Extrusion head for use in extrusion-based layered deposition modeling

• US 7,625,200 B2
• Filed: 07/31/2007
• Issued: 12/01/2009
• Est. Priority Date: 07/31/2007
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: Leavitt, Paul J.
• Primary Examiner(s): EWALD, MARIA VERONICA
• Application Number:
  US11/888,076
• Publication Number:
  US 20090035405A1
• Time in Patent Office: 854 Days
• Field of Search: 425/174.4, 425/375, 425/182, 425/192.R, 425/376.1, 264/308, 264/401, 264/497, 264/113
• US Class Current: 425/375
• CPC Class Codes: B28B 1/14 by simple casting, the material being neither forcibly fed nor positively compacted for molten material B28B1/54
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• CPC Class Codes: B29C 48/08 flexible, e.g. films
• CPC Class Codes: B29C 48/303 using dies or die parts movable in a closed circuit, e.g. mounted on movable endless support B29C48/35 takes precedence
• 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 64/209 Heads; Nozzles
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor

Abstract

An extrusion head comprising at least one mounting structure, a first liquefier pump secured to the at least one mounting structure, a second liquefier pump disposed adjacent to the first liquefier pump, a toggle mechanism supported by the at least one mounting structure and configured to move the second liquefier pump relative to the first liquefier pump along a first axis, and a slot engagement assembly connected in part to the second liquefier pump for defining a range of motion for the second liquefier pump along the first axis.

Claims

1. An extrusion head comprising:

at least one mounting structure;

a first liquefier pump secured to the at least one mounting structure;

a second liquefier pump disposed adjacent to the first liquefier pump;

a toggle mechanism supported by the at least one mounting structure, and configured to move the second liquefier pump relative to the first liquefier pump along a first axis; and

a slot engagement mechanism connected in part to the second liquefier pump for defining a range of motion for the second liquefier pump along the first axis, wherein the slot engagement mechanism comprises a slot having a first perimeter and a second perimeter offset along the first axis and an engagement member disposed in the slot.

2. The extrusion head of claim 1, wherein one of the slot and the engagement member is disposed in the second liquefier pump.

3. The extrusion head of claim 2, wherein the second of the slot and the engagement member is disposed in the first liquefier pump.

4. The extrusion head of claim 2, wherein a contact between the engagement member and at least one of the first perimeter and the second perimeter of the slot substantially prevents movement of the second liquefier pump relative to the first liquefier pump along a second axis that is perpendicular to the first axis.

5. The extrusion head of claim 1, wherein the toggle mechanism comprises:

a motor secured to the at least one mounting structure;

a threaded actuator operably secured to the motor; and

a retention component secured to the second liquefier pump and threadedly engaged with the threaded actuator.

6. The extrusion head of claim 5, wherein the toggle mechanism further comprises:

a motor shaft secured to the motor, the motor shaft having a longitudinal length;

a coupling pin secured to the motor shaft in a direction orthogonal to the longitudinal length; and

a coupling operably secured to the threaded actuator and having at least one slot, wherein the coupling pin extends within the at least one slot.

7. The extrusion head of claim 1, wherein the range of motion for the second liquefier pump along the first axis comprises a first position and a second position, and wherein the second liquefier pump comprises a build tip that is aligned along the first axis when the second liquefier pump is disposed at the first position and at the second position.

8. The extrusion head of claim 1, wherein the toggle mechanism is a first toggle mechanism and the slot engagement mechanism is a first slot engagement mechanism, and wherein the extrusion head further comprises:

a third liquefier pump disposed adjacent to the first liquefier pump;

a second toggle mechanism supported by the at least one mounting structure, and configured to move the third liquefier pump relative to the first liquefier pump along the first axis; and

a second slot engagement mechanism connected in part to the third liquefier pump for defining a range of motion for the third liquefier pump along the first axis.

9. An extrusion head comprising:

at least one mounting structure;

a first liquefier pump secured to the at least one mounting structure;

a second liquefier pump disposed adjacent to the first liquefier pump, and comprising a first of a slot and an engagement member disposed in the slot for defining a range of motion for the second liquefier pump along a first axis;

a component substantially immobile relative to the first liquefier pump and that comprises a second of the slot and the engagement member; and

a toggle mechanism engaged with the second liquefier pump for moving the second liquefier pump along the first axis.

10. The extrusion head of claim 9, wherein the component that is substantially immobile relative to the first liquefier pump constitutes a portion of the first liquefier pump.

11. The extrusion head of claim 9, wherein the second liquefier pump comprises the engagement member and the component comprises the slot.

12. The extrusion head of claim 9, wherein the slot has a first perimeter and a second perimeter offset along the first axis, and wherein a contact between the engagement member and at least one of the first perimeter and the second perimeter of the slot substantially prevents movement of the second liquefier pump relative to the first liquefier pump along a second axis that is perpendicular to the first axis.

13. The extrusion head of claim 9, wherein the toggle mechanism comprises:

a motor secured to the at least one mounting structure;

a threaded actuator operably secured to the motor; and

a retention component secured to the second liquefier pump and threadedly engaged with the threaded actuator.

14. The extrusion head of claim 13, wherein the range of motion for the second liquefier pump along the first axis comprises a first position and a second position, and wherein the second liquefier pump comprises a build tip that is aligned along the first axis when the second liquefier pump is disposed at the first position and at the second position.

15. An extrusion head comprising:

at least one mounting structure;

a motor secured to the at least one mounting structure;

a threaded actuator operably secured to the motor, wherein the motor is configured to rotate the threaded actuator;

a first liquefier pump secured to the at least one mounting structure, and comprising a first of a slot and an engagement member, the slot having a first perimeter and a second perimeter offset along a first axis; and

a second liquefier pump threadedly engaged with the threaded actuator, wherein the second liquefier pump comprises a second of the slot and the engagement member, the engagement member being disposed in the slot between the first perimeter and the second perimeter, and wherein the rotation of the threaded actuator moves the second liquefier pump along the first axis.

16. The extrusion head of claim 15, wherein a contact between the engagement member and at least one of the first perimeter and the second perimeter of the slot substantially prevents movement of the second liquefier pump relative to the first liquefier pump along a second axis that is perpendicular to the first axis.

17. The extrusion head of claim 15, further comprising:

a motor shaft secured to the motor, the motor shaft having a longitudinal length;

a coupling pin secured to the motor shaft in a direction orthogonal to the longitudinal length; and

a coupling operably secured to the threaded actuator and having at least one slot, wherein the coupling pin extends within the at least one slot.

18. The extrusion head of claim 15, further comprising at least one deflection disk operably secured between the motor and the threaded actuator.

19. The extrusion head of claim 15, wherein the slot also has a third perimeter and

a fourth perimeter offset along a second axis that is perpendicular to the first axis by a first offset distance that is greater than a diameter of the engagement member.

20. The extrusion head of claim 15, wherein the motor is a first motor and the threaded actuator is a first threaded actuator, and wherein the extrusion head further comprises:

a second motor secured to the at least one mounting structure;

a second threaded actuator operably secured to the second motor, wherein the second motor is configured to rotate the second threaded actuator;

a third liquefier pump threadedly engaged with the second threaded actuator; and

a slot engagement mechanism connected in part to the third liquefier pump for defining a range of motion for the third liquefier pump along the first axis.