Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
  • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
  • B29C45/16—Making multilayered or multicoloured articles
  • B29C45/1657—Making multilayered or multicoloured articles using means for adhering or bonding the layers or parts to each other
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
  • B29C45/16—Making multilayered or multicoloured articles
  • B29C45/1671—Making multilayered or multicoloured articles with an insert
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
  • B29C64/10—Processes of additive manufacturing
  • B29C64/188—Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
  • B33Y40/20—Post-treatment, e.g. curing, coating or polishing

Definitions

• thermoplastic material to the face of a three- dimensional print
• the present invention relates to a method for the manufacture of products by layer moulding from material of thermoplastics or thermoplastic alloys such as ABS, poly- carbonate (PC) 5 nylon (PA), or the like. More particularly, the invention relates to layer moulding on physical three-dimensional basic components formed by means of additive fabrication, whereby there is provided a product having desired nature, in particular at the surface thereof.
• each basic component is a three-dimensional print from a printer of FDM, SLA, SLS, FDM, "epoxy", for instance, or another machined version.
• the present invention is directed to remedy such an uncertainty by means of a substantial improvement of the nature of existing prints as mentioned above, whereby there is provided products at least having approximately the same surface nature as the end product.
• the products shall desirably have equal technical and functional properties like surface qualities of products made by conventional injection moulding technology, while minimizing the need expensive mould- ing tools for lower product series having demanding complexity.
• injection moulding is defined as: Moulding plastic products in that liquid plastics, plastics in powdered form, plastics as pellet, or plastics in pasty form are injected into a moulding tool under pressure and harden or adhere by cooling, by supply of energy, or by setting.
• Additive fabrication is derived from the English term "Additive fabrication” which according to Wohlers Report 2008 by Terry T. Wohler; Wohlers Associates, Inc. Fort Collins CO, USA is defined in this manner: "Additive fabrication refers to a group of technologies used for building physical models, prototypes, tooling components, and finished series production parts-all from 3D computer-aided design (CAD) data, CT or MRI scans, or data from 3D scanning systems.
• CAD computer-aided design
• additive systems join together liquid, powder, or sheet materials to form objects. Parts that may be difficult or impossible to fabricate by any other method may be produced by additive fabrication. Based on thin horizontal cross sections take from a 3D computer model, they produce plastic, metal, ceramic or composite parts, layer upon layer.”
• Fig. 1 a-c shows schematically a variant of a product illustrated in perspective, bottom and cross-section views, respectively, comprising a middle three-dimensional print externally and internally provided with a layer of suitable plastic material by means of injection moulding;
• Fig. 2a-c shows schematically the same as Fig. la-c, except the injection moulded layer is only applied on an internal or external surface, respectively, of the three-dimensional print;
• Fig. 3 a-c shows schematically the same as Fig. la-c, except the three-dimensional print is provided with a bushing or another type of insert,
• Fig 4a-c shows schematically another variant of a large number of other possible products in top and to cross-section views, respectively.
• Fig. 5 shows schematically a cross-section view of a moulding tool for use when injection moulding of the product in Fig. 2b.
• the unique by the principle according to the present invention for the manufacture of an actual product having desired configuration and material quality in the surface thereof, for instance, is that injection moulding is utilized for applying a layer 2 at least one portion of a face the basis component 1.
• the layer 2 may be made from any suitable thermoplastics or thermoplastic alloys as well.
• the basis component 1 consti- tutes completely or partly a basis for the injection moulded layer 2 and forms along with this the end product.
• the basis component 1 is preferentially provided in the form a three-dimensional print.
• the basis component 1 is created using additive fabrication.
• the basis component 1 Prior to the injection moulding of the layer 2, the basis component 1 is preferentially located within a moulding tool for injection moulding, either by hand or using robots.
• the properties of the basis component itself are of importance to enable such a layer moulding which involves that it in particular relates to form stability, strength and rigidness thereof.
• the choice of moulding tool effects the size, configuration and complexity of the product.
• Another issue to be considered is how to possibly seal porous surfaces of the basis component and to bond the material used during injection moulding. It is also a presumption that bushings, inserts, or the like may be part of the product.
• An appropriate combination of materials for the injection moulded layer and the basis component effect the strength, adhesion, shrinkage, surfaces, tolerances, and deformations.
• the basis component may resist an injection pressure of up to 2500 kg/cm2 and a temperature until 400 0 C during the injection moulding.
• the moulding tools may have a conventional construction or be based on product specific inserts situated within standard basic moulds.
• Fig. 5 it is as an example illustrated an appropriate moulding tool for use in connection with the present in- vention.
• the moulding tool consists of a inlet nozzle 5 ending in an insert 6 at an injection side of the tool.
• the moulding tool for mounting of the basis component 1, there is in addition at an outlet side of the tool an insert 7 having at least one associated ejector 8.
• any prior art moulding tool is applicable as well.
• the basis component may be present in the form of a panel, cube, pyramid, sphere, combinations thereof, or any arbitrary configurations.
• Each basis component may be provided by means of any process of additive fabrication such as SLA, SLS, FDM, "epoxy", etc.
• the basis component may be provided by a machining of appropriate type.
• the basis component may be formed of synthetic materials, minerals and combinations thereof and in addition wood.
• the injection moulded layer may cover small, large or all faces of the basis component in any thickness. The injection moulded layer may be applied to the basis component in one or more moulding tools and operations.
• the moulded layer may also completely or partly fill open spaces between surfaces of or in connection with basis component. It is possible that the moulded layer may have any surface structure formed by rubbing, polishing, eroding, photo-etching, and the like. The moulded layer may have any colour or combination of desired colours. Moreover, it is possible the injection moulded layer may be utilized as a filling when large material thickness.
• a moulded layer in the form of a injection moulded layer may be fastened to the basis component by adhesion, as an example in that the basis component is provided with glue prior to the injection moulding, in that the basis component is treated with other sorts of surface-treatment such as e.g. thermal treatment or any type of chemical struc- rural change, or in that the basis component is equipped with undercuts, holes, pockets, etc.
• the basis component when the moulded layer is applied, the basis component may be formed with other elements 4 such as bushings and inserts of metal or other materi- als. If so, these may be attached directly to the basis component, or alternatively using the injection moulded layer.
• the final injection moulded product may be thermal treated in any suitable manner.

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• 2008
  • 2008-12-19 NO NO20085327A patent/NO331237B1/no not_active IP Right Cessation
• 2009
  • 2009-12-15 WO PCT/NO2009/000435 patent/WO2010071445A1/en active Application Filing
  • 2009-12-15 EP EP09833680.3A patent/EP2367669A4/de not_active Withdrawn

Patent Citations (5)

Non-Patent Citations (1)

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