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Shape forming process and application thereof for creating structural elements and designed objects

a technology of shape forming and design objects, applied in auxillary shaping apparatus, conductive materials, non-conductive materials with dispersed conductive materials, etc., can solve the problems of adding to the development cycle time, consuming unnecessary time, materials, and waste of composite parts,

Inactive Publication Date: 2015-05-21
FLEMING ROBERT J
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

This patent describes a system and method for creating shaped or designed objects by forming three-dimensional structural elements. The system includes a tool that delivers resin and fiber onto a target region and uses a controller to manipulate the resin and fiber into a desired shape. The structural elements can be used to create objects without the need for a solid support structure, making the process faster and more cost-effective. The technical effects of this patent include improved efficiency and accuracy in creating complex objects and reduced waste and cost associated with traditional methods.

Problems solved by technology

Composite materials are typically formed into shape via pre-formed molds that are costly and add to the development cycle time.
These steps consume unnecessary time, materials, and waste adding to the cost of composite parts.

Method used

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  • Shape forming process and application thereof for creating structural elements and designed objects
  • Shape forming process and application thereof for creating structural elements and designed objects
  • Shape forming process and application thereof for creating structural elements and designed objects

Examples

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example

[0058]FIG. 9 illustrates an example of a shaped object produced using a structural element such as described with examples provided herein. In FIG. 9, a wiring board 900 is fabricated to have a desired shape, such as to conform to specifications for a wearable electronic device. In an example of FIG. 9, non-electrically conductive fibers and resins are integrated with conductive wires (tapes, strips, foils) and resins into a circuit board with curved shape and conductive traces in a given orientation in free space. The wiring board 900 can include sections 910, each of which is formed separately using a tool such as described with any of the examples provided herein. Electrical components can be formed or assembled on the surface of the wiring board 900. In some embodiments, the sections formed using, for example, a three-dimensional printing tool such as described with an example of FIG. 1, with structural elements include a fiber core or resin exterior which carry conductive trace...

examples

[0060]With reference to examples provided above, the tool 100 can be implemented as 3-axis machine with 3 stepper motors and a microcontroller. In such an example, the robotic arm 104 can, for example, enable movement of about 6 inches in Z-direction, and 18 inches in x and y directions.

[0061]The fiber source can correspond to, for example, a reel of S-glass fiber roving purchased from AGY CORORATION (provided under the product name of ZENTRON758-AB-675)

[0062]In some variations, a glass roving can be created by pulling a bobbin and pushed through a tube into a feedblock. The individual fiber can be around 10-20 microns in diameter and the roving can be around 0.5 mm in diameter The glass roving can be pulled / pushed in a controlled metering fashion using a stepper motor driven soft wheel and a steel bearing. Simultaneously a resin delivery mechanism can be implemented using a UV curable liquid resin, which can be metered to a feedblock using a syringe pump. A fiber coated with resin ...

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Abstract

A tool provided that individually creates three-dimensional structural elements which are sequentially positioned into formation of a shaped object.

Description

RELATED APPLICATIONS[0001]This application claims benefit of priority to Provisional U.S. Patent Application No. 61 / 905,052, filed Nov. 15, 2013; the aforementioned priority application being hereby incorporated by reference in its entirety for all purposes.TECHNICAL FIELD[0002]Embodiments described herein relate generally to a shape forming process, and more specifically, to a shape forming process and application thereof for creating structural elements and designed objects.BACKGROUND[0003]Composites refer generally to a heterophase material containing a binder and a solid. A growing class of structural composites consist of an organic polymer binder or “resin” and a fiber, typically composed of glass, carbon, or natural. In some variations, the fiber can be formed from metal. The fiber is in the form of a filament (continuous or chopped), narrow strips of woven cloth, a bundle or roving, a braid, or made into strips or “tape”. The structural composites industry is growing because...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): C08F122/10B29C67/00H05K1/02H01B1/20C03C25/28B29C70/02C08F120/32
CPCC08F122/10B29C70/021B29C67/0066C08F120/32H01B1/20B29L2031/3425H05K1/0284B33Y30/00B29K2105/122B29K2105/0002B29K2995/0005C03C25/285B29D11/00009B29D11/00432B33Y10/00B33Y80/00B29C64/106B29C64/118B29C64/135B29C64/188C08J5/08C08F222/103H05K3/0014Y10T428/2933
Inventor FLEMING, ROBERT J.
Owner FLEMING ROBERT J
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