APPARATUS AND METHODS FOR ADDITIVELY MANUFACTURING ADHESIVE INLET AND OUTLET PORTS

• US 20190322040A1
• Filed: 04/20/2018
• Published: 10/24/2019
• Est. Priority Date: 04/20/2018
• Status: Active Grant

• Current Assignee: Divergent Technologies, Inc.
• Original Assignee: Divergent Technologies, Inc.
• Inventors: Martinez, JR., Antonio Bernerd, Zafar, Muhammad Faizan, Okoli, Chukwubuikem Marcel, Kreig, William David, Smith, Roy, TenHOUTEN, David Brian
• Granted Patent: US 11,613,078 B2
• Time in Patent Office: Days
• 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 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/379 Handling of additively manufactured objects, e.g. using robots
• 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 80/00 Products made by additive manufacturing

Abstract

Apparatus and methods for additively manufacturing adhesive inlet and outlet ports are presented herein. Adhesive inlet and outlet ports are additively manufactured to include additively manufactured (AM) valves for reducing and/or eliminating sealant leakage and backflow. Robot end effectors are tailored to interface with the AM inlet and outlet ports and to provide an adhesive source and/or a vacuum source. AM inlet and outlet ports enable robust, lightweight, multi-material AM parts connected via adhesive joining.

Claims

1. An apparatus comprising:

an additively manufactured (AM) inlet port configured to receive an adhesive; and

an AM outlet port comprising an AM outlet adhesive valve configured to impede an adhesive outflow at the AM outlet port.

2. The apparatus of claim 1, wherein the adhesive flow is unidirectional from the AM inlet port to the AM outlet port.

3. The apparatus of claim 1, wherein the AM outlet adhesive valve comprises a lattice configured to impede the adhesive outflow at the AM outlet port.

4. The apparatus of claim 1,

wherein the AM outlet port is configured to receive a vacuum;

and

wherein the AM outlet adhesive valve is configured to facilitate the adhesive flow from the AM inlet port to the AM outlet port by engaging the vacuum.

5. The apparatus of claim 4, wherein the AM outlet adhesive valve comprises a lattice configured to:

engage the vacuum by passing air; and

impede the adhesive outflow at the AM outlet port.

6. The apparatus of claim 5, wherein the AM outlet adhesive valve comprises a plurality of outlet spring loaded tangs configured to:

couple with a vacuum effector;

facilitate the vacuum when coupled with the vacuum effector; and

impede the adhesive outflow at the AM outlet port when decoupled from the vacuum effector.

7. The apparatus of claim 4, wherein the AM outlet adhesive valve comprises:

a gap region; and

an AM ball configured to

facilitate the vacuum by passing air through the gap region, and

impede the adhesive outflow at the AM outlet port by blocking the gap region when the adhesive reaches the gap region.

8. The apparatus of claim 7, wherein the AM outlet adhesive valve further comprises a spring positioned to provide support to the AM ball.

9. The apparatus of claim 4, wherein the AM outlet adhesive valve comprises a flap configured to:

facilitate the vacuum by passing air; and

impede the adhesive outflow at the AM outlet port by blocking the outlet port when the adhesive reaches the outlet port.

10. The apparatus of claim 9, wherein the flap is configured to lock into place upon completion of an adhesive fill within the apparatus.

11. The apparatus of claim 1, wherein the AM inlet port comprises an AM inlet adhesive valve configured to:

facilitate the adhesive flow from the AM inlet port to the AM outlet port; and

impede an adhesive outflow at the AM inlet port.

12. The apparatus of claim 1, wherein the AM outlet adhesive valve comprises a pop-in element configured to receive a pressure spike when adhesive reaches the pop-in element to indicate that a corresponding adhesive channel is approximately full.

13. The apparatus of claim 12, wherein the AM inlet adhesive valve comprises a lattice configured to impede the adhesive outflow at the AM inlet port.

14. The apparatus of claim 12, wherein the AM inlet adhesive valve comprises a plurality of inlet spring loaded tangs configured to:

couple with an adhesive effector;

facilitate the adhesive flow from the AM inlet port to the AM outlet port when coupled with the adhesive effector; and

impede the adhesive outflow at the AM inlet port when decoupled from the adhesive effector.

15. The apparatus of claim 12, wherein the AM inlet adhesive valve comprises a flap configured to:

facilitate the adhesive flow from the AM inlet port to the AM outlet port when the adhesive is applied at the inlet port; and

impede the adhesive outflow at the AM inlet port by blocking the inlet port when the adhesive is removed from the inlet port.

16. The apparatus of claim 15, wherein the flap is configured to lock into place upon completion of an adhesive fill within the apparatus.

17. An apparatus comprising an AM effector for applying adhesive to an AM adhesive port, the AM effector comprising:

a first channel supporting a seal plug; and

a second channel coupled to the first channel and configured to provide an adhesive to the AM adhesive port.

18. The apparatus of claim 17, wherein the AM adhesive port comprises an AM plug acceptor co-printed with the AM effector.

19. A method of manufacturing an AM node, the method comprising:

additively manufacturing an AM inlet port configured to receive an adhesive; and

additively manufacturing an AM outlet port to comprise an AM outlet adhesive valve configured to facilitate an adhesive flow from the AM inlet port to the AM outlet port and to impede an adhesive outflow at the AM outlet port.

20. The method of claim 19, wherein the adhesive flow is unidirectional from the AM inlet port to the AM outlet port.

21. The method of claim 19, wherein additively manufacturing the AM outlet port to comprise an AM outlet adhesive valve further comprises:

additively manufacturing a lattice within the AM outlet adhesive valve, the lattice configured to impede the adhesive outflow at the AM outlet port.

22. The method of claim 19,

wherein the AM outlet port is configured to receive a vacuum;

and

wherein the AM outlet adhesive valve is configured to facilitate the unidirectional adhesive flow from the AM inlet port to the AM outlet port by facilitating the vacuum.

23. The method of claim 22, wherein additively manufacturing the AM outlet port to comprise an AM outlet adhesive valve comprises:

additively manufacturing a lattice within the AM outlet adhesive valve, the lattice configured to facilitate the vacuum by passing air and to impede the adhesive outflow at the AM outlet port.

24. The method of claim 22, wherein additively manufacturing the AM outlet port to comprise an AM outlet adhesive valve comprises:

additively manufacturing a plurality of outlet spring loaded tangs configured to couple with a vacuum effector, to facilitate the vacuum when coupled with the vacuum effector, and to impede the adhesive outflow at the AM outlet port when decoupled from the vacuum effector.

25. The method of claim 22, wherein additively manufacturing the AM outlet port to comprise an AM outlet adhesive valve comprises:

additively manufacturing a gap region; and

additively manufacturing an AM ball configured to facilitate the vacuum by passing air through the gap region and to impede the adhesive outflow at the AM outlet port by blocking the gap region when the adhesive reaches the gap region.

26. The method of claim 25, wherein additively manufacturing the AM outlet port to comprise an AM outlet adhesive valve further comprises:

additively manufacturing a spring positioned to provide support to the AM ball.

27. The method of claim 22, wherein additively manufacturing the AM outlet port to comprise an AM outlet adhesive valve comprises:

additively manufacturing a flap configured to facilitate the vacuum by passing air and to impede the adhesive outflow at the AM outlet port by blocking the outlet port when the adhesive reaches the outlet port.

28. The method of claim 27, wherein the flap is configured to lock into place upon completion of an adhesive fill.

29. The method of claim 22, wherein additively manufacturing the AM inlet port configured to receive an adhesive comprises:

additively manufacturing the inlet port to comprise an AM inlet adhesive valve configured to facilitate the unidirectional adhesive flow from the AM inlet port to the AM outlet port and to impede an adhesive outflow at the AM inlet port.

30. The method of claim 29, wherein additively manufacturing the AM inlet port to comprise an AM inlet adhesive valve comprises:

additively manufacturing a lattice within the AM inlet adhesive valve, the lattice configured to facilitate the unidirectional adhesive flow from the AM inlet port to the AM outlet port and to impede an adhesive outflow at the AM inlet port.

31. The method of claim 29, wherein additively manufacturing the AM inlet port to comprise an AM inlet adhesive valve comprises:

additively manufacturing a plurality of inlet spring loaded tangs configured to couple with an adhesive effector, to facilitate the unidirectional adhesive flow from the AM inlet port to the AM outlet port when coupled with the adhesive effector, and to impede the adhesive outflow at the AM inlet port when decoupled from the adhesive effector.

32. The method of claim 29, wherein additively manufacturing the AM inlet port to comprise an AM inlet adhesive valve comprises:

additively manufacturing a flap configured to facilitate the unidirectional adhesive flow from the AM inlet port to the AM outlet port when the adhesive is applied at the inlet port and to impede the adhesive outflow at the AM inlet port by blocking the inlet port when the adhesive is removed from the inlet port.

33. The method of claim 32, wherein the flap is configured to lock into place upon completion of an adhesive fill.

34. A method of applying an adhesive to an apparatus comprising an AM inlet port and an AM outlet port, the method comprising:

providing an adhesive at the AM inlet port;

facilitating an adhesive flow from the AM inlet port to the AM outlet port using an AM valve; and

terminating the adhesive flow.

35. The method of claim 34, wherein the AM outlet port comprises the AM valve and the method further comprises:

impeding an adhesive outflow at the AM outlet port.

36. The method of claim 35,

wherein the AM valve comprises a lattice;

wherein facilitating an adhesive flow from the AM inlet port to the AM outlet port using the AM valve comprises;

providing a vacuum at the AM outlet port; and

orienting the lattice to facilitate the adhesive flow from the AM inlet port to the AM outlet port using the AM valve; and

wherein terminating the adhesive flow comprises;

measuring a pressure increase indicative of the adhesive reaching the lattice; and

terminating the adhesive flow in response to the pressure increase.

37. The method of claim 35,

wherein the AM valve comprises a plurality of spring loaded AM tangs;

wherein facilitating an adhesive flow from the AM inlet port to the AM outlet port using the AM valve comprises;

coupling a vacuum effector with the plurality of spring loaded AM tangs; and

drawing a vacuum with the vacuum effector; and

wherein terminating the adhesive flow comprises;

removing the vacuum effector when the adhesive reaches the AM outlet port.

38. The method of claim 35,

wherein the AM valve comprises an AM gap region and an AM ball;

wherein facilitating an adhesive flow from the AM inlet port to the AM outlet port using the AM valve comprises;

passing air through the gap region; and

wherein terminating the adhesive flow comprises;

blocking the gap region when the adhesive reaches the gap region.

39. The method of claim 38, wherein the AM valve comprises an AM spring positioned to provide support to the AM ball.

40. The method of claim 35,

wherein the AM valve comprises a flap;

wherein facilitating an adhesive flow from the AM inlet port to the AM outlet port using the AM valve comprises;

deflecting the flap to pass air over the flap; and

wherein terminating the adhesive flow comprises;

blocking the outlet port with the flap when the adhesive reaches the outlet port.

41. The method of claim 34, wherein the AM inlet port comprises the AM valve and the method further comprises:

impeding an adhesive outflow at the AM inlet port.

42. The method of claim 41,

wherein the AM valve comprises a lattice;

wherein facilitating an adhesive flow from the AM inlet port to the AM outlet port using the AM valve comprises;

orienting the lattice to facilitate the adhesive flow from the AM inlet port to the AM outlet port using the AM valve.

43. The method of claim 41,

wherein the AM valve comprises a plurality of spring loaded AM tangs;

wherein providing an adhesive at the AM inlet port comprises;

coupling an adhesive effector with the plurality of spring loaded AM tangs; and

wherein terminating the adhesive flow comprises;

removing the adhesive effector when the adhesive reaches the AM outlet port.

44. The method of claim 41,

wherein the AM valve comprises a flap;

wherein facilitating an adhesive flow from the AM inlet port to the AM outlet port using the AM valve comprises;

deflecting the flap to allow adhesive to pass over the flap; and

wherein terminating the adhesive flow comprises;

blocking the inlet port with the flap when the adhesive reaches the outlet port.

45. The method of claim 34, wherein the AM valve comprises a pop-in element, the method further comprising terminating adhesive flow when a pressure spike is noticed in the pop-in-element.