Methods And Apparatuses For Additively Manufacturing Rubber

• US 20160185040A1
• Filed: 11/12/2015
• Published: 06/30/2016
• Est. Priority Date: 12/31/2014
• Status: Active Grant

• Current Assignee: Bridgestone Americas Tire Operations LLC (Bridgestone Corporation)
• Original Assignee: Bridgestone Americas Tire Operations LLC (Bridgestone Corporation)
• Inventors: Costlow, Douglas B.
• Granted Patent: US 10,456,978 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29C 2071/022 Annealing
• CPC Class Codes: B29C 48/475 using pistons, accumulators or press rams
• 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 64/188 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 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/295 Heating elements
• CPC Class Codes: B29C 64/30 Auxiliary operations or equipment
• CPC Class Codes: B29C 64/321 Feeding
• 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: B29C 71/02 Thermal after-treatment B29C71/0063 and B29C71/0072 take precedence
• CPC Class Codes: B29K 2021/00 Use of unspecified rubbers as moulding material
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing

Abstract

An apparatus, system, and method for disposing green rubber, via 3D Printing or additive manufacturing, are provided. The apparatus includes at least a housing, a nozzle, and a heating element. Green rubber is forced through the nozzle and deposited in an iterative build process. The apparatus may be used in a variety of applications, including tire applications.

Claims

1. An apparatus for disposing green rubber comprising:

a housing comprising a base and at least one support structure;

an inlet for receiving green rubber from an external source;

a nozzle for disposing green rubber, wherein the nozzle is mounted to the support structure and receives green rubber from the external source via a path from the inlet;

a heating element and a regulator configured to maintain a temperature of green rubber in the apparatus below a predetermined setpoint;

a cutting instrument mounted to the apparatus and configured to separate green rubber dispensed from the nozzle;

a propulsion assembly that forces green rubber through the nozzle;

a build surface upon which green rubber is disposed;

an actuator capable of moving at least one of the nozzle and the build surface.

2. The apparatus of claim 1, wherein the cutting instrument is a metal blade.

3. The apparatus of claim 1, further comprising at least one vibration transducer that vibrates the nozzle or the cutting instrument.

4. The apparatus of claim 1, wherein the heating element warms the nozzle and path through resistive heating.

5. The apparatus of claim 1, wherein the propulsion assembly pressurizes green rubber in the apparatus between 200 and 3,200 psi.

6. The apparatus of claim 1, wherein the support structure is a robotic arm.

7. The apparatus of claim 1, wherein the apparatus further comprises a second nozzle for disposing viscous material.

8. A system for additive manufacturing of green rubber, comprising:

an electronic machine that facilitates control of a printing apparatus by a software system,

wherein the printing apparatus comprises a hopper, a feeder, a line, a thermal regulator, an egress, a printing surface, and a motion control assembly, and

wherein the software system comprises at least one software module that receives user input selecting specifications for a three-dimensional object, at least one software module that retrieves specifications for a three-dimensional object, at least one software module that creates control commands based on the received user input and the retrieved specifications, and at least one software module that executes control commands effectuating motion in the motion control assembly.

9. The system of claim 8, wherein the software system further comprises at least one software module that retrieves green rubber properties from a database of green rubber properties.

10. The system of claim 8, wherein the software system further comprises at least one software module that generates identification information imparted to printed rubber.

11. The system of claim 8, wherein the at least one software module that retrieves specifications for a three-dimensional object retrieves the specifications from a database of tire tread designs.

12. The system of claim 8, wherein the printing apparatus further comprises an agitator that agitates green rubber in the hopper.

13. The system of claim 8, wherein the printing apparatus further comprises a belt that moves printed rubber from the printing apparatus.

14. A method of additively printing green rubber comprising,

providing power to a printing apparatus;

providing materials to the printing apparatus, the materials including un-vulcanized rubber and a plasticizer, wherein the plasticizer is an additive or oil;

decreasing a viscosity of at least one of the materials provided to the printing apparatus by warming;

pressurizing the un-vulcanized rubber provided to the printing apparatus to a pressure of at least 800 psi;

identifying a three dimensional structure to be printed by the printing apparatus;

identifying a series of motion commands to build the three dimensional structure;

positioning a dispenser at a beginning of a series of motion control commands;

commencing an iterative build process comprising steps of dispensing un-vulcanized rubber over an area and separating dispensed un-vulcanized rubber from the dispenser;

terminating the iterative build process;

removing the dispensed un-vulcanized rubber from the printing apparatus.

15. The method of claim 14, wherein the iterative build process further comprises moving the dispenser vertically.

16. The method of claim 14, wherein decreasing the viscosity of at least one of the materials includes regulating a temperature using a setpoint control loop.

17. The method of claim 14, further comprising vulcanizing the dispensed un-vulcanized rubber in an autoclave.

18. The method of claim 14, wherein the area over which the un-vulcanized rubber is dispensed is a tread component.

19. The method of claim 14, further comprising utilizing a support to buttress dispensed green rubber.

20. The method of claim 14, further comprising monitoring the amount of un-vulcanized rubber in the printing apparatus and generating an alert when the amount falls below or exceeds predetermined thresholds.