Print head for additive manufacturing system

• US 10,589,463 B2
• Filed: 04/24/2018
• Issued: 03/17/2020
• Est. Priority Date: 06/29/2017
• Status: Active Grant

• Current Assignee: Continuous Composites Inc.
• Original Assignee: Continuous Composites Inc.
• Inventors: Stockett, Ryan C., Tyler, Kenneth Lyle
• Primary Examiner(s): Wilson, Michael H.
• Assistant Examiner(s): Kessie, Jennifer A
• Application Number:
  US15/961,084
• Publication Number:
  US 20190001562A1
• Time in Patent Office: 693 Days
• CPC Class Codes: B22F 10/00 Additive manufacturing of workpieces or articles from metallic powder apparatus or devices therefor B22F12/00
• CPC Class Codes: B22F 10/25 Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• CPC Class Codes: B22F 12/22 Driving means
• CPC Class Codes: B22F 12/53 Nozzles
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 2035/0833 using actinic light
• CPC Class Codes: B29C 2035/0838 using laser
• CPC Class Codes: B29C 2035/0855 using microwave
• CPC Class Codes: B29C 2035/0877 using electron radiation, e.g. beta-rays
• CPC Class Codes: B29C 35/0261 using ultrasonic or sonic vibrations
• CPC Class Codes: B29C 35/0805 using electromagnetic radiation
• CPC Class Codes: B29C 48/15 incorporating preformed parts or layers, e.g. extrusion moulding around inserts
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• 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 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/218 Rollers
• CPC Class Codes: B29C 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/255 Enclosures for the building material, e.g. powder containers
• CPC Class Codes: B29C 64/291 for operating globally, e.g. together with selectively applied activators or inhibitors
• CPC Class Codes: B29C 64/295 : Heating elements
• CPC Class Codes: B29C 64/336 : of two or more materials
• CPC Class Codes: B29C 64/393 : for controlling or regulating additive manufacturing processes
• 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 70/06 : Fibrous reinforcements only
• CPC Class Codes: B29C 70/16 : using fibres of substantial or continuous length non-woven fabrics per se D04H3/00
• CPC Class Codes: B29C 70/24 : oriented in at least three directions forming a three dimensional structure
• CPC Class Codes: B29C 70/384 : Fiber placement heads, e.g. component parts, details or accessories
• CPC Class Codes: B29C 70/50 : for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
• CPC Class Codes: B29C 70/523 : and impregnating the reinforcement in the die
• CPC Class Codes: B29K 2101/10 : Thermosetting resins
• CPC Class Codes: B29K 2105/08 : of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
• CPC Class Codes: B29K 2105/251 : Particles, powder or granules expandable particles B29K2105/046
• 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 50/02 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 70/00 : Materials specially adapted for additive manufacturing
• CPC Class Codes: F16L 9/128 : Reinforced pipes
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

A print head is disclosed for use with an additive manufacturing system. The print head may include a nozzle, and a traveling anchor point mounted at a trailing side of the nozzle. The traveling anchor point may include an arm extending radially outward from the nozzle, and a plunger slidingly disposed in the arm. The traveling anchor point may also include an actuator configured to selectively move the plunger from a stowed position to an engaged position against material discharging from the nozzle.

Claims

1. A print head for an additive manufacturing system, comprising:

a nozzle configured to discharge a material; and

a traveling anchor point mounted at a trailing side of the nozzle and configured to selectively tack an end of the material as an anchor for discharge from the nozzle, the traveling anchor point including;

an arm extending radially outward from the nozzle;

a plunger slidingly disposed in the arm; and

an actuator configured to selectively move the plunger from a stowed position to an engaged position against the material discharging from the nozzle.

2. The print head of claim 1, further including a bushing connecting the plunger to the arm.

3. The print head of claim 2, wherein:

the bushing is moveable along a length of the arm during travel of the nozzle away from the plunger; and

the plunger is configured to maintain engagement with the material during movement of the bushing.

4. The print head of claim 3, further including a mechanized device configured to move the bushing relative to the arm.

5. The print head of claim 4, wherein the mechanized device is one of a rack-and-pinion and a lead screw.

6. The print head of claim 1, wherein the actuator is an electric solenoid.

7. The print head of claim 1, further including a spring configured to return the plunger to the stowed position.

8. The print head of claim 1, wherein the plunger includes:

a pin; and

a roller operatively connected to an end of the pin.

9. The print head of claim 1, further including a cure enhancer mounted to a side of the arm, between the nozzle and the plunger.

10. The print head of claim 9, wherein the cure enhancer is a UV light.

11. The print head of claim 1, wherein the arm is connected to pivot around the nozzle.

12. The print head of claim 1, wherein:

a base end of the arm is disposed within a channel that surrounds the nozzle; and

the print head further includes a rotary actuator configured to move the base end of the arm.

13. A print head for an additive manufacturing system, comprising:

a nozzle configured to discharge a material;

a traveling anchor point mounted at a trailing side of the nozzle and configured to selectively tack an end of the material as an anchor, the traveling anchor point including;

an arm extending radially outward from the nozzle;

a bushing mounted to move along a length of the arm during tacking of the end of the material;

a plunger mounted to slide through the bushing; and

an actuator configured to selectively move the plunger from a stowed position to an engaged position against the material discharging from the nozzle; and

a cure enhancer mounted to the arm between the nozzle and the plunger,

wherein the plunger maintains engagement with the material during movement of the bushing along the length of the arm.

14. The print head of claim 13, further including a spring configured to return the plunger to the stowed position.

15. The print head of claim 13, wherein the plunger includes:

a pin; and

a roller operatively connected to an end of the pin.

16. The print head of claim 13, wherein the cure enhancer is a UV light.

17. The print head of claim 13, wherein:

a base end of the arm is disposed within a channel that surrounds the nozzle; and

the print head further includes a rotary actuator configured to move the base end of the arm.

18. An additive manufacturing system, comprising:

a moveable support;

a print head connected to the moveable support and configured to discharge a continuous reinforcement that is wetted with a liquid matrix, the print head including;

a matrix reservoir;

a nozzle fluidly connected to the matrix reservoir;

an arm extending radially outward from the nozzle;

a bushing mounted to move along a length of the arm;

a plunger mounted to slide through the bushing and configured to tack the continuous reinforcement for use as an anchor during pulling of the continuous reinforcement through the matrix reservoir and from the nozzle;

an actuator configured to selectively move the plunger from a stowed position to an engaged position against the continuous reinforcement discharging from the nozzle; and

a UV light mounted to the arm between the nozzle and the plunger; and

a controller configured to regulate operation of the moveable support, the actuator, and the UV light.

19. The additive manufacturing system of claim 18, wherein the print head further includes a spring configured to return the plunger to the stowed position.

20. The print head of claim 18, wherein the plunger includes:

a pin; and

a roller operatively connected to an end of the pin,

wherein the roller maintains engagement with the material during movement of the nozzle away from the roller.