Process of making a component with a passageway
First Claim
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1. A method of making a component including at least one liquid-carrying passageway, the method comprising:
- (a) creating a first layer of material to define a first section of the component comprising a washer jet;
(b) emitting light onto the first layer to perform at least one of;
(a) hardening, (b) curing or (c) bonding the first layer;
(c) creating a second layer of the material upon the first layer to define a second section of the component after the prior step;
(d) emitting light onto the second layer to perform at least one of;
(a) hardening, (b) curing or (c) bonding the second layer;
(e) creating at least a third layer of the material upon the second layer to define at least a third section of the component after the prior step;
(f) emitting light onto the third layer to perform at least one of;
(a) hardening, (b) curing or (c) bonding the third layer; and
(g) removing the finished component from a machine which performs the creating and emitting steps, with the layers all being integrally connected to their adjacent layers;
the component being integrally formed as a single piece, functionally durable, made by the machine in less than ninety minutes, and including the at least one liquid-carrying passageway defined by an offset elongated directional configuration.
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Abstract
A component is provided that includes at least one passageway. In another aspect, a component, such as a lamp or a vehicular washer jet, is made of layers of material, a light curable material and/or multiple built-up materials. Another aspect uses a three-dimensional printing machine to emit material from an ink jet printing head to build up a component.
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Citations
37 Claims
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1. A method of making a component including at least one liquid-carrying passageway, the method comprising:
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(a) creating a first layer of material to define a first section of the component comprising a washer jet; (b) emitting light onto the first layer to perform at least one of;
(a) hardening, (b) curing or (c) bonding the first layer;(c) creating a second layer of the material upon the first layer to define a second section of the component after the prior step; (d) emitting light onto the second layer to perform at least one of;
(a) hardening, (b) curing or (c) bonding the second layer;(e) creating at least a third layer of the material upon the second layer to define at least a third section of the component after the prior step; (f) emitting light onto the third layer to perform at least one of;
(a) hardening, (b) curing or (c) bonding the third layer; and(g) removing the finished component from a machine which performs the creating and emitting steps, with the layers all being integrally connected to their adjacent layers; the component being integrally formed as a single piece, functionally durable, made by the machine in less than ninety minutes, and including the at least one liquid-carrying passageway defined by an offset elongated directional configuration. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method of making a washer jet, the method comprising:
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(a) depositing a layer of material onto a support surface, the layer defining an outer surface of the washer jet; (b) additively depositing subsequent layers of the material upon each prior layer until the washer jet is completely created; (c) creating the washer jet to comprise a head including a curved liquid-carrying passageway therein, a body attached to the head, and vehicular panel-engaging wings flexibly extending from the body wherein the head, the body, and the vehicular panel-engaging wings are simultaneously created during the material depositing steps such that the material forming at least two of;
the head, the body, and the vehicular panel-engaging wings is deposited within the same layer;(d) surrounding at least a majority of the washer jet with a gas during the depositing and creating steps; and (e) curing the washer jet so that the layers of the material bond together. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24)
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25. A method of making a component including at least one passageway, the method comprising:
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(a) creating a first layer of material to define a first section of the component which comprises a washer jet; (b) emitting light onto the first layer to perform at least one of;
(a) hardening, (b) curing or (c) bonding the first layer;(c) creating a second layer of the material upon the first layer to define a second section of the component after the prior step; (d) emitting light onto the second layer to perform at least one of;
(a) hardening, (b) curing or (c) bonding the second layer;(e) creating at least a third layer of the material upon the second layer to define at least a third section of the component after the prior step; (f) emitting light onto the third layer to perform at least one of;
(a) hardening, (b) curing or (c) bonding the third layer;(g) creating the washer jet to include a flexible panel engagement segment extending from a stem configured to attach to an automotive vehicular panel with an easier insertion force than extraction force, at least one of the first section, the second section, and the third section including different materials forming the flexible panel engagement segment and the stem respectively; and (h) removing the finished washer jet from a machine which performs the creating and emitting steps, with the layers all being integrally connected to their adjacent layers. - View Dependent Claims (26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37)
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Specification