Method of making winged fasteners by three-dimensional printing

• US 10,207,461 B2
• Filed: 11/22/2016
• Issued: 02/19/2019
• Est. Priority Date: 06/02/2011
• Status: Expired due to Fees

• Current Assignee: A Raymond Et Compagnie
• Original Assignee: A Raymond Et Compagnie
• Inventors: Jackson, Nicholas
• Primary Examiner(s): Tentoni, Leo B
• Application Number:
  US15/359,043
• Publication Number:
  US 20170072630A1
• Time in Patent Office: 819 Days
• Field of Search: 2642971, 2642978, 264308, 264401, 264460, 264461, 264462, 264463, 264494, 264496, 264497, 21912164, 21912166, 21912185
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/47 characterised by structural features
• CPC Class Codes: B22F 5/06 of threaded articles, e.g. nuts
• CPC Class Codes: B28B 1/001 Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 35/0805 using electromagnetic radiation
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/129 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/147 using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 64/171 specially adapted for manufacturing multiple 3D objects
• CPC Class Codes: B29C 64/176 Sequentially
• CPC Class Codes: B29C 64/182 in parallel batches
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29K 2105/0002 monomers or prepolymers
• CPC Class Codes: B29L 2001/005 Nuts
• CPC Class Codes: B29L 2031/727 : Fastening elements bolts B29L2001/002; nuts B29L2001/005; screws B29L2001/007; slide fasteners B29L2005/00; buttons for haberdashery B29L2019/00
• CPC Class Codes: B33Y 10/00 : Processes of additive manufacturing
• CPC Class Codes: B33Y 50/02 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 70/00 : Materials specially adapted for additive manufacturing
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: F16B 19/002 : Resiliently deformable pins F16B21/06 takes precedence
• CPC Class Codes: F16B 19/1081 : fastened by a drive-pin F16B19/109 takes precedence
• CPC Class Codes: F16B 2200/75 : Fasteners made by sintering powders
• CPC Class Codes: F16B 29/00 : Screwed connection with deformation of nut or auxiliary member while fastening Nuts fastened to surfaces by riveting F16B37/065; members deformed for locking screws, bolts or nuts F16B39/22
• CPC Class Codes: F16B 33/006 : Non-metallic fasteners using screw-thread
• CPC Class Codes: F16B 37/00 : Nuts or like thread-engaging members specially shaped for rotations by a tool F16B23/00
• CPC Class Codes: F16B 37/041 : Releasable devices F16B37/044, F16B37/045 take precedence
• CPC Class Codes: F16B 37/0842 : fastened to the threaded bolt with snap-on-action, e.g. push-on nuts for stud bolts F16B37/0857 takes precedence; snap-on-action of a pin, spigot, shaft or the like and a member surrounding it F16B21/06
• CPC Class Codes: F16B 39/30 : Locking exclusively by special shape of the screw-thread
• CPC Class Codes: F16B 5/0233 : allowing for adjustment perpendicular to the plane of the plates
• CPC Class Codes: F16B 5/0635 : fastened over the edges of the sheets or plates
• CPC Class Codes: F16B 5/0642 : the plates being arranged one on top of the other and in full close contact with each other
• CPC Class Codes: F16B 5/065 : the plates being one on top of the other and distanced from each other, e.g. by using protrusions to keep contact and distance
• CPC Class Codes: F16B 7/0493 : forming a crossed-over connection
• CPC Class Codes: H02G 3/32 : using mounting clamps
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

A fastener is provided. In another aspect, a fastener 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 fastener.

Claims

1. A method of making a fastener, the method comprising:

(a) creating a first layer of material to define a first section of the fastener;

(b) emitting light onto the first layer after the prior step to cure, harden or bond the layer;

(c) creating a second layer of the material upon the first layer to define a second section of the fastener after the prior step;

(d) emitting light onto the second layer after the prior step to cure, harden or bond 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 fastener after the prior step;

(f) emitting light onto the third layer after the prior step to cure, harden or bond the third layer;

(g) making a head, an elongated shaft and a flexible workpiece-engaging wing from the material which is a printable polymeric material, as part of at least some of the creating steps, the shaft extending from the head and the wing being flexibly attached to the shaft with an undercut and hollow cavity created between the shaft and an inwardly facing surface of the wing;

(h) removing the finished fastener from a machine which performs the creating and emitting steps, with the layers all being integrally connected to their adjacent layers; and

(i) the finished fastener being functional and made by the machine in less than ninety minutes.

2. The method of claim 1, further comprising depositing the first layer of the material from a printing head onto a support surface of the machine in an ambient and unpressurized air environment.

3. The method of claim 1, wherein the light is ultraviolet light which is immediately passed over each layer of the fastener after it is deposited.

4. The method of claim 1, further comprising making two of the flexible workpiece-securing wings, the elongated shaft and the head, which is laterally enlarged, as part of at least some of the creating steps, the head being layered before the wings are layered in the machine.

5. The method of claim 1, further comprising creating the fastener in an additive manner with a pair of the flexible workpiece-engaging wings, each of the wings including arcuate internal and external surfaces when viewed from above.

18. The method of claim 1, wherein the making step further comprises creating a circular and laterally enlarged periphery of the head from which perpendicularly and centrally extends the shaft.

19. The method of claim 1, wherein the making step further comprises creating a tapered distal end opposite the head where the wing and the shaft join together.

20. The method of claim 1, wherein the making step further comprises creating a longitudinally elongated slot adjacent an edge of the wing, the slot being accessible to the cavity, the slot being parallel to an elongated length of the shaft, and an edge of the wing opposite the slot being attached to the shaft.

21. The method of claim 1, wherein the making step further comprises creating a slot between halves of the wing on a side of the shaft.

22. The method of claim 1, wherein the making step further comprises creating a longitudinally elongated slot between a substantially semi-circular portion of the wing and the shaft.

23. The method of claim 1, wherein the making step further comprises creating the cavity to be open toward an underside of the head.

6. A method of making a fastener, the method comprising:

(a) depositing a layer of material onto a support surface, the layer defining an outer surface of the fastener;

(b) depositing subsequent layers of the material upon each prior layer until the fastener is completely created;

(c) creating the fastener to comprise a head, a central shaft extending from the head and circumferentially arcuate wings flexibly attached to the shaft, with an undercut hollow cavity created between the shaft and an inwardly facing surface of each of the wings, made of the material as part of the depositing steps;

(d) surrounding at least a majority of the fastener with a gas during the depositing and creating steps;

(e) curing the fastener so that the layers of the material bond together; and

(f) removing the completed fastener from the support surface.

7. The method of claim 6, wherein the gas is air, and the fastener is a single piece.

8. The method of claim 6, further comprising flowing the material from a machine head positioned above the support surface, at least one of the machine head and the support surface automatically moving relative to the other according to computer instructions in order to create identical multiples of the fastener in the same machine cycle, free of contraction or expansion due to the manufacture thereof.

9. The method of claim 6, wherein the material is a three-dimensionally printable polymer.

10. The method of claim 6, wherein the material is a polymeric string emitted from a moveable machine head in a continuous manner from a spool which supplies the string to the head.

11. The method of claim 6, wherein at least ten of the fasteners are substantially simultaneously manufactured in a single machine cycle in less than ninety minutes.

12. The method of claim 6, further comprising flowing the material from an ink jet printing head including openings arranged in an array such that multiple material flows are simultaneously occurring for each layer of the fastener.

13. The method of claim 6, wherein the material is a light curable polymer.

14. The method of claim 6, wherein a light is ultraviolet light which is immediately passed over each of the layers of the fastener after it is deposited as part of the curing step.

15. The method of claim 6, wherein the creating step further comprises creating a tapered distal end opposite the head adjacent where the wings and the shaft join together.

16. The method of claim 6, wherein the creating step further comprises creating a longitudinally elongated slot adjacent an edge of each of the wings, the slot being accessible to the cavity, the slot being parallel to an elongated length of the shaft, and an edge of each of the wings opposite the slot being attached to the shaft.

17. The method of claim 6, wherein the creating step further comprises creating a slot between halves of each of the wings on one side of the shaft.

24. A method of making a fastener, the method comprising:

(a) three dimensionally printing;

(i) a laterally enlarged head, (ii) a shaft longitudinally extending perpendicularly to the head, and (iii) wings each having a first longitudinally elongated edge attached to the shaft and a free opposite second elongated edge defining a slot;

(b) an undercut hollow cavity being created between the shaft and an inwardly facing surface of each of the wings;

(c) the wings and shaft joining together adjacent a tapered distal end opposite the head; and

(d) light curing the head, shaft and wings to make the fastener.

25. The method of claim 24, wherein the gas is air, and the fastener is a single piece.

26. The method of claim 25, further comprising flowing a layerable material from a machine head positioned above the support surface, at least one of the machine head and the support surface automatically moving relative to the other according to computer instructions in order to create identical multiples of the fastener in the same machine cycle, free of contraction or expansion due to the manufacture thereof, and the wings being flexible relative to the shaft.

27. The method of claim 24, wherein at least ten of the fasteners are substantially simultaneously manufactured in a single machine cycle in less than ninety minutes, and the wings are flexible relative to the shaft.

28. The method of claim 27, further comprising flowing a layerable material from an ink jet printing head including openings arranged in an array such that multiple material flows are simultaneously occurring for each layer of the fastener.

29. The method of claim 24, wherein the fastener is made of a light curable polymer.

30. The method of claim 24, wherein the light is ultraviolet light which is immediately passed over each layer of the fastener after it is deposited as part of the curing step.

31. The method of claim 24, further comprising creating a tapered distal end opposite the head adjacent where the wings and the shaft join together.

32. The method of claim 24, wherein the slot is longitudinally elongated and created to be accessible to the cavity, the slot is parallel to an elongated length of the shaft and the second edge of each of the wings has cross-sectionally curved corners both internally facing the cavity and externally.

33. The method of claim 24, further comprising creating the slot between halves of each of the wings on each side of the shaft.

34. The method of claim 24, further comprising making the fastener such that workpiece-contacting surfaces of the wings flex toward the shaft when inserted into a workpiece hole, the wings creating a greater workpiece-extraction force than insertion force, and the hollow cavity is die-locked.