Filament loading system in an extrusion apparatus

• US 20040126452A1
• Filed: 12/15/2003
• Published: 07/01/2004
• Est. Priority Date: 06/23/1999
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: Hopkins, Paul E., Swanson, William J., Popa, Mihnea A., Turley, Patrick W., Hahn, Andrew M., Kimm, Daniel I., Pollard, David L., Brose, Steve
• Granted Patent: US 6,923,634 B2
• Time in Patent Office: Days
• US Class Current: 425/73
• CPC Class Codes: B29C 2071/022 Annealing
• CPC Class Codes: B29C 2791/005 Using a particular environment, e.g. sterile fluids other than air
• CPC Class Codes: B29C 31/04 Feeding of the material to be moulded, e.g. into a mould cavity B29C39/08 takes precedence; using a material distribution system to two or more fixed injection moulds B29C45/125
• CPC Class Codes: B29C 41/36 Feeding the material on to the mould, core or other substrate
• CPC Class Codes: B29C 41/52 Measuring, controlling or regulating
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• 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 71/02 Thermal after-treatment B29C71/0063 and B29C71/0072 take precedence
• CPC Class Codes: B29K 2055/02 ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
• 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 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: C08K 5/0016 Plasticisers
• CPC Class Codes: C08L 33/02 Homopolymers or copolymers of acids; Metal or ammonium salts thereof
• CPC Class Codes: G05B 2219/49019 Machine 3-D slices, to build 3-D model, stratified object manufacturing SOM
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

An apparatus which extrudes flowable material from a liquifier includes a system for loading filament supplied in a cassette. The cassette is loaded into a loading bay of the apparatus. A strand of filament from the cassette is engaged and advanced along a path to the liquifier using a drive wheel or roller pair. A conduit having an entrance in the loading bay guides the filament as it is advanced. The filament loading system of the present invention provides a convenient manner of loading and unloading filament in a three-dimensional modeling machine, and can be implemented in a manner that protects the filament from environmental moisture.

Claims

1. An extrusion apparatus having a liquifier that receives a feedstock of material in filament form and delivers the material in a flowable state, comprising:

a loading bay;

a substantially enclosed cassette containing spooled filament, inserted in the loading bay; and

means for engaging a strand of the filament in the loading bay and advancing the filament strand along a path to the liquifier.

2. The extrusion apparatus of claim 1, and further comprising:

a conduit having an entrance in the loading bay for guiding the filament strand as it is advanced.

3. The extrusion apparatus of claim 2, wherein the entrance of the conduit makes an airtight seal with an exit orifice of the cassette.

4. The extrusion apparatus of claim 2, and further comprising:

registration means for aligning the cassette with the conduit.

5. A three-dimensional modeling machine having a liquifier that receives modeling material in filament form and delivers the material in a flowable state, comprising:

a loading bay for receiving a cassette containing spooled filament;

means for engaging a strand of the filament in the loading bay; and

means for automatically advancing the filament strand along a path to the liquifier.

6. The three-dimensional modeling machine of claim 5, and further comprising:

a conduit having an entrance in the loading bay for guiding the filament strand as it is advanced.

7. The three-dimensional modeling machine of claim 5, and further comprising:

registration means for aligning the cassette with the conduit.

8. The three-dimensional modeling machine of claim 5, and further comprising:

latching means for engaging and disengaging the cassette in the loading bay.

9. The three-dimensional modeling machine of claim 5, and further comprising:

means for ejecting the cassette from the loading bay.

10. A three-dimensional modeling machine having a liquifier that receives modeling material in filament form and delivers the material in a flowable state, comprising:

a loading bay for receiving a cassette containing spooled filament; and

a filament cassette receiver for engaging the cassette in the loading bay, said receiver comprising;

a conduit for receiving a filament strand from the cassette and guiding the filament strand along a path to the liquifier; and

means for advancing the filament strand through the conduit.

11. The three-dimensional modeling machine of claim 10, wherein the means for advancing comprises:

a pair of feed rollers having a nip therebetween for receiving the filament strand; and

a drive mechanism coupled to the feed rollers.

12. The three-dimensional modeling machine of claim 11, wherein the feed rollers are in the conduit.

13. The three-dimensional modeling machine of claim 10, wherein the means for advancing comprises:

a drive wheel configured to mate with a follower wheel on the cassette; and

a drive mechanism coupled to the drive wheel.

14. The three-dimensional modeling machine of claim 13, wherein the filament cassette receiver further comprises:

a drive engagement means for engaging and disengaging the drive wheel.

15. The three-dimensional modeling machine of claim 10, and further comprising:

a sensor for detecting presence of the filament strand at a sensing position of the path approaching the liquifier;

wherein the means for advancing is disabled in response to a detection indication provided by the sensor.

16. The three-dimensional modeling machine of claim 15, and further comprising:

a pair of feed rollers located proximate the sensing position.

17. The three-dimensional modeling machine of claim 10, wherein the filament cassette receiver further comprises:

registration means for aligning an exit orifice of the cassette with an entrance of the conduit.

18. The three-dimensional modeling machine of claim 10, wherein an entrance of the conduit is configured to make an airtight seal with an exit orifice of the cassette.

19. A three-dimensional modeling machine having a liquifier that receives modeling material in filament form and delivers the material in a flowable state, comprising:

a loading bay for receiving a cassette containing spooled filament;

a conduit configured to mate with an exit orifice of the cassette for receiving a filament strand from the cassette and guiding the filament strand along a path to the liquifier; and

a drive roller for advancing the filament strand through the conduit.

20. The three-dimensional modeling machine of claim 19, and further comprising:

a latch for engaging and disengaging the cassette in the loading bay.

21. The three-dimensional modeling machine of claim 19, wherein the entrance of the conduit makes an airtight seal with an exit orifice of the cassette.

22. The three-dimensional modeling machine of claim 19, and further comprising:

registration means for aligning the cassette with the conduit.

23. The three-dimensional modeling machine of claim 19, and further comprising:

means for ejecting the cassette from the loading bay.

24. The three-dimensional modeling machine of claim 19, and further comprising:

a follower roller positioned opposite the drive roller.

25. The three-dimensional modeling machine of claim 24, wherein the drive roller and the follower roller are in the conduit.

26. The three-dimensional modeling machine of claim 19, wherein the drive roller is a wheel configured to engage a follower wheel on the cassette.

27. The extrusion apparatus of claim 26, and further comprising:

drive engagement means for engaging and disengaging the drive roller from the cassette.

28. The extrusion apparatus of claim 27, and further comprising:

a pair of feed rollers positioned along the path proximate the liquifier; and

a sensor for detecting presence of the filament strand between the feed rollers and providing a detection indication;

wherein the drive engagement means disengages the drive roller in response to the detection indication.