METHODS AND APPARATUS FOR MOBILE ADDITIVE MANUFACTURING OF ADVANCED STRUCTURES AND ROADWAYS

• US 20140374933A1
• Filed: 06/20/2014
• Published: 12/25/2014
• Est. Priority Date: 06/23/2013
• Status: Active Grant

• Current Assignee: Addibots, LLC
• Original Assignee: Addibots, LLC
• Inventors: Flitsch, Robert A., Flitsch, Frederick A
• Granted Patent: US 9,724,877 B2
• Time in Patent Office: Days
• US Class Current: 264/36.1
• 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 mobile additive manufacturing apparatus comprising:

a controller capable of executing algorithms and providing control signals;

an additive manufacturing system to deposit at least a first material in prescribed locations across a surface according to a first digital model processed by the controller, wherein the at least a first material is extruded into a molding form to form the deposit;

a drive system operative to transport the additive manufacturing system along the surface;

a navigation system to determine a location of the additive manufacturing system and guide the drive system; and

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

2. The apparatus of claim 1 wherein:

the molding form is shaped into a portion of a wall.

3. The apparatus of claim 2 wherein:

the molding form comprises an internal closed shape.

4. The apparatus of claim 1 wherein:

the molding form is shaped into a cross-hatch pattern.

5. The apparatus of claim 1 wherein:

the deposit is formed at a height approximately equal to or less than the height of a bed of a roadway.

6. The apparatus of claim 5 wherein:

the deposit includes regions that form channels.

7. The apparatus of claim 1 additionally comprising:

a vision system to create a second digital model of a topology of the surface in a region proximate to the mobile additive manufacturing apparatus.

8. The apparatus of claim 1 additionally comprising:

a material storage system capable to store at least the first material to be supplied to the additive manufacturing system.

9. The apparatus of claim 1 additionally comprising:

a surface preparation system capable to remove one or more of flaked surface material, dust, dirt, fluids and debris from a surface region in advance of the additive manufacturing system.

10. The apparatus of claim 1 additionally comprising:

a communication system capable of transmitting signals outside the mobile additive manufacturing apparatus and receiving signals originating from outside the mobile additive manufacturing apparatus.

11. 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,

an additive manufacturing system to deposit at least a first material in prescribed locations across the surface according to a digital model processed by the controller, 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 a second material on the different location.

12. The method of claim 11 wherein the first material is extruded into a molding form to form the first deposit.

13. The method of claim 12 wherein the first material is identical to the second material.

14. The method of claim 13 wherein a channel is formed within the deposit.

15. The method of claim 14 wherein a wire or fiber is located within the channel.

16. The method of claim 15 additionally comprising:

adding a roadway bed upon the surface and the first deposit; and

transporting an internet connected signal through the wire or fiber.

17. The method of claim 12 additionally comprising:

adding a roadway bed upon the surface and the first deposit.

18. A method for forming a wall 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,

an additive manufacturing system to deposit at least a first material in prescribed locations across the surface according to a digital model processed by the controller, wherein the at least a first material is extruded into a molding form to form the deposit, and

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

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

wherein the region is a portion of the surface upon which the wall is formed;

moving the apparatus to a different location; and

forming a second deposit of the material at the different location.

19. The method of claim 18 additionally comprising:

adding a solidifying material to regions within the first and second deposit.

20. The method of claim 19 wherein the solidifying material comprises concrete.