s): Bhat, Nina
• Application Number:
  US15/828,439
• Publication Number:
  US 20190168455A1
• Time in Patent Office: 690 Days
• Field of Search: 4251335
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/321 Feeding
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• 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
• CPC Class Codes: B33Y 40/10 Pre-treatment

Abstract

A system for feeding filament to a nozzle in an additive manufacturing machine is provided. A filament extrusion assembly is configured to extrude the filament from a spool. A nozzle holder comprises a protruded portion. The nozzle holder defines a through hole which extends into the protruded portion. The through hole receives the filament extruded by the filament extrusion assembly. The protruded portion is located immediately below a point where the filament exits the filament extrusion assembly. A nozzle assembly comprises a cooling chamber which defines a through hole aligned with the through hole of the nozzle holder. The cooling chamber defines at least one groove coaxial with the through hole of the cooling chamber. The groove receives at least one sealing member wherein the groove is defined where the nozzle holder interfaces with the cooling chamber.

Claims

1. A system for feeding filament to a nozzle in an additive manufacturing machine, the system comprising:

a filament extrusion assembly configured to extrude the filament from a spool;

a nozzle holder comprising a protruded portion, wherein,

the nozzle holder defines a through hole;

the through hole extends into the protruded portion;

the through hole receives the filament extruded by the filament extrusion assembly; and

the protruded portion is located immediately below a point where the filament exits the filament extrusion assembly; and

a nozzle assembly comprising a cooling chamber defining a through hole aligned with the through hole of the nozzle holder, wherein,

the cooling chamber defines at least one groove coaxial with the through hole of the cooling chamber;

the groove receives at least one sealing member; and

the groove is defined where the nozzle holder interfaces with the cooling chamber.

2. The system of claim 1, wherein the filament extrusion assembly comprises a pusher arm, a bearing, a gear and a tension spring, wherein, the pusher arm is pivotably mounted to interface the tension spring and the bearing such that the pusher arm pushes the bearing against the gear.

3. The system of claim 2, wherein the pusher arm defines a through hole, which is in alignment with the through hole of the nozzle holder, for the filament to be fed between the gear and the bearing.

4. The system of claim 2, further comprising a threaded stud interfacing with the tension spring, wherein the threaded stud is operable to adjust tension in the tension spring.

5. The system of claim 1, wherein the groove on the cooling chamber is defined such that its diameter is larger than the through hole defined by the cooling chamber.

6. The system of claim 5, wherein the groove is bored into the cooling chamber to a predefined depth to accommodate the sealing member.

7. The system of claim 1, wherein the sealing member is made of a flexible elastic material.

8. The system of claim 7, wherein the sealing member is an O-ring seal.

9. The system of claim 1, wherein the cooling chamber comprises at least a plurality of fins to dissipate heat.

10. The system of claim 1, wherein the cooling chamber defines at least a plurality of openings for cool fluid to circulate through the cooling chamber.

11. The system of claim 10, wherein the cooling chamber is engaged to a plurality of cooling ducts, wherein,

the cooling ducts are affixed to the plurality of openings;

and

the cooling ducts circulate cool fluid between a cooling mechanism and the cooling chamber.

12. The system in claim 1, wherein the filament extrusion assembly, the nozzle holder, the sealing member and the nozzle assembly are aligned and arranged in a way such that an air tight path is formed, from a point where the filament exits the filament extrusion assembly to a point where the filament exits the nozzle through a nozzle tip, for the filament to pass through.

13. The system in claim 12, wherein the filament extrusion assembly, the nozzle holder, the sealing member and the nozzle assembly alignment is configured in a way to maintain a constant tension in the filament.

14. The system of claim 1, wherein the nozzle assembly comprises a nozzle cap provided around a nozzle.

15. The system of claim 14, wherein the nozzle cap surrounds the nozzle assembly below the cooling chamber.

16. The system of claim 1, further comprising an exhaust fan, wherein the exhaust fan for cooling the cooling chamber.

17. The system of claim 1, wherein the system is engaged to a first tower, wherein the first tower is configured to traverse along a first axis, thereby enabling the system to traverse along the first axis.

18. The system of claim 17, wherein the first tower is configured to traverse along a second axis, the second axis being perpendicular to the first axis, thereby enabling the system to traverse along the second axis.

19. The system of claim 1, wherein the nozzle assembly comprises a nozzle and a filament tube, wherein the wherein the filament passes through the filament tube to reach the nozzle, wherein the filament is heated and melted in the nozzle, wherein at least a part of the filament tube is received by the cooling chamber and at least another part of the filament tube interfaces with the nozzle.

20. The system of claim 19, the filament tube has lower thermal conductivity compared to the nozzle, and the cooling chamber has higher thermal conductivity compared to the filament tube.