Methods and apparatus for mobile additive manufacturing of advanced structures and roadways

• US 9,724,877 B2
• Filed: 06/20/2014
• Issued: 08/08/2017
• Est. Priority Date: 06/23/2013
• Status: Active Grant

• Current Assignee: Addibots, LLC
• Original Assignee: Robert A. Flitsch
• Inventors: Flitsch, Robert A., Flitsch, Frederick A
• Primary Examiner(s): Snelting, Erin
• Application Number:
  US14/310,556
• Publication Number:
  US 20140374933A1
• Time in Patent Office: 1,145 Days
• CPC Class Codes: B22F 10/30 Process control
• CPC Class Codes: B22F 10/80 Data acquisition or data processing
• 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 64/20 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B29C 64/227 Driving means
• CPC Class Codes: B29C 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29L 2031/776 Walls, e.g. building panels
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: E01C 11/005 Methods or materials for repairing pavings E01C7/35 takes precedence; for concrete coverings E01C7/147; for bituminous coverings E01C7/187; devices for repair works E01C23/06; repairing bridge floorings E01D22/00
• CPC Class Codes: E01C 23/01 Devices or auxiliary means for setting-out or checking the configuration of new surfacing, e.g. templates, screed or reference line supports form rails E01C19/50; Applications of apparatus for measuring, indicating, or recording the surface configuration of existing surfacing, e.g. profilographs E01C23/07 takes precedence; measuring roughness or irregularity in general G01B
• CPC Class Codes: E01C 23/06 Devices or arrangements for working the finished surface working freshly laid paving E01C19/42 - E01C19/44, E01C23/02; mining picks E21C35/18; Devices for repairing or reconditioning the surface of damaged paving; Recycling in place or on the road
• CPC Class Codes: E01C 23/065 Recycling in place or on the road, i.e. hot or cold reprocessing of paving in situ or on the traffic surface, with or without adding virgin material or lifting of salvaged material; Repairs or resurfacing involving at least partial reprocessing of the existing paving in situ mixing of hydraulic cement concrete E01C19/025; apparatus for in-plant recycling E01C19/1004, E01C19/1036
• CPC Class Codes: E01C 23/07 Apparatus combining measurement of the surface configuration of paving with application of material in proportion to the measured irregularities measuring means only E01C23/01 G01B
• CPC Class Codes: E01C 23/0966 for filling or priming, with or without working the surface of the filling or applying particulate material thereto, e.g. for filling the joints of stone-sett paving E01C23/096, E01C23/0993 take precedence
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

The present disclosure provides various aspects for mobile and automated processing utilizing additive manufacturing and the methods for their utilization. In some examples, the mobile additive manufacturing apparatus may perform surface treatments that support the building of walls. Other examples may involve the support of creating and repairing advanced roadways.

Claims

1. A method for forming and repairing a roadway comprising:

transmitting a control signal to an apparatus, wherein the apparatus is a mobile additive manufacturing apparatus comprising;

a drive system operative to move the apparatus along a surface,

a navigation system to determine location,

a controller capable of executing algorithms and providing control signals,

a vision system capable of scanning the surface and measuring a topography of the surface;

an additive manufacturing system to deposit at least a first material in a prescribed location on the surface according to a digital model processed by the controller wherein the additive manufacturing system that deposits the first material comprises;

a heated extrusion head which heats an extrusion material to a molten or semi-molten form,

the extrusion material formed into a filament, and

a feeding apparatus which feeds the filament into the heated extrusion head and extrudes the melted material to the prescribed location on a roadway, and

a power system capable of providing power to operate at least the drive system, navigation system, controller and additive manufacturing system;

forming a first deposit of a first material on the surface;

moving the apparatus to a different location; and

forming a second deposit of the first material on the different location.

2. The method of claim 1 wherein a channel is formed within the roadway.

3. The method of claim 2 wherein a wire or fiber is located within the channel.

4. The method of claim 3 additionally comprising:

adding a second roadway bed, wherein the second roadway bed comprises asphalt, upon the roadway and the first deposit; and

transporting an internet connected signal through the wire or fiber.

5. The method of claim 1 additionally comprising:

adding a second roadway bed, wherein the second roadway bed comprises asphalt upon the roadway and the first deposit, and wherein the first deposit at least partially mixes into the roadway bed comprising asphalt as it is applied.