Continuous extruded bead object fabrication apparatus

• US 5,204,124 A
• Filed: 11/12/1991
• Issued: 04/20/1993
• Est. Priority Date: 10/09/1990
• Status: Expired due to Fees

• Current Assignee: Earl T. Bayless, Stanley Secretan
• Original Assignee: Earl T. Bayless, Stanley Secretan
• Inventors: Secretan, Stanley, Bayless, Earl T.
• Primary Examiner(s): Chiesa, Richard L.
• Application Number:
  US07/789,977
• Time in Patent Office: 525 Days
• Field of Search: 425/135, 425/174, 425/174.4, 425/145, 425/150, 264/22, 264/308, 364/468, 364/473, 118/696, 118/697, 118/620, 118/323, 156/58, 156/59, 156/272.8, 156/273.3, 156/275.5, 156/379.6, 427/53.1, 427/54.1, 427/55, 427/56.1
• US Class Current: 425/145
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: G05B 2219/49015 Wire, strang laying, deposit fluid, welding, adhesive, hardening, solidification, fuse

Abstract

A apparatus for economically producing both large and small objects wherein a continuous extrusion of viscous liquid is to be dispensed from a nozzle mounted directly adjacent to an object support platform. Preprogrammed movement is achieved between the nozzle and the object support platform in accordance with the size and shape of the object that is to be fabricated. A viscous liquid is to be dispensed a layer at a time resulting in building of the object layer-by-layer from the bottom of the object to the top of the object. Fibers may be added to the viscous liquid when fabricating large objects, thus providing structural reinforcements. The viscous liquid is to be rapidly curable upon the application of light energy with this light energy supplied at a three hundred sixty degree pattern about the nozzle. A light shield immediately adjacent to the nozzle prevents premature curing of viscous liquid. The high viscosity of the liquid retains the controlled shape prior to curing. After a layer is produced by the nozzle, vertical, horizontal or angular relative movement between the nozzle and the object support platform occurs with another layer then being produced.

Claims

1. An apparatus for producing large and small objects comprising:

an object support platform upon which an object is to be created;

a source of curable viscous liquid including an outlet liquid tube through which said liquid is flowable and terminating in a nozzle tip through which said viscous liquid is to be extruded, said nozzle tip being located directly adjacent and above said object support platform, viscous liquid from said source is sufficiently viscous to be capable of retaining its shape while being deposited directly on said object support platform, said viscous fluid being curable into a solid when subjected to light energy, horizontal relative movement to occur between said object support platform and said nozzle tip while said nozzle tip is continuously extruding said viscous liquid while ultraviolet light continuously strikes said viscous liquid that is extruded and affects a cure thus forming the first layer and basic shape of said object to be fabricated, after completion of said first layer vertical relative movement to occur between said object support platform and said nozzle tip of a distance equal to the thickness of said first layer in a direction away from said object support platform preparing said nozzle tip to initiate making a second layer of said object and so on until said object is completed;

programmable means to produce said relative movement, said programmable means to be preprogrammed according to the size and shape of said object, said programmable means directing said relative movement along with controlling the flow of said viscous liquid;

an ultraviolet light source emitting a light beam directed toward said nozzle, said light beam to cure said viscous liquid;

a light shield mounted on said outlet tube and located directly adjacent said nozzle tip, said light shield preventing premature solidification of the extruded said viscous liquid which would cause clogging of said nozzle tip, said light shield being located between said light source and said nozzle tip, said light shield comprising a washer shaped structure shadowing said nozzle tip; and

a cone-shaped light observing window attached to said outlet tube and said light source, said outlet tube and said light source being fixedly secured to said light observing window, said light observing window surrounding said light beam and said nozzle tip, said light observing window permitting observing of said light beam by a human being without causing injury to the eyes of the human being.

2. The apparatus as defined in claim 1 wherein:

said viscous liquid being translucent thereby allowing complete cure to take place as the object is created.

3. The apparatus as defined in claim 1 including:

means for emitting said light source in a three hundred sixty degree pattern about said nozzle tip.

4. The apparatus as defined in claim 3 including:

means for moving said nozzler tip simultaneously with said light source.

5. An apparatus for producing a prototype comprising:

a prototype support platform upon which a prototype is to be created;

a liquid source terminating in a nozzle through which a viscous liquid is to be dispensed, said nozzle being located directly adjacent said prototype support platform and viscous liquid from said liquid source is capable of being deposited directly on said prototype support platform, the viscous liquid being curable into a solid when subjected to light energy, horizontal relative movement to occur between said prototye support platform and said nozzle, the depositing of the viscous liquid being continuous in the form of a narrow bead during said horizontal relative movement, vertical relative movement to occur between said prototype support platform and said nozzle with said vertical relative movement comprising an incremental series of short distances in a direction away from said prototype support platform, said horizontal movement normally occurring between a directly adjacent sequence of said series of short distances of said vertical movement;

programmable means to produce said relative movement, said programmable means being preprogrammed according to the size and shape of said prototype, said programmable means directing said relative movement along with the dispensing of the viscous liquid to produce said prototype;

a source of light for producing light energy for curing said viscous liquid, light direction means located directly adjacent to said nozzle, said light direction means for beaming the light energy toward said nozzle, the light energy from said source of light being transmitted to said light direction means prior to being applied to said prototype, said light direction means emits said light energy in a three hundred sixty degree pattern about said nozzle;

a light shield, said light shield being mounted directly adjacent said nozzle, said light shield comprising a washer shaped structure shadowing said nozzle, said light shield to prevent light from contacting the immediately dispensed said viscous liquid preventing premature curing of said viscous liquid; and

a cone-shaped light observing window, said nozzle and said light direction means being fixedly mounted on said light observing window, said light observing window surrounding said nozzle, said light observing window permitting observing said light energy in the area of said nozzle by a human being without causing injury to the eyes of the human being.

6. The apparatus as defined in claim 5 wherein:

said horizontal movement being constant during the production of said narrow bead.

7. The apparatus as defined in claim 6 wherein:

said short distances of said vertical relative movement being substantially equal.

8. The apparatus as defined in claim 7 including:

means for moving said nozzle to attain said vertical relative movement.

9. The apparatus as defined in claim 5 including:

means for moving said nozzle simultaneously with said light direction means.