Consumable assembly for use in extrusion-based layered deposition systems

• US 8,403,658 B2
• Filed: 01/07/2009
• Issued: 03/26/2013
• Est. Priority Date: 01/08/2008
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: Swanson, William J.
• Primary Examiner(s): HAUTH, GALEN H
• Application Number:
  US12/811,411
• Publication Number:
  US 20100283172A1
• Time in Patent Office: 1,539 Days
• Field of Search: 264/308, 425/190, 425/376.1, 425/377, 206/204
• US Class Current: 425/190
• CPC Class Codes: B29C 48/00 Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor extrusion blow-moulding B29C49/04
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• CPC Class Codes: B29C 48/18 the components being layers
• 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: B29C 64/255 Enclosures for the building material, e.g. powder containers
• 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

Abstract

A consumable assembly comprising a container portion configured to retain a supply of filament, a guide tube connected to the container portion, and a pump portion connected to the guide tube.

Claims

1. A consumable assembly for use in an extrusion-based layered deposition system, the consumable assembly comprising:

a pump portion configured to be inserted in a mount of the extrusion-based layered deposition system to extrude a material of a filament in a molten state, wherein the pump portion comprises an electrical connection configured to receive electrical power from the extrusion-based layered deposition system when the pump portion is inserted in the mount;

a container portion configured to retain a supply of the filament, wherein the container portion is configured to be offset from the pump portion when the pump portion is inserted in the mount; and

a guide tube interconnecting the container portion and the pump portion, wherein the guide tube is configured to guide the filament from the container portion to the pump portion;

wherein the pump portion, the guide tube, and the container portion are configured to be removed together from use with the extrusion-based layered deposition system.

2. The consumable assembly of claim 1, wherein the container portion comprises:

an outer casing; and

at least one liner disposed within the outer casing.

3. The consumable assembly of claim 2, wherein the container portion further comprises a spool assembly disposed within the at least one liner, the spool assembly being the component of the container portion that retains the supply of the filament.

4. The consumable assembly of claim 1, wherein the container portion comprises at least one data chip configured to communicate with an extrusion-based layered deposition system when the consumable assembly is loaded to the extrusion-based layered deposition system.

5. The consumable assembly of claim 1, wherein the pump portion comprises a drive mechanism configured to feed successive portions of the filament.

6. The consumable assembly of claim 5, wherein the pump portion further comprises:

a liquefier component configured to at least partially melt the successive portions of the filament fed by the drive mechanism to provide the material of the filament in the molten state; and

an extrusion tip disposed downstream from the liquefier component, and configured to provide an exit location for extruding the material of the filament in the molten state.

7. The consumable assembly of claim 5, wherein the pump portion further comprises a motor configured to operate the drive mechanism.

8. The consumable assembly of claim 1, wherein the supply of the filament in the container portion comprises a coil of the filament.

9. The consumable assembly of claim 1, and further comprising the supply of filament, wherein the filament comprises:

a first portion being the portion of the filament that is retained in the container portion;

a second portion extending through the guide tube; and

a third portion extending at least partially through the pump portion.

10. The consumable assembly of claim 9, wherein the pump portion comprises a drive mechanism that is engaged with the third portion of the filament.

22. The consumable assembly of claim 1, wherein the pump portion comprises:

a filament drive mechanism; and

a motor engaged with the filament drive mechanism in a worm gear manner.

11. A consumable assembly for use in an extrusion-based layered deposition system, the consumable assembly comprising:

a pump portion wherein the pump portion is configured to be inserted in a mount of the extrusion-based layered deposition system, wherein the pump portion comprises an electrical connection configured to receive electrical power from the extrusion-based layered deposition system when the pump portion is inserted in the mount;

a container portion configured to be offset from the pump portion when the pump portion is inserted in the mount;

a guide tube interconnecting the container portion and the pump portion; and

a supply of filament comprising;

a first portion retained in the container portion;

a second portion extending through the guide tube; and

a third portion extending at least partially through the pump portion;

wherein the pump portion, the guide tube, and the container portion are configured to be removed together from use with the extrusion-based layered deposition system.

12. The consumable assembly of claim 11, wherein the container portion comprises:

an outer casing; and

at least one liner disposed within the outer casing, wherein the first portion of the filament is retained within the at least one liner.

13. The consumable assembly of claim 12, wherein the container portion further comprises a spool assembly disposed within the at least one liner, the spool assembly being the component of the container portion that retains the first portion of the filament.

14. The consumable assembly of claim 11, wherein the pump portion comprises a drive mechanism that is engaged with the third portion of the supply of filament.

15. The consumable assembly of claim 14, wherein the pump portion further comprises:

a liquefier component configured to at least partially melt the successive portions of the filament fed by the drive mechanism to provide the material of the filament in a flowable state; and

an extrusion tip disposed downstream from the liquefier component, and configured to provide an exit location for extruding the material of the filament in the flowable state.

16. A consumable assembly for use in an extrusion-based layered deposition system, the consumable assembly comprising:

a filament;

a container portion, wherein a first portion of the filament is retained in the container portion; and

a flexible guide tube having a first end engaged with the container portion, and a second end, wherein a second portion of the filament extends through the guide tube; and

a pump portion configured to be inserted in a mount of the extrusion-based layered deposition system, wherein the pump portion comprises;

a casing connected to the second end of the flexible guide tube, wherein a third portion of the filament extends at least partially through the casing;

a liquefier component extending from the casing; and

an electrical connection configured to receive electrical power from the extrusion-based layered deposition system when the pump portion is inserted in the mount;

wherein the container portion is configured to be offset from the pump portion when the pump portion is inserted in the mount; and

wherein the pump portion, the guide tube, and the container portion are configured to be removed together from use with the extrusion-based layered deposition system.

17. The consumable assembly of claim 16, wherein the container portion further comprises a spool assembly, the spool assembly being the component of the container portion that retains the first portion of the filament.

18. The consumable assembly of claim 16, wherein the first portion of the filament is coiled in the at least one liner without a spool.

19. The consumable assembly of claim 16, wherein the pump portion further comprises:

a filament drive mechanism retained by the casing; and

a motor retained by the casing and engaged with the filament drive mechanism.

20. The consumable assembly of claim 19, wherein the motor is engaged with the filament drive mechanism in a worm gear manner.

21. The consumable assembly of claim 16, wherein the container portion comprises:

at least one liner, wherein the first portion of the filament is retained in the at least one liner; and

a tube connector, wherein the first end of the flexible guide tube is engaged with the container portion at the tube connector to provide a moisture seal.