Spool assembly with locking mechanism for additive manufacturing system, and methods of use thereof

• US 9,321,608 B2
• Filed: 12/22/2011
• Issued: 04/26/2016
• Est. Priority Date: 12/22/2011
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: Beery, Chad E., Kozlak, David M., Hjelsand, Timothy A.
• Primary Examiner(s): Sanders, James
• Assistant Examiner(s): Le, Ninh
• Application Number:
  US13/334,896
• Publication Number:
  US 20130161439A1
• Time in Patent Office: 1,587 Days
• Field of Search: 425/375, 242/598, 242/598.5, 242/598.6, 242/595.1, 242/170, 242/171, 242/384.3
• US Class Current: 1/1
• 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 64/321 Feeding
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 99/00 Subject matter not provided for in other groups of this subclass
• CPC Class Codes: B65H 2701/313 Synthetic polymer threads
• CPC Class Codes: B65H 2701/537 Stopping the winding or unwinding of reels which do not feature spring motors
• CPC Class Codes: B65H 49/322 Enclosing boxes with supporting means for the package or reel during unwinding
• CPC Class Codes: B65H 49/34 Arrangements for effecting positive rotation of packages
• CPC Class Codes: B65H 49/36 Securing packages to supporting devices replacing or removing cores, receptacles, or completed packages at paying-out, winding, or depositing stations B65H67/00
• CPC Class Codes: B65H 75/30 Arrangements to facilitate driving or braking

Abstract

A spool assembly comprising a housing structure, a spool rotatably retained in an interior region of the housing structure, and a sealed sheath encasing the housing structure to define a barrier for the encased housing structure and the rotatably retained spool. The spool assembly further comprises a locking arm disposed outside of the sealed sheath and configured to operably engage the spool through the sealed sheath and through the housing structure in a manner that does not penetrate the sealed sheath, where the locking arm prevents the spool from rotating relative to the housing mechanism when operably engaged with the spool. The locking arm may disengage from the spool in a hands-free manner when the spool assembly is loaded into a bay of an additive manufacturing system.

Claims

1. A spool assembly comprising:

a housing structure having an interior region;

a spool rotatably retained in the interior region of the housing structure, the spool configured to receive a supply of filament;

a sealed sheath encasing the housing structure to define a barrier for the encased housing structure, the spool, and the supply of filament; and

a locking arm disposed outside of the sealed sheath and configured to operably engage the spool through the sealed sheath and through the housing structure in a manner that does not penetrate the sealed sheath, wherein the locking arm prevents the spool from rotating relative to the housing mechanism when operably engaged with the spool wherein the locking arm comprises;

a collarbone member that is moveable relative to the housing structure;

a pair of opposing appendages each extending at an angle from the collarbone member; and

a pair of contact tips extending from the appendages, the pair of contact tips being the portions of the locking arm that operably engage with the spool.

2. The spool assembly of claim 1, wherein the locking arm is configured to actuate between an engaged state in which the locking arm is operably engaged with the spool and a disengaged state in which the locking arm is disengaged from the spool.

3. The spool assembly of claim 1, and further comprising a handle secured to the sealed sheath, the handle being separate from the housing structure, wherein the locking arm is moveably connected to the handle.

4. The spool assembly of claim 1, wherein the spool comprises:

a shaft having a first end and a second end offset along an axis of rotation; and

a first flange extending from the first end of the shaft, the first flange comprising a plurality of first indentations or openings extending radially around the first flange, each of the plurality of first indentations or openings being configured to operably engage with the locking arm; and

a second flange extending from the second end of the shaft.

5. The spool assembly of claim 4, wherein the second flange comprises a plurality of second indentations or openings extending radially around the second flange, and wherein each of the plurality of second indentations or openings are also configured to operably engage with the locking arm.

6. The spool assembly of claim 1, wherein the housing structure comprises an engagement opening, and wherein the spool assembly further comprises a flexure tab disposed across the engagement opening, wherein one of the pair of contact tips biases a portion of the flexure tab toward the spool when the one contact tip is operably engaged with the spool.

7. The spool assembly of claim 1, and further comprising:

a flexible tube comprising;

a first end disposed within the interior region of the housing structure; and

a second end; and

a print head comprising;

a cartridge assembly retaining the second end of the flexible tube; and

a liquefier pump assembly coupled to the cartridge assembly.

8. A spool assembly for use with an additive manufacturing system, the spool assembly comprising:

a housing structure having an interior region;

a spool configured to retain a supply of a filament for use in the additive manufacturing system;

a sealed sheath encasing the spool and the housing structure;

a locking arm disposed outside of the sealed sheath, wherein the locking arm is configured to operably engage the spool through the sealed sheath in a non-penetrating manner while in an engaged state to prevent the spool from rotating in the sealed sheath, and wherein the locking arm is further configured to be disengaged from the spool while in a disengaged state to allow the spool to rotate within the sealed sheath;

wherein the spool assembly is configured to be inserted into a bay of the additive manufacturing system; and

wherein the locking arm is configured to actuate from the engaged state to the disengaged state when the spool assembly is inserted into the bay wherein the locking arm comprises;

a collarbone member that is moveable relative to the housing structure;

a pair of opposing appendages each extending at an angle from the collarbone member; and

a pair of contact tips extending from the appendages, the pair of contact tips being the portions of the locking arm that operably engage with the spool.

9. The spool assembly of claim 8, and further comprising a housing structure encased within the sealed sheath, wherein the spool is retained within the housing structure in a manner that is free or substantially free of any hub engagement.

10. The spool assembly of claim 9, and further comprising a pair of bearing rollers configured to support the spool in the housing structure.

11. The spool assembly of claim 10, wherein the spool has an axis of rotation, and wherein the spool assembly is configured to be inserted into the bay of the additive manufacturing system in a manner such that when the spool assembly is fully inserted into the bay, the axis of rotation of the spool is substantially horizontal.

12. The spool assembly of claim 8, and further comprising a handle secured to the sealed sheath, the handle being separate from the housing structure, wherein the locking arm is movably connected to the handle.