WO2012166505A1 - Elément structural formé par impression en trois dimensions - Google Patents

Elément structural formé par impression en trois dimensions Download PDF

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Publication number
WO2012166505A1
WO2012166505A1 PCT/US2012/039310 US2012039310W WO2012166505A1 WO 2012166505 A1 WO2012166505 A1 WO 2012166505A1 US 2012039310 W US2012039310 W US 2012039310W WO 2012166505 A1 WO2012166505 A1 WO 2012166505A1
Authority
WO
WIPO (PCT)
Prior art keywords
handle
vehicular
layer
core
creating
Prior art date
Application number
PCT/US2012/039310
Other languages
English (en)
Inventor
Walter B. PIPP, Jr.
Original Assignee
A. Raymond Et Cie
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by A. Raymond Et Cie filed Critical A. Raymond Et Cie
Publication of WO2012166505A1 publication Critical patent/WO2012166505A1/fr

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E05—LOCKS; KEYS; WINDOW OR DOOR FITTINGS; SAFES
    • E05B—LOCKS; ACCESSORIES THEREFOR; HANDCUFFS
    • E05B85/00—Details of vehicle locks not provided for in groups E05B77/00 - E05B83/00
    • E05B85/10—Handles
    • 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
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/112—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
    • 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
    • B33Y10/00—Processes of additive manufacturing
    • 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
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • 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
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • E—FIXED CONSTRUCTIONS
    • E05—LOCKS; KEYS; WINDOW OR DOOR FITTINGS; SAFES
    • E05B—LOCKS; ACCESSORIES THEREFOR; HANDCUFFS
    • E05B17/00—Accessories in connection with locks
    • E05B17/0004—Lock assembling or manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B29L2031/3029—Handgrips
    • 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
    • B33Y80/00—Products made by additive manufacturing

Definitions

  • the present invention relates generally to structural components and more particularly to manufacturing of a vehicular component.
  • polymeric parts are made by injection or extrusion molding.
  • a heated polymeric liquid is inserted into match metal dies under high pressure, after which the dies are internally cooled in order to cure the manufactured parts. Air is vented from the die cavity when the molten polymer is injected therein.
  • Injection and extrusion molding are ideally suited for high volume production where one hundred thousand or more parts per year are required.
  • These traditional manufacturing processes disadvantageously require very expensive machined steel dies, which are difficult and time consuming to modify if part revisions are desired, and are subject to problematic part-to-part tolerance variations. Such variations are due to molding shrinkage during curing, molding pressure differences, part warpage due to internal voids and external sink marks, and the like. The expense of this traditional die tooling makes lower volume production of polymeric parts prohibitively expensive.
  • stereolithography it is also known to use stereolithography to produce nonfunctional polymeric parts.
  • Such conventional stereolithography methods use a laser to create a layered part on a moving platform within a vat of liquid polymer. The part rises from the liquid as it is being made. These parts are extremely slow to produce and impractically brittle.
  • a structural component is provided.
  • a vehicular component such as a handle
  • a vehicular component is made of layers of material, a light curable material and/or multiple built-up materials.
  • Another aspect uses a three-dimensional printing machine to emit material from an ink jet printing head to build up a structural component.
  • a further aspect provides a method of making a door handle by depositing material in layers and/or a built-up additive arrangement.
  • Yet another aspect makes a structural handle by depositing material in an environment where the handle is essentially surrounded by a gas, such as air, during the material deposition.
  • a method of making a multi-material and/or pre-assembled vehicular handle is also employed in another aspect.
  • the present structural components and method are advantageous over traditional devices.
  • the present vehicular handles and method do not require any unique tooling or dies, thereby saving hundreds of thousands of dollars and many weeks of die manufacturing time.
  • the present method allows for quick and inexpensive design and part revisions from one manufacturing cycle to another.
  • part- to-part tolerance variations are essentially non-existent with the present structural components and method such that at least ten, and more preferably at least forty, identical door handles can be produced in a single machine manufacturing cycle.
  • multiple head openings, a stationary support for the built-up components within the machine, and the ambient air manufacturing environment allow for increased manufacturing speed, simpler machinery and ease of access to the manufactured components.
  • the present vehicular handle and method are advantageously capable of creating die-locked part configurations that would otherwise be prohibitively expensive, if not impossible, to produce with conventional dies.
  • the present vehicular components and method reduce post-manufacturing assembly by creating mating parts in a pre-installed or pre-assembled condition within the same manufacturing machine cycle; for example, this can apply to covers, inserts and/or seals. Materials of different characteristics, such as flexibility, tensile strength, hoop strength, chemical resistance, UV fade resistance, or even color can be deposited to create different sections of the vehicular component at essentially the same time. Additional advantages and features of the present invention can be found in the following description and appended claims as well as in the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS
  • Figure 1 is a perspective view showing door handles on an automotive vehicle of the present invention
  • Figure 2 is a perspective view showing the door handle of the present invention.
  • Figure 3 is a top elevational view showing the door handle
  • Figure 4 is a cross-sectional view, taken along line 4-4 of Figure 2, showing the door handle
  • Figure 5 is a cross-sectional view, taken along line 5-5 of Figure
  • Figure 6 is a perspective view showing a machine manufacturing the door handles, with an upper cover of the machine removed;
  • Figures 7A-C are a series of diagrammatic side views showing the machine building up the door handles.
  • FIGS 1 -5 illustrate an automotive vehicle 31 including various three-dimensionally printed structural components, including handles 35 and 37.
  • Exterior handle 37 is mounted to a vehicular door outer panel 41 while interior handle 35 is mounted to an interior door trim panel or structural door inner panel 43.
  • the preferred example disclosed hereinafter is the interior handle but many aspects thereof are also applicable to the exterior handle or even an interior side rail-mounted assist handle.
  • Interior door handle 35 includes an aesthetically pleasing cover 101 , a structural core 103, a seal 105 and a functional lever 107.
  • Core 103 is three-dimensionally printed from a rigid and durable polymeric material, but which does not require ultraviolet light-fade resistance or good color matching properties.
  • Core 103 includes a peripheral shell 1 1 1 within which are multiple transverse and longitudinal walls and/or ribs 1 13 and 1 15, respectively. Open spaces 1 17 of predetermined size, shape and location, are located between many of the adjacent walls or ribs and are entirely enclosed within shell 1 1 1 .
  • Cover 101 is three-dimensionally printed integrally with each associated pass of the machine head along with core 1 1 1 such that they are essentially simultaneously created together.
  • Cover 101 is made of a different and more resilient, ultraviolet light-fade resistant and color matchable polymeric material than is the material for core 1 1 1 .
  • either the cover or core can be printed from a metallic material while the other is polymeric.
  • Cover 101 optionally includes transversely enlarged gripping bumps 121 extending from the nominal surface thereof. Cover 101 essentially surrounds all of core except at a hidden end 123 thereof.
  • Seal 105 is integrally formed with core 1 1 1 and/or cover 101 as an integral deposited part with the three-dimensional printing process. Seal 105 is made of a third material which is more resilient than that of core 1 1 1 and cover 101 . Seal 105 deters water, gas (for example, exhaust), and/or dust flow through an opening 131 in vehicular panel 143.
  • Lever 107 is integrally created as part of core 1 1 1 and has offset angled sections. Furthermore, lever has a generally hollow, internal shape throughout its length and may be optionally blocked by a solid distal end 133. A door latch rod, cable, or other mechanism, is moveably coupled to lever 107 for actuation when handle 35 is pivoted by a vehicle user. Exemplary mechanisms and alternate handle shapes are disclosed in U.S. Patent No. 5,961 ,166 entitled “Automotive Vehicle Door Handle Assembly” which issued to Edwards on October 5, 1999; and U.S. Patent No. 5,895,081 entitled “Inside Door Handle Assembly for Vehicles” which issued to Tanimoto et al. on April 20, 1999; both of which are incorporated by reference herein. It is also envisioned that the present three-dimensionally printed handle can alternately be used as an exterior vehicular door handle, a handle on a watercraft vehicle and/or a handle on an airspace vehicle.
  • a three-dimensional printing machine 1501 includes a stationary support surface 1503 upon which a set of identical handles 35 are created.
  • Machine 1501 further includes at least one ink jet printer head 1505, and preferably eight heads, which traverse side to side along one or more gantry rails 1507 by an electric motor or other automatically controlled actuators.
  • the gantry rail also moves fore and aft above support surface 1503 along outboard tracks 1509, driven by an electric motor or other automatically controlled actuator.
  • At least two storage tanks 151 1 or removable cartridges are connected to head 1505 via supply hoses 1513 in order to feed the same or different polymeric materials 1515 contained within each tank 151 1 to multiple ink jet printer openings 1517 in head 1505.
  • Openings 1517 may constitute an array of 10 x 10 or even 100 x 100 nozzles, and more preferably 96 nozzles, arranged in a linear array such that multiple material flows are simultaneously emitted during a single head pass.
  • the material is preferably an ultraviolet light-curable photopolymer in the form of a powder and water mixture.
  • a spool containing an elongated and flexible string or filament of the polymeric material can be fed to the head, melted and emitted onto the support surface as a layered and continuous string.
  • a computer controller 1519 having an input keyboard 1521 , an output display screen 1523, and a microprocessor, is connected to a central processing unit 1525 of machine 1501 to control the feed of material from tanks 151 1 and the actuator movement of head 1505 relative to support surface 1503.
  • the machine user downloads a CAD file containing a design of the handle into non-transient computer memory, such as RAM, ROM, a hard drive or removable storage, associated with computer controller 1519.
  • the user uses software instructions stored in the memory to digitally lay out the desired quantity of the components onto support surface 1503 and position the handles in a manufacturing orientation, while adding any supports 1527 or pixel bridges to the design which are later removed after the manufacturing.
  • the user also inputs the material(s) to be used in the manufacturing, whereafter the microprocessor in computer controller 1519 and CPU 1525 runs the software to cause head 1505 to begin its movement and material deposition in order to create the set of handle components.
  • ink jet printing openings 1517 emit streams of polymeric material 1515 and lay down a first layer, constituting a bottom external surface with a first transverse pass of head 1505; for the preferred interior handles, an outermost layer of cover 101 or seal 105.
  • This first pass lays down a material thickness of approximately 0.1 -1 .0 mm of the handle.
  • the machine head continues in its transverse path, it will also lay down the same exact material layer for each adjacent handle being manufactured in the same manufacturing cycle. Alternately, if the array of openings is large enough, spread out or contained on multiple machine heads, then multiple handles 35 can be simultaneously deposited.
  • One or more ultraviolet lights 1541 are attached to head 1505 which serve to emit light onto the layered material immediately after its deposition which binds together and cures the layer of material deposited. After the first layer has been deposited for each of the multiple handles, head 1505 then emits a second layer of polymeric material 1515 upon the already deposited first layer which is then bound to the first layer when cured by lights 1541 . This layering and curing is repeated many times, for example, with more than fifty layers or head passes, until the handle is fully created.
  • each removed handle 35 is dipped into a hardener, solvent or final curing solution, which also serves to dissolve any supports 1527 or bridges, especially when they are made of a solvent-dissolvable material, different from the primary material defining the cover, core, seal and lever of the handle.
  • a hardener, solvent or final curing solution which also serves to dissolve any supports 1527 or bridges, especially when they are made of a solvent-dissolvable material, different from the primary material defining the cover, core, seal and lever of the handle.
  • the seal is made of a more flexible, UV curable polymer (for one exemplary configuration, DM 9870 material) as compared to the adjacent rigid core and lever (for one exemplary configuration, Verogray material). It is noteworthy that the seal is integrally connected and made as a single part with the remainder of the handle such that post- manufacturing assembly is not required.
  • the seal can optionally have a dove tail engagement within an undercut of the adjacent core thereby providing an additional mechanical connection to provide extra durability.
  • pre- assembled or separately printed washers, seals, brackets or gaskets can be simultaneously made by the layering and building up process of three- dimensional printing as discussed herein. It should also be realized that while pre-assembled manufacturing is advantageous, the components may be separately manufactured and assembled although many of the present advantages will not be achieved. Additionally, entirely enclosed hollow spaces of predetermined size and shape can be designed and manufactured inside thickened walls of any of the present components (for example, inside gripping bumps 121 ) in order to save material costs and weight, and/or to add greater flexibility.
  • the present three-dimensional printing method can be used to manufacture other structural vehicular components having an aesthetically pleasing outer cover essentially encapsulating or surrounding at least a majority of a structural inner core, with enclosed air pockets or predetermined spaces therein, for use with automobiles, boats, airplanes, or other vehicles.
  • the three-dimensionally printed handle may have its core fixed at both ends and be part of an interior door trim panel, rear lift gate-mounted handle, or interior trim-mounted assist handle. Any of the component functions, features and segments thereof may be interchanged with any of the other components disclosed hereinabove, although certain benefits may not be realized. Nevertheless, such changes, modifications or variations are not to be regarded as a departure from the spirit and scope of the present invention.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)

Abstract

L'invention concerne un élément structural. Selon un autre aspect, un composant de véhicule, tel qu'une poignée, est formé de couches de matière, d'une matière durcissable par la lumière et/ou de matières de construction multiples. Un autre aspect utilise une machine d'impression tridimensionnelle pour projeter une matière sortant d'une tête d'impression à jet d'encre pour construire un élément structural.
PCT/US2012/039310 2011-06-02 2012-05-24 Elément structural formé par impression en trois dimensions WO2012166505A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201161492424P 2011-06-02 2011-06-02
US61/492,424 2011-06-02

Publications (1)

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WO2012166505A1 true WO2012166505A1 (fr) 2012-12-06

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Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104029275A (zh) * 2014-05-28 2014-09-10 宁夏共享模具有限公司 行走式3d打印生产线
WO2014204476A1 (fr) * 2013-06-20 2014-12-24 Hewlett-Packard Development Company, L.P. Système d'impression tridimensionnelle de formation de modèle, et son procédé
WO2015197495A1 (fr) 2014-06-27 2015-12-30 Koninklijke Philips N.V. Dispositif et procédé d'impression pour l'impression 3d
WO2017040728A1 (fr) 2015-08-31 2017-03-09 Divergent Technologies, Inc. Systèmes et procédés pour sous-ensembles de véhicule et fabrication
WO2017093264A1 (fr) * 2015-11-30 2017-06-08 Greiner Perfoam Gmbh Procédé et utilisation d'une imprimante tridimensionnelle pour fabriquer un élément d'équipement intérieur de véhicule automobile et élément d'équipement intérieur de véhicule automobile fabriqué par ce procédé
US9975179B2 (en) 2014-07-02 2018-05-22 Divergent Technologies, Inc. Systems and methods for fabricating joint members
JPWO2019087557A1 (ja) * 2017-11-06 2020-12-03 オリンパス株式会社 内視鏡システム
US10960929B2 (en) 2014-07-02 2021-03-30 Divergent Technologies, Inc. Systems and methods for vehicle subassembly and fabrication

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Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2014204476A1 (fr) * 2013-06-20 2014-12-24 Hewlett-Packard Development Company, L.P. Système d'impression tridimensionnelle de formation de modèle, et son procédé
CN104029275A (zh) * 2014-05-28 2014-09-10 宁夏共享模具有限公司 行走式3d打印生产线
WO2015197495A1 (fr) 2014-06-27 2015-12-30 Koninklijke Philips N.V. Dispositif et procédé d'impression pour l'impression 3d
US9975179B2 (en) 2014-07-02 2018-05-22 Divergent Technologies, Inc. Systems and methods for fabricating joint members
US10960929B2 (en) 2014-07-02 2021-03-30 Divergent Technologies, Inc. Systems and methods for vehicle subassembly and fabrication
US10960468B2 (en) 2014-07-02 2021-03-30 Divergent Technologies, Inc. Stress-based method for optimization of joint members within a complex structure
WO2017040728A1 (fr) 2015-08-31 2017-03-09 Divergent Technologies, Inc. Systèmes et procédés pour sous-ensembles de véhicule et fabrication
EP3344522A4 (fr) * 2015-08-31 2019-05-15 Divergent Technologies Inc. Systèmes et procédés pour sous-ensembles de véhicule et fabrication
WO2017093264A1 (fr) * 2015-11-30 2017-06-08 Greiner Perfoam Gmbh Procédé et utilisation d'une imprimante tridimensionnelle pour fabriquer un élément d'équipement intérieur de véhicule automobile et élément d'équipement intérieur de véhicule automobile fabriqué par ce procédé
JPWO2019087557A1 (ja) * 2017-11-06 2020-12-03 オリンパス株式会社 内視鏡システム

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