Filament container and methods of use thereof

• US 8,157,202 B2
• Filed: 04/08/2011
• Issued: 04/17/2012
• Est. Priority Date: 10/22/2008
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: Taatjes, Thomas L., Turley, Patrick W., Zalusky, Martin G., Paul, Thomas P.
• Primary Examiner(s): Dondero, William E
• Application Number:
  US13/082,602
• Publication Number:
  US 20110180652A1
• Time in Patent Office: 375 Days
• Field of Search: 242/170, 242/171, 242/563, 242/563.2, 242/564, 242/564.1, 242/564.3, 242/564.4, 242/565, 242/566, 242/588, 242/588.3, 242/588.6, 242/615, 242/615.3, 242/615.4, 242/129, 226/110, 226/128
• US Class Current: 242/563.2
• CPC Class Codes: B29C 31/04 Feeding of the material to be moulded, e.g. into a mould cavity B29C39/08 takes precedence; using a material distribution system to two or more fixed injection moulds B29C45/125
• CPC Class Codes: B29C 64/255 Enclosures for the building material, e.g. powder containers
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 40/00 Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: B65H 49/322 Enclosing boxes with supporting means for the package or reel during unwinding
• CPC Class Codes: B65H 63/036 characterised by the combination of the detecting or sensing elements with other devices, e.g. stopping devices for material advancing or winding mechanism
• CPC Class Codes: B65H 63/086 responsive to completion of unwinding of a package

Abstract

A container comprising a housing that is configured to rotatably mount a filament supply spool, and a filament guide mechanism mountable within a channel of the housing, where the filament guide mechanism comprises a filament pathway configured to guide the filament from the filament supply spool rotatably mounted in the interior chamber, and a sensor configured to detect the presence of the filament through at least a portion of the filament pathway.

Claims

1. A method for supplying a filament of a material to a digital manufacturing system, the method comprising:

loading a container to the digital manufacturing system, the container comprising an interior chamber and a channel extending from the interior chamber to an exterior surface of the container, wherein the filament is located in the interior chamber and extends at least partially through the channel;

detecting the presence of the filament at a first location in the channel with a sensor within the channel;

communicating between the sensor located within the channel and the digital manufacturing system while the container is loaded to the digital manufacturing system;

engaging a drive wheel of the digital manufacturing system with the filament in the channel at a second location that is downstream along the channel from the sensor; and

rotating the drive wheel of the digital manufacturing system in a first rotational direction to drive successive portions of the filament through the channel.

2. The method of claim 1, and further comprising inserting a filament guide mechanism into the channel of the container, wherein the filament guide mechanism comprises the sensor and wherein the filament is channeled through the filament guide mechanism.

3. The method of claim 1, wherein communicating between the sensor and the digital manufacturing system comprises:

transmitting first electrical signals between the sensor and a first electrical contact located in the channel;

transmitting second electrical signals between the first electrical contact and an electrical connection accessible from the exterior surface of the container; and

transmitting third electrical signals between the electrical connection and the digital manufacturing system.

4. The method of claim 1, and further comprising:

detecting when the filament is no longer present at the first location within the channel; and

stopping the rotation of the drive wheel in the first rotational direction based on the detection that the filament is no longer present at the first location within the channel.

5. The method of claim 4, wherein stopping the rotation of the drive wheel in the first rotational direction is performed prior to a trailing end of the filament exiting the channel.

6. The method of claim 1, and further comprising:

loading a spool that contains the filament into the container;

detaching a filament guide mechanism from the spool, wherein the filament guide mechanism comprises the sensor; and

inserting the filament guide mechanism into the channel of the container.

7. The method of claim 6, and further comprising interfacing a first electrical contact located on the filament guide mechanism with a second electrical contact located in the channel, the first electrical contact being in signal communication with the sensor.

8. The method of claim 1, wherein engaging the drive wheel with the filament comprises directing motion of the drive wheel toward the filament with a beveled surface located along the channel.

9. A method for supplying a filament of a material to a digital manufacturing system, the method comprising:

loading a supply of the filament into a container, wherein a leading edge of the filament extends through a filament guide mechanism, the filament guide mechanism comprising a filament pathway and a sensor accessible to the filament pathway;

inserting the filament guide mechanism into an exit channel of the container;

loading the container containing the supply of the filament to the digital manufacturing system;

detecting the presence of the filament in the filament pathway with the sensor;

transmitting first electrical signals between the sensor and a first electrical contact located in the channel;

transmitting second electrical signals between the first electrical contact and an electrical connection accessible from the exterior surface of the container; and

transmitting third electrical signals between the electrical connection and the digital manufacturing system.

10. The method of claim 9, and further comprising:

engaging a drive wheel of the digital manufacturing system with the filament in the exit channel at a location that is downstream along the exit channel from the sensor; and

rotating the drive wheel of the digital manufacturing system in a first rotational direction to drive successive portions of the filament through the exit channel.

11. The method of claim 10, and further comprising:

detecting the absence of filament in the filament pathway; and

stopping the rotation of the drive wheel in the first rotational direction based on the detection that the filament is no longer present at the first location within the channel.

12. The method of claim 11, wherein stopping the rotation of the drive wheel in the first rotational direction is performed prior to a trailing end of the filament exiting the exit channel.

13. A method for supplying a filament of a material to a digital manufacturing system, the method comprising:

providing a filament supply to the digital manufacturing system, wherein the provided filament supply comprises the filament, an electrical contact located at an exterior surface of the filament supply, and a filament guide mechanism, wherein the filament guide mechanism comprises a housing having an inlet end and an outlet end, a filament pathway extending between the inlet end and the outlet end, a sensor accessible to the filament pathway between the inlet end and the outlet end, and an engagement region accessible to the filament pathway between the sensor and the outlet end such that the engagement region is downstream from the sensor, and wherein a leading edge of the filament extends through the filament pathway past the sensor and at least to the engagement region;

engaging the electrical contact of the provided filament supply with the digital manufacturing system;

detecting the presence of the filament in the filament pathway with the sensor;

communicating between the sensor and the digital manufacturing system through the engaged electrical contact;

engaging a drive mechanism with the filament in the filament pathway at the engagement region; and

operating the drive mechanism to drive successive portions of the filament through the filament pathway and into a filament feed pathway of the digital manufacturing system.

14. The method of claim 13, and further comprising:

detecting the absence of filament in the filament pathway with the sensor; and

stopping the operation of the drive mechanism based on the detection by the sensor that the filament is no longer present in the filament pathway at a location of the sensor.

15. The method of claim 14, wherein stopping the operation of the drive mechanism is performed prior to a trailing end of the filament moving past the engagement region.

16. The method of claim 15, and further comprising:

operating the drive mechanism to draw a remaining portion of the filament back to the filament supply; and

disengaging the electrical contact from the digital manufacturing system.

17. The method of claim 13, and further comprising maintaining a moisture seal for the filament in the filament supply.

18. The method of claim 13, wherein the drive mechanism comprises a drive wheel of the digital manufacturing system.