IP Library Granted Patent US 11,161,300
Granted Patent B2
US 11,161,300 · App. 16/368,776 · Granted Nov 2, 2021

System and print head for additive manufacturing system

Inventors: Trevor David Budge (Coeur d'Alene, ID); Ryan C. Stockett (Spokane, WA); Tyler B. Alvarado (Coeur d'Alene, ID); Kenneth Lyle Tyler (Coeur d'Alene, ID); Colin Hugh Hambling (Medina, WA); Brian Dunham (Sagle, ID); Nathan Andrew Stranberg (Post Falls, ID)
Assignee: Continuous Composites Inc.
B29C64/209B29C64/165B29C64/291B33Y10/00B33Y30/00B33Y70/00B29B11/16B29C35/0805B29C70/388B29C70/543B29C2793/0027B32B38/0004B32B38/1808B33Y40/00B33Y80/00
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Quick Facts
Patent No.
US 11,161,300
App. No.
16/368,776
Granted
Nov 2, 2021
Kind
B2
Abstract

A print head is disclosed for use in an additive manufacturing system. The print head may include a receiving end configured to receive a matrix and a continuous reinforcement, and a discharging end configured to discharge the continuous reinforcement at least partially coated in the matrix. The print head may also include a compactor located at the discharging end and forming a tool center point for the print head.

Claims (35)

1. A print head for an additive manufacturing system, comprising:

a receiving end configured to separately receive a matrix and a continuous reinforcement;

a discharging end configured to discharge the continuous reinforcement at least partially coated in the matrix;

a module located between the receiving end and the discharging end and configured to disburse the matrix through the continuous reinforcement;

a compactor located at the discharging end and forming a tool center point for the print head;

a source of cure energy mounted remote from the discharge end; and

a transmission line extending from the source to the compactor.

2. The print head of claim 1 , wherein the continuous reinforcement contacts the compactor before contacting a surface onto which the continuous reinforcement is to be discharged.

3. The print head of claim 1 , wherein the continuous reinforcement is first coated with the matrix at a location inside of the module.

4. The print head of claim 3 , wherein the includes at least one channel to receive the continuous reinforcement, the at least one channel having a width that is greater than a thickness.

5. The print head of claim 3 , wherein the module includes at least one contact surface that generates a pressure differential within the continuous reinforcement.

6. The print head of claim 4 , wherein the at least one channel tapers along its length.

7. The print head of claim 4 , wherein the at least one channel has a cross-sectional area 40% greater than an area of the continuous reinforcement passing through the at least one channel.

8. The print head of claim 4 , wherein the module includes:

at least one entrant roller; and

a piloting subassembly located downstream of the at least one entrant roller.

9. The print head of claim 1 , further including a final guide associated with the compactor.

10. The print head of claim 9 , wherein the final guide is configured to bias the continuous reinforcement toward the compactor.

11. The print head of claim 1 , wherein the compactor is moveable relative to the discharging end from a threading position away from the continuous reinforcement to a compacting position against the continuous reinforcement.

12. The print head of claim 11 , wherein the compactor is further moveable at the compacting position to adjust a pressure exerted by the compactor on the continuous reinforcement.

13. The print head of claim 11 , further including an actuator configured to adjust positions of the compactor.

14. The print head of claim 13 , further including a lash adjuster located between the actuator and the compactor.

15. The print head of claim 1 , wherein the transmission line is configured to direct cure energy to a trailing side of the compactor.

16. A print head for an additive manufacturing system, comprising:

a receiving end configured to separately receive a matrix and a plurality of continuous reinforcements;

a discharging end configured to discharge a ribbon made from the plurality of continuous reinforcement and the matrix;

a module located between the receiving end and the discharging end and configured to disburse the matrix through the plurality of continuous reinforcements;

a compactor located at the discharging end and forming a tool center point for the print head; and

a cure module configured to direct cure energy to the ribbon.

17. The print head of claim 16 , wherein the cure module includes:

a source of cure energy; and

a transmission line extending from the source to the compactor.

18. The print head of claim 16 , wherein the module includes a plurality of channels, each configured to receive one of the plurality of continuous reinforcements.

19. The print head of claim 18 , wherein the plurality of channels converge toa wards each other at an exit end.

20. The print head of claim 18 , wherein each of the plurality of channels has a width that is greater than a thickness.

Assignments (2)
CHANGE OF NAME Recorded Jul 16, 2019
From: CC3D LLC
To: CONTINUOUS COMPOSITES INC.
Reel/Frame 049772/0013 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 28, 2019
From: BUDGE, TREVOR DAVID; STOCKETT, RYAN C; ALVARADO, TYLER B; TYLER, KENNETH LYLE; HAMBLING, COLIN HUGH; DUNHAM, BRIAN; STRANBERG, NATHAN ANDREW
To: CC3D LLC
Reel/Frame 048733/0516 →
Continuity (2)
Provisional Application 62656155 · Apr 11, 2018
Related Publication 20190315057A1 · Oct 17, 2019