The present disclosure concerns a system for delivering a photocurable resin to a three dimensional printing system. More particularly, the present disclosure concerns a resin container that forms part of a system enabling resin-carrying components to be quickly removed and replaced for maintenance or changing resins.
Three dimensional printing systems that utilize curable resins are in wide use. Such systems can utilize variety of resins such as photocurable liquids, resin binders, support material resins, and various treatment fluids. Challenges with such systems include reliability, maintenance, contamination, and a desire to utilize different and/or improved formulations. There is a need for a system that allows for maintenance or changing resins with minimal difficulty and no contamination.
In a first aspect of the disclosure, a resin container is configured to provide a photocurable resin to a three dimensional printing system. The three dimensional printing system includes a receptacle configured to provide the resin to a print engine. The resin container includes a housing enclosing an internal reservoir which contains an impeller. The resin container has a leading end and a trailing end relative to a direction of insertion or installation of the resin container into the receptacle. The leading end includes a fluid outlet extending downwardly from a first lateral location, an electrical connector extending downwardly from a second lateral location, and a gear coupled to the impeller and extending downwardly from a third lateral location.
In one implementation the housing includes an upper portion and a lower portion that couple together to define the internal reservoir therebetween. The upper portion defines the trailing end and the lower portion defines the leading end. The upper and lower portions have overlapping cylindrical surfaces that compress an O-ring therebetween to provide a fluid seal for the internal reservoir. The impeller has at least two blades that extend radially from an axial shaft about which the blades can be rotated. The axial shaft has two ends that are rotatably supported by engagement with the upper and lower housing portions. The housing portions includes radially extending ribs that encircle the housing portions to improved structural rigidity of the housing.
In another implementation the third lateral location of the gear is central to the leading end. The gear includes an upwardly extending axial shaft that coincides with an axis of rotation for the impeller. The lower housing portion has a central opening through which the upwardly extending axial shaft extends. The upwardly extending axial shaft of the gear couples to the impeller. Between the central opening and the axial shaft is a seal for preventing resin leakage. The leading end of the resin container has a peripheral edge. Each of the first and second locations are between the gear and the peripheral edge.
In yet another implementation the electrical connector includes an arrangement of contacts that are arranged along a first lateral axis. The contacts are contact pads that face along a second lateral axis that is perpendicular to the first lateral axis.
In a further implementation the first, second, and third lateral locations are arranged along a first lateral axis. The container can have a lateral shape that defines a circle or ellipse. The first lateral axis can be oriented along an axis of the circle or ellipse.
In a yet further implementation the receptacle has an upper portion having an opening with a guiding feature. An outer surface of the resin container has a shape that is complementary to the opening and the resin container is constrained to a proper orientation with respect to a vertical axis and to align the leading end to the receptacle.
In another implementation the receptacle has an upper portion having an opening including a laterally extending slot. The resin container includes a fin or rib that extends laterally. Engagement between the fin or rib and the slot aligns the resin container as it is inserted into the opening. The resin container includes an outer shell that covers the upper and lower housing portions. The shell has an opening through which the fin or rib extends.
The print engine 6 includes a resin vessel 10, a support fixture 12 coupled to a motorized transport system 14, and a light engine 16. The resin vessel 10 includes a transparent sheet 18 on a lower side and contains a photocurable resin 20. The support fixture 12 supports a three dimensional article 22 having a lower face 24 in facing relation with the transparent sheet 18. Between the transparent sheet 18 and lower face 24 is a thin layer of the resin 20 defining a build plane 26 that is proximate to the lower face 24.
The transport system 14 is configured to vertically position the support fixture 12. The transport system 14 is thereby configured to control an optimal distance H(t) between the transparent sheet 18 and the lower face 24 during the manufacture of the three dimensional article 22.
The light engine 16 generates and projects pixelated light 28 up through the transparent sheet and to the build plane 26. The application of the pixelated light 28 selectively hardens a layer of the resin 20 at the build plane 26 and onto the lower face 24. In the illustrated embodiment, the light engine 16 includes a light source 30 and a spatial light modulator 32.
The resin supply subsystem 4 includes a conduit assembly 36 and a resin level sensor 38. The conduit assembly 36 includes a fluid outlet 40 positioned above the resin vessel 20. Resin 20 is transported through conduit assembly 36 and then dispensed into resin vessel 10.
Controller 8 is configured to receive signals from sensors such as resin level sensor 38 and to control transport system 14, light engine 16, resin supply subsystem 4, and other portions of the printing system 2. The controller 8 can have one location or multiple locations within the printing system 2. The controller 8 includes a processor coupled to an information storage device. The information storage device includes a non-transient or a non-volatile media storing software instructions. The software instructions are executed by the processor to read signals from sensors and to operate portions of the printing system 2.
While a particular embodiment of the print engine 6 is depicted in
The receptacle 42 is configured to receive, align, and couple to the resin container 44. The receptacle 42 includes an upper portion 48 and an interface portion 50 which will be discussed in more detail infra. At the interface portion 50, the resin container 44 is fluidically coupled to the conduit assembly 36.
The conduit assembly 36 includes a pump head 52 that is mechanically coupled to the pump motor system 46. In response to an operation of the pump motor system 46, resin flows out of the resin container 44, through the conduit assembly 36, and to the print engine 6.
Conduit assembly 36 and resin container 44 are easily removed and replaced from the printing system 2. This allows the printing system 2 to be changed from a first (old) resin to a second (new) resin with minimal difficulty by removing and replacing resin container 44, conduit assembly 36, and the resin vessel 10. Because no other portion of printing system 2 is contacted by resin, contamination of the second resin by the first resin is avoided while allowing a very rapid changeover. The conduit assembly 36 and resin container 44 can be provided together as a kit for quickly changing out resin from a previous version of resin to that contained within resin container 44.
See
The pump motor system 46 includes a mounting surface 88, a pump actuator 90, and a pump motor 92 (under the mounting surface 88). The pump motor 92 is coupled to the pump actuator 90. The mounting surface 88 includes a plurality of mounting features 94.
Mounting or coupling the pump head 52 to the pump motor system 46 is a very quick process. First, the pump head 52 is placed against the mounting surface 88 and the pump actuator 90 engages the rotary roller 84. Second, the complementary mounting features (86 and 94) are coupled together. In one embodiment, the mounting features (86 and 94) are aligned holes and include hand assembled thumb screws that pass through the aligned holes and secure the outer housing 82 to the mounting surface 88. In another embodiment, the complementary mounting features (86 and 94) are magnetic materials that mutually attract each other. In yet another embodiment, the complementary mounting features (86 and 94) include combinations of pins and openings that are press fit together to provide a friction-based mounting. In a further embodiment, the complementary mounting features (86 and 94) include a combination of wrench-adjustable screws and threaded holes. These are but a few examples.
With the pump head 52 mounted to the pump motor system 46, the pump motor 92 can now controllably rotate the rotary roller 84. Rotation of the rotary roller 84 progressively squeezes the tube 80 to impart fluid motion according to the direction of the rotation.
In another embodiment, the mounting feature 60 can be mounted to the support plate 98. In yet another embodiment, the fluid outlet 40 can be supported proximate to a main support 100 which supports the support plate 98 (see element 40B near the main support 100). In one embodiment a support is provided for both the fluid outlet 40B and a non-contact sensor 38.
Extending downwardly from the leading end 106 is a fluid outlet 110, a gear 112, and an electrical connector 114. The electrical connector includes a plurality of contact pads 116 that are electrically coupled to an information storage device 118.
The outer housing 102 includes a plurality of ribs 120 that provide structural reinforcement and rigidity for the outer housing 102. Also extending from an outside surface of housing 102 is an aligning feature or rib 122 for aligning the resin container 44 into the receptacle 42.
Disposed within the internal reservoir 124 is an impeller 128 for stirring the resin 20. The impeller 128 is coupled to the gear 112 and turns about a vertical axial shaft 130 that is supported by and rotatably mounted to the trailing 104 and leading 106 ends of the housing 102. The impeller 128 includes at least two blades 131 that extend radially from the axial shaft 130. The blades 131 rotate about a vertical axis of rotation defined by the axial shaft 130.
The fluid outlet 110, the gear 112, and the electrical connector 114 are arranged along the lateral axis Y. The planar arrangement of contact pads 116 are arranged along the lateral axis Y so that they face in a lateral direction −X that is perpendicular to Y. See
In
The leading end 106 of the resin container 44 includes the fluid outlet 110, the gear 112, and the electrical connector 114 which are in alignment with the lower interface portion 50 features as a result of the action of the aligning feature 122 within slot 148. The fluid outlet 110 of resin container 44 is aligned with fluid inlet 54 of conduit assembly 36. Gear 112 is in alignment with motorized rotary actuator 150. Container electrical connector 114 contact pads 116 are in alignment with the electrical connector 154 contacts 156. The contact pads 116 face in the −X direction and the spring contacts 156 extend in the +X direction.
According to step 162, resin-handling components with old resin are removed. The old resin container 44 is lifted out of the receptacle 42. The old conduit assembly 36 is disconnected including unlatching the fluid inlet 54 from the interface portion 50 (see
According to step 164, resin-handling components with new resin are installed. A new print engine 6 component is installed (e.g., a clean and empty resin vessel 10). A new conduit assembly is installed 36 including latching the fluid inlet in the interface portion (
According to step 166, the controller 8 can then read from and write to the information storage device 118 as a result of the electrical connection between connectors 114 and 154. If the new resin requires stirring, then the stirring motor 152 is activated according to step 168.
According to step 170, the controller 8 activates the pump motor 92 to begin pumping resin from the resin container 44, through the conduit assembly 36, and to the resin vessel 10. The controller concurrently monitors sensor 38 to avoid overfilling the resin vessel 10. Step 170 can continue to operate repeatedly to maintain a proper resin level in resin vessel 10.
According to step 172, the controller receives a signal from sensor 158 indicative of whether resin is present in the first conduit 56. If there is no resin in first conduit 56, then the system may halt and require installation of a new resin container 44 or a correction of a system error. According to step 174, the information storage device is updated according to an estimate or calculation of resin remaining in the internal reservoir 124. According to step 176, the print engine 6 is operated to manufacture a three dimensional article 22 with the new resin 20.
The steps of manufacturing method 160 can take place in varying orders relative to the flowchart depicted in
This non-provisional patent application claims priority to U.S. Provisional Application Ser. No. 62/649,022, Entitled “THREE DIMENSIONAL PRINTING SYSTEM ADAPTABLE TO VARYING RESIN TYPES” by Rodney Hill et al., filed on Mar. 28, 2018, incorporated herein by reference under the benefit of U.S.C. 119(e).
Number | Date | Country | |
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62649022 | Mar 2018 | US |