RIBBON FILAMENT AND ASSEMBLY FOR USE IN EXTRUSION-BASED DIGITAL MANUFACTURING SYSTEMS

• US 20120258190A1
• Filed: 06/22/2012
• Published: 10/11/2012
• Est. Priority Date: 09/30/2009
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: Batchelder, J. Samuel, Swanson, William J., Crump, S. Scott
• Granted Patent: US 9,586,357 B2
• Time in Patent Office: Days
• US Class Current: 425/375
• CPC Class Codes: B29C 48/002 combined with surface shaping
• CPC Class Codes: B29C 48/0021 combined with joining, lining or laminating
• CPC Class Codes: B29C 48/0022 combined with cutting
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• CPC Class Codes: B29C 48/06 Rod-shaped
• CPC Class Codes: B29C 48/18 the components being layers
• CPC Class Codes: B29C 48/21 the layers being joined at their surfaces
• CPC Class Codes: B29C 48/832 Heating
• CPC Class Codes: B29C 48/914 cooling drums
• 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 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29C 69/001 a shaping technique combined with cutting, e.g. in parts or slices combined with rearranging and joining the cut parts for reinforced material B29C70/545; B29C49/4278, B29C51/268 take precedence
• CPC Class Codes: B29K 2101/12 Thermoplastic materials
• CPC Class Codes: B29K 2509/00 Use of inorganic materials not provided for in groups B29K2503/00 - B29K2507/00, as filler
• CPC Class Codes: B29K 2509/02 Ceramics
• CPC Class Codes: B29K 2509/04 Carbides; Nitrides
• CPC Class Codes: B29K 2509/08 Glass
• CPC Class Codes: B29K 2509/10 Mica
• CPC Class Codes: B29L 2007/007 Narrow strips, e.g. ribbons, tapes, bands belts B29L2029/00; tapes as carrier of sound or information B29L2017/008
• CPC Class Codes: B32B 2038/045 : Slitting
• CPC Class Codes: B32B 2250/02 : 2 layers
• CPC Class Codes: B32B 2250/03 : 3 layers
• CPC Class Codes: B32B 2250/24 : All layers being polymeric
• CPC Class Codes: B32B 2264/10 : Inorganic particles
• CPC Class Codes: B32B 2264/101 : Glass
• CPC Class Codes: B32B 2264/102 : Oxide or hydroxide
• CPC Class Codes: B32B 2264/104 : Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
• CPC Class Codes: B32B 2264/107 : Ceramic
• CPC Class Codes: B32B 2264/108 : Carbon, e.g. graphite particles
• CPC Class Codes: B32B 37/153 : at least one layer is extruded and immediately laminated while in semi-molten state
• CPC Class Codes: B32B 38/0004 : Cutting, tearing or severing, e.g. bursting; Cutter details cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence
• CPC Class Codes: B32B 38/185 : combined with the cutting of one or more layers
• 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 50/02 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 70/00 : Materials specially adapted for additive manufacturing
• CPC Class Codes: D01D 5/423 : by fibrillation of films or filaments
• CPC Class Codes: D01D 5/426 : by cutting films
• CPC Class Codes: Y10T 428/2913 : Rod, strand, filament or fiber
• CPC Class Codes: Y10T 428/2929 : Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]
• CPC Class Codes: Y10T 428/2973 : Particular cross section

Abstract

A consumable material for use in an extrusion-based digital manufacturing system, the consumable material comprising a length and a cross-sectional profile of at least a portion of the length that is axially asymmetric. The cross-sectional profile is configured to provide a response time with a non-cylindrical liquefier of the extrusion-based digital manufacturing system that is faster than a response time achievable with a cylindrical filament in a cylindrical liquefier for a same thermally limited, maximum volumetric flow rate.

Claims

1. A ribbon filament for use in an extrusion-based digital manufacturing system with a ribbon liquefier to build a three-dimensional model in a layer-by-layer manner, the ribbon filament comprising:

a composition comprising at least one extrudable material;

a length that is continuous for at least a distance such that the ribbon filament is feedable from a supply source to the ribbon liquefier retained by a moveable head of the extrusion-based digital manufacturing system; and

a cross-sectional profile of the length that is axially asymmetric and having a width and a thickness, wherein the width ranges from about 1.0 millimeter to about 10.2 millimeters, wherein the thickness ranges from about 0.51 millimeters to about 1.0 millimeter, and wherein the cross-sectional profile of the ribbon filament has a cross-sectional aspect ratio of the width to the thickness ranging from about 2.5;

1 to about 20;

1;

wherein the ribbon filament exhibits a flexibility such that the ribbon filament does not plastically deform or fracture while retained by the supply source or when fed from the supply source to the ribbon liquefier; and

wherein the ribbon filament further exhibits a Young'"'"'s Modulus value ranging from about 1.0 gigapascal to about 5.0 gigapascals.

2. The ribbon filament of claim 1, wherein the at least one extrudable material comprises a thermoplastic polymeric material.

3. The ribbon filament of claim 1, wherein the cross-sectional profile is configured to mate with the ribbon liquefier having an entrance cross-sectional area A_e and a hydraulic diameter D_h with the ribbon filament, wherein D_h<

0.95√

{square root over (A_e)}.

4. The ribbon filament of claim 3, wherein D_h<

0.90√

{square root over (A_e)} and D_h>

0.40√

{square root over (A_e)}.

5. The ribbon filament of claim 1, wherein the ribbon filament is configured to mate with the ribbon liquefier in a manner that exhibits a response time for extruding the melted consumable material that is at least 50% faster than a response time achievable with a cylindrical filament in a cylindrical liquefier for a same thermally limited, maximum volumetric flow rate.

6. The ribbon filament of claim 1, wherein the ribbon filament further comprises a base portion having a first surface and a second surface, and a layer disposed on the first surface of the base portion, and wherein the base portion and the first surface are derived from different materials.

7. The ribbon filament of claim 1, wherein the cross-sectional aspect ratio of the width to the thickness ranges from about 3:

1 to about 10;

1.

8. An assembly for use in an extrusion-based digital manufacturing system with a ribbon liquefier to build a three-dimensional model in a layer-by-layer manner, the assembly comprising:

a supply source configured to engage the extrusion-based digital manufacturing system; and

a ribbon filament retained by the supply source, the ribbon filament comprising;

a composition comprising at least one extrudable material;

a length that is continuous for at least a distance such that the ribbon filament is feedable from the supply source to the ribbon liquefier retained by a moveable head of the extrusion-based digital manufacturing system; and

a rectangular cross-sectional profile of the length, which is configured to mate with the ribbon liquefier having an entrance cross-sectional area A, and a hydraulic diameter D_h with the ribbon filament, wherein D_h<

0.95√

{square root over (A_e)}, and wherein the rectangular cross-sectional profile has a width and a thickness with a cross-sectional aspect ratio of the width to the thickness ranging from about 2.5;

1 to about 20;

1;

wherein the ribbon filament exhibits a flexibility such that the ribbon filament does not plastically deform or fracture while retained by the supply source; and

wherein the ribbon filament further exhibits a Young'"'"'s Modulus value ranging from about 1.0 gigapascal to about 5.0 gigapascals.

9. The assembly of claim 8, wherein the at least one extrudable material comprises a thermoplastic polymeric material.

10. The assembly of claim 8, wherein D_h<

0.90√

{square root over (A_e)} and D_h>

0.40√

{square root over (A_e)}.

11. The assembly of claim 8, wherein the supply source comprises a spool on which at least a portion of the ribbon filament is wound.

12. The assembly of claim 11, wherein the supply source further comprises a container, wherein the spool is retained within the container.

13. The assembly of claim 8, wherein the width ranges from about 1.0 millimeter to about 10.2 millimeters, wherein the thickness ranges from about 0.51 millimeters to about 1.0 millimeter.

14. An assembly for use in an extrusion-based digital manufacturing system with a ribbon liquefier to build a three-dimensional model in a layer-by-layer manner, the assembly comprising:

a container configured to engage the extrusion-based digital manufacturing system;

a pathway from the container and configured to extend to a ribbon liquefier retainable by a moveable head of the extrusion-based digital manufacturing system; and

a ribbon filament at least partially retained within the container and feedable through the pathway from the container to the ribbon liquefier, the ribbon filament comprising;

a composition comprising at least one extrudable material;

a length;

a rectangular cross-sectional profile of the length, which is configured to mate with the ribbon liquefier having an entrance cross-sectional area A, and a hydraulic diameter D_h with the ribbon filament, wherein D_h<

0.95√

{square root over (A_e)} and wherein the rectangular cross-sectional profile has a width and a thickness with a cross-sectional aspect ratio of the width to the thickness ranging from about 2.5;

1 to about 20;

1;

wherein the ribbon filament exhibits a flexibility such that the ribbon filament does not plastically deform or fracture while retained by the supply source; and

wherein the ribbon filament further exhibits a Young'"'"'s Modulus value ranging from about 1.0 gigapascal to about 5.0 gigapascals.

15. The assembly of claim 14, wherein the at least one extrudable material comprises a thermoplastic polymeric material.

16. The assembly of claim 14, wherein D_h<

0.90√

{square root over (A_e)} and D_h>

0.40√

{square root over (A_e)}.

17. The assembly of claim 14, and further comprising a spool retained in the container, wherein at least a portion of the ribbon filament is wound on the spool.

18. The assembly of claim 14, and further comprising the ribbon liquefier.

19. The assembly of claim 14, wherein the width ranges from about 1.0 millimeter to about 10.2 millimeters, wherein the thickness ranges from about 0.51 millimeters to about 1.0 millimeter.

20. The assembly of claim 14, wherein the ribbon filament further comprises a base portion having a first surface and a second surface, and a layer disposed on the first surface of the base portion, and wherein the base portion and the first surface are derived from different materials.