Conductive liquid three dimensional printer

• US 9,616,494 B2
• Filed: 03/28/2014
• Issued: 04/11/2017
• Est. Priority Date: 03/28/2014
• Status: Active Grant

• Current Assignee: Alloy Acquisition Corporation LLC
• Original Assignee: Scott Vader, Zachary Vader
• Inventors: Vader, Scott, Vader, Zachary
• Primary Examiner(s): Tankersley, Blake A
• Assistant Examiner(s): Nguyen, Quang X
• Application Number:
  US14/228,681
• Publication Number:
  US 20150273577A1
• Time in Patent Office: 1,110 Days
• Field of Search: 164513, 164498, 1641471, 164502, 164 46
• CPC Class Codes: B22D 21/007 with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
• CPC Class Codes: B22D 23/003 Moulding by spraying metal on a surface
• CPC Class Codes: B22F 10/22 Direct deposition of molten metal
• CPC Class Codes: B22F 12/10 Auxiliary heating means
• CPC Class Codes: B22F 12/53 Nozzles
• CPC Class Codes: B22F 2202/05 Use of magnetic field
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• 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: Y02P 10/25 Process efficiency

Abstract

A printer that produces objects from liquid conductive material is disclosed. In one embodiment, the printhead has a chamber for containing liquid conductive material surrounded by an electromagnetic coil. A DC pulse is applied to the electromagnetic coil, resulting in a radially-inward force on the liquid conductive material. The force on the liquid conductive material in the chamber results in a drop being expelled from an orifice. In response to a series of pulses, a series of drops fall onto a platform in a programmed pattern, resulting in the formation of an object.

Claims

1. A device for printing conductive material, comprising:

a structure incorporating at least one first chamber to accumulate a liquid conductive material;

a partition at least partially submerged in a pool of liquid conductive material in the first chamber, said pool of liquid conductive material extends continuously and without interruption by gas pockets from the partition to an orifice during operation of the structure;

wherein the pool of liquid conductive material is suspended above the orifice such that liquid conductive material does not flow out of the orifice under gravity alone;

an electromagnetic coil to produce a radially-directed electromotive force on said liquid conductive material in response to a pulse of DC voltage applied to the electromagnetic coil;

wherein the radially-directed electromotive force causes the liquid conductive material to flow within the first chamber;

wherein the first chamber is adapted to direct the flow of liquid conductive material with the partition working in conjunction with the electromagnetic coil to redirect upward flow caused by the radially-directed electromotive force within the pool of liquid conductive material downward to push out a drop of liquid conductive material from the orifice.

2. The device of claim 1 wherein said structure is generally nonconductive and has a generally cylindrical first chamber in fluid communication with at least one channel;

said channel having an opening at an upstream end to receive conductive material from a source;

wherein said conductive material generally moves from said upstream end in a downstream direction through said channel;

said channel defines an axially extending flow region for said liquid conductive material to flow to said generally cylindrical first chamber;

said generally cylindrical first chamber being enclosed by a housing, wherein said electromagnetic coil is disposed adjacent and radially-outward surrounding said housing and said generally cylindrical first chamber;

said coil operatively arranged to produce a magnetic field being axially-directed within said first chamber resulting in said radially-directed electromotive force being applied circumferentially to said liquid conductive material in said generally cylindrical first chamber.

3. The device of claim 2 wherein said first chamber is proximate a downstream end to a second chamber in which said liquid conductive material accumulates;

said second chamber serving to damp negative pressure on the liquid conductive material, thereby allowing said second chamber to remain filled with liquid conductive material after a drop is expelled from the opening;

said second chamber opening at its downstream end to said orifice, wherein said second chamber and said orifice are incorporated into a generally cylindrical nozzle concentric with and extending from said housing.

4. The device of claim 3 wherein said first chamber contains the partition to direct said liquid conductive material from said channel to a perimeter of said first chamber;

said partition separating said first chamber into a lower region and an upper region wherein said lower region is defined as the space between a downstream surface of said partition and a downstream surface of said first chamber.

5. The device of claim 4 wherein said partition has a generally circular downstream section with said downstream surface parallel to an x-axis and a y-axis disposed radially-outward and downstream to a generally conical section;

said partition having a set of dividers disposed proximate to and upstream of said circular downstream section and said conical section;

said conical section having a radially-inward circular partition platform parallel to the x-axis and y-axis;

said partition platform being disposed axially downstream of the channel opening such that liquid conductive material exiting the downstream end of said channel contacts said partition platform and flows to the perimeter of said first chamber through a set of gaps between said set of dividers.

6. The device of claim 5 wherein said channel is enclosed by a tundish heated by a furnace to a temperature required to melt a solid conductive material.

7. The device of claim 6 wherein said first chamber is enclosed by a generally bell shaped housing having an upper housing extending radially-outward and downstream from said channel at an approximately 45 degree angle and a lower housing having a wall extending downstream from said angled upper housing and generally parallel with said channel and a bottom extending from the downstream end of the wall portion inward generally perpendicular to said outer wall portion.

8. The device of claim 7 wherein said electromagnetic coil is disposed adjacent said nozzle and surrounding said second chamber and orifice therein.

9. The device of claim 8 wherein said channel is connected to an inlet for inert gas thereby directing inert gas to flow through the device, wherein said inert gas pressure is regulated to maintain an appropriate meniscus of liquid conductive material at the orifice.

10. The device of claim 9 wherein the housing is enclosed in a housing chamber;

said housing chamber being connected to an inlet for inert gas allowing said inert gas to flow externally to said housing and nozzle to protect liquid conductive material from oxidation after leaving said orifice.

11. The device of claim 10, wherein said coil is disposed adjacent said nozzle and surrounding but displaced radially-outward from said orifice.

12. The device of claim 1, wherein the pool of liquid conductive material is suspended by surface tension at the nozzle.

13. A method for printing conductive material, comprising:

a. providing a partition disposed in a first chamber;

b. at least partially filling the first chamber with a liquid conductive material;

c. suspending a pool of liquid conductive material in the first chamber;

d. at least partially submerging the partition with the pool of liquid conductive material;

e. generating a pulse of DC voltage in an electromagnetic coil surrounding the first chamber;

f. applying a radially-inward directed electromotive force circumferentially to said liquid conductive material in said first chamber;

g. the partition working in conjunction with the electromagnetic coil to redirect an upward flow of liquid conductive material produced by the radially-inward directed electromotive force downward to push out a drop of liquid conductive material from an orifice.

14. The method of claim 13 comprising directing the flow of liquid conductive material in a first radially-outward direction to a perimeter of said first chamber, thereby allowing said liquid conductive material to flow radially-inward toward said orifice.

15. The method of claim 14 further comprising filling a second cylindrical chamber, concentric and downstream to the first chamber.

16. The method of claim 15 further comprising dividing the flow of liquid conductive material along the partition to direct the flow of liquid conductive material to separate sections of a perimeter of the first chamber.

17. The method of claim 16 wherein an inert gas is supplied to prevent oxidation of the liquid conductive material.

18. The method of claim 13, wherein the pool of liquid conductive material is suspended by surface tension at the nozzle.

19. A device for printing conductive material, comprising:

A supply of solid conductive material, wherein said solid conductive material is fed into a structure having an upstream and a downstream end;

said structure incorporating a channel having an inlet at its upstream end, wherein said channel incorporates a wire guide and gas seal;

said channel being proximate a tundish, wherein said tundish is enclosed by a furnace;

wherein said furnace heats the tundish to a temperature sufficient to melt a solid conductive material;

said channel opening at its downstream end to a cylindrical first chamber in liquid communication with said channel;

said first chamber being enclosed by a generally bell shaped housing having an upper housing extending radially-outward and downstream from said channel at an angle;

said first chamber having a lower housing comprising a wall extending in a downstream direction from said upper housing and generally parallel with said channel and a bottom extending from the downstream end of the wall inward and generally perpendicular to said wall;

said first chamber containing a partition to direct liquid conductive material exiting the downstream end of said channel to a perimeter of said first chamber, wherein said partition has a generally circular section with a surface generally parallel to an x-axis and a y-axis disposed radially-outward and downstream to a generally conical section;

said partition having a set of dividers disposed proximate and to and upstream said circular section and said conical section of said partition;

said conical section having a radially-inward circular partition platform generally parallel to the x-axis and y-axis;

said partition platform being disposed axially downstream of the channel opening such that liquid conductive material exiting the downstream end of said channel contacts said partition platform and flows to a perimeter of said first chamber through a set of gaps between said set of dividers, wherein said dividers are equidistantly disposed relative to adjacent said dividers;

said first chamber being proximate at its downstream end to a second chamber;

said second chamber being in liquid communication with said first chamber;

said second chamber serving to damp negative pressure on the liquid conductive material, thereby allowing said second chamber to remain filled with liquid conductive material;

said second chamber having an orifice at its downstream end to expel a drop of liquid conductive material;

said second chamber and said orifice being incorporated into a generally cylindrical nozzle concentric with and extending downstream said housing;

an electromagnetic coil disposed adjacent and radially-outward said housing and surrounding said first chamber therein;

said coil being operable to produce a magnetic field being axially-directed within said first chamber resulting in a radially-directed electromotive force applied circumferentially to said liquid conductive material;

wherein said electromagnetic coil is further disposed adjacent said nozzle and surrounding said second chamber and orifice therein and displaced radially-outward from said orifice;

said electromagnetic coil receiving a pulse of DC voltage resulting in the radially-directed electromotive force on said liquid conductive material;

said channel being connected to an inlet for an inert gas thereby directing the inert gas to flow through the device;

said housing being enclosed in a housing chamber;

said housing chamber being connected to an additional inlet for inert gas allowing said inert gas to flow around said housing and said nozzle to prevent oxidation of said liquid conductive material;

the partition at least partially submerged in a pool of liquid conductive material;

said pool of liquid conductive material extending continuously and without interruption from the partition to an orifice during operation of the structure;

wherein the pool of liquid conductive material is suspended above the orifice by surface tension at the nozzle such that liquid conductive material does not flow out of the orifice under gravity alone;

wherein the first chamber is adapted to direct a flow of liquid conductive material, produced in response to a pulse of DC voltage applied to the electromagnetic coil, with the partition working in conjunction with the electromagnetic coil to redirect an upward flow of liquid conductive material caused by the radially-directed electromotive force within the pool of liquid conductive material downward to push out a drop of liquid conductive material from the orifice.