公开(公告)号：US11738515B2

公开(公告)日：2023-08-29

申请号：US17545159

申请日：2021-12-08

申请人： UT Battelle, LLC

发明人： Seokpum Kim ,  Ahmed Arabi Hassen ,  Lonnie J. Love ,  Vlastimil Kunc

IPC分类号： B29C64/386 ,  B29C64/118 ,  B33Y50/00 ,  B33Y30/00 ,  B33Y10/00

CPC分类号： B29C64/386 ,  B29C64/118 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/00

摘要： Systems and methods for generating molecular dynamic graded lattice structures that can be used as infill for additively manufactured articles. Molecular dynamically generated lattice infill is based on force balancing a node distribution instead of a circle packing. Field data can be utilized to adjust the spacing of the node distribution according to a force balance equilibrium model that accounts for the field expected to be experienced by the article being additively manufactured. The resultant non-uniform honeycomb structures from force-balancing robustly and efficiently address the connection issues with traditional non-uniform lattice structures.

公开(公告)号：US11325281B2

公开(公告)日：2022-05-10

申请号：US16519746

申请日：2019-07-23

申请人： UT-Battelle, LLC

发明人： Vlastimil Kunc ,  Craig A. Blue ,  Ahmed A. Hassen ,  John M. Lindahl ,  Lonnie J. Love ,  Brian K. Post

IPC分类号： B29C31/08 ,  B29C43/34 ,  B29C43/18 ,  B29C31/04

摘要： A method for rapid manufacturing of three dimensional discontinuous fiber preforms is provided. The method includes the deposition of a polymeric material containing fibers on a surface to form a tailored charge for compression molding. The reinforced polymeric material may be a thermoplastic or a reactive polymer with viscosity low enough to allow flow through an orifice during deposition, yet high enough zero shear viscosity to retain the approximate shape of the deposited charge. The material can be deposited in a predetermined pattern to induce the desired mechanical properties through alignment of the fibers. This deposition can be performed in a single layer or in multiple layers. The alignment is achieved passively by shear alignment of the fibers or actively through fiber orientation control or mixing. The fibers can be of the desired material, length, and morphology, including short and long filaments.

公开(公告)号：US20210154896A1

公开(公告)日：2021-05-27

申请号：US16953425

申请日：2020-11-20

申请人： UT-Battelle, LLC

发明人： Vlastimil Kunc ,  Ahmed A. Hassen ,  John M. Lindahl ,  Seokpum Kim

IPC分类号： B29C45/00 ,  B29C45/54

摘要： An improved method for obtaining high fiber volume fraction, long fiber injection molded articles is provided. According to one embodiment, the method includes forming an injection molding feedstock by cutting pre-impregnated fiber-reinforced tape into platelets. The platelets can be coated with a thin layer of polymer to allow sliding of the platelets with respect to each other at the early stages of plastication, rather than forcing relative motion of fibers with respect to each other. The method can further include the dispersion of material only in the final stages of the injection molding screw to promote gentle motion of the feedstock at the earlier stages of the plastication process. The method allows improvement of mechanical properties of articles manufactured with equipment and techniques that are prevalent in high volume automotive and consumer industries.

公开(公告)号：US10766181B2

公开(公告)日：2020-09-08

申请号：US15796110

申请日：2017-10-27

申请人： UT-Battelle, LLC ,  Magnet Applications Inc.

发明人： Mariappan Parans Paranthaman ,  Ling Li ,  Vlastimil Kunc ,  Brian K. Post ,  Orlando Rios ,  Robert H. Fredette ,  John Ormerod

IPC分类号： B29C67/00 ,  B29C48/00 ,  B29C64/314 ,  H01F1/057 ,  B29C48/04 ,  B29C48/875 ,  H01F41/02 ,  B29C48/92 ,  B29C48/80 ,  C08K3/08 ,  B29C64/106 ,  B33Y10/00 ,  B33Y70/00 ,  B29K77/00 ,  B29K103/06 ,  B29K505/12

摘要： A method for producing magnet-polymer pellets useful as a feedstock in an additive manufacturing process, comprising: (i) blending thermoplastic polymer and hard magnetic particles; (ii) feeding the blended magnet-polymer mixture into a pre-feed hopper that feeds directly into an inlet of a temperature-controlled barrel extruder; (iii) feeding the blended magnet-polymer mixture into the barrel extruder at a fixed feed rate of 5-20 kg/hour, wherein the temperature at the outlet is at least to no more than 10° C. above a glass transition temperature of the blended magnet-polymer mixture; (iv) feeding the blended magnet-polymer mixture directly into an extruding die; (v) passing the blended magnet-polymer mixture through the extruding die at a fixed speed; and (vi) cutting the magnet-polymer mixture at regular intervals as the mixture exits the extruding die at the fixed speed. The use of the pellets as feed material in an additive manufacturing process is also described.

公开(公告)号：US20200023556A1

公开(公告)日：2020-01-23

申请号：US16519746

申请日：2019-07-23

申请人： UT-Battelle, LLC

发明人： Vlastimil Kunc ,  Craig A. Blue ,  Ahmed A. Hassen ,  John M. Lindahl ,  Lonnie J. Love ,  Brian K. Post

IPC分类号： B29C31/08 ,  B29C31/04 ,  B29C43/18 ,  B29C43/34

摘要： A method for rapid manufacturing of three dimensional discontinuous fiber preforms is provided. The method includes the deposition of a polymeric material containing fibers on a surface to form a tailored charge for compression molding. The reinforced polymeric material may be a thermoplastic or a reactive polymer with viscosity low enough to allow flow through an orifice during deposition, yet high enough zero shear viscosity to retain the approximate shape of the deposited charge. The material can be deposited in a predetermined pattern to induce the desired mechanical properties through alignment of the fibers. This deposition can be performed in a single layer or in multiple layers. The alignment is achieved passively by shear alignment of the fibers or actively through fiber orientation control or mixing. The fibers can be of the desired material, length, and morphology, including short and long filaments.

公开(公告)号：US20190338106A1

公开(公告)日：2019-11-07

申请号：US16403995

申请日：2019-05-06

申请人： UT-BATTELLE, LLC

发明人： Vlastimil Kunc ,  John M. Lindahl ,  Lonnie J. Love ,  Brian K. Post ,  Ahmed Hassen ,  Peng Liu ,  Thomas Zeke Sudbury

IPC分类号： C08K7/28 ,  C08K7/06 ,  B29C64/165 ,  B29C64/118 ,  B33Y70/00

摘要： A method of forming a low-density three-dimensional article is provided. The method includes printing a low-density composition on a substrate to form at least one layer comprising the low-density composition. The low-density composition includes a (P) polymer component and (M) a microsphere component in a ratio by volume (P):(M). The method also includes selectively controlling a density of the low-density composition during printing to give the at least one layer on the substrate. Selectively controlling the density of the low-density composition includes varying the ratio (P):(M) during printing. The method further includes repeating the printing and selectively controlling the density of the low-density composition to form additional layer(s), thereby forming the low-density three-dimensional article. A low-density three-dimensional article prepared in accordance with the method is also provided.

公开(公告)号：US20190091927A1

公开(公告)日：2019-03-28

申请号：US16135548

申请日：2018-09-19

申请人： UT-BATTELLE, LLC

发明人： Vlastimil Kunc ,  Seokpum KIM ,  John M. LINDAHL ,  Jordan A. FAILLA ,  Chad E. DUTY

IPC分类号： B29C64/209 ,  B29C64/232 ,  B29C64/295 ,  B29C64/106 ,  B29C64/165 ,  B29C64/336 ,  B29C47/06 ,  B29C70/06

摘要： An apparatus and device for creating a vertical strengthening feature within a 3D printed article of manufacture for improving mechanical performance in the Z-direction. Fill material is deposited in voids vertically crossing multiple layers during the build of 3D printing. The device includes a penetrating extension that fits within the void to create a vertical strengthening feature via heat and/or extruded fill material. The size and/or movement of the heated extension can impact the void side walls to reflow the build material and blend the layers together within the void side walls.

公开(公告)号：US20170151728A1

公开(公告)日：2017-06-01

申请号：US14953515

申请日：2015-11-30

申请人： UT-Battelle, LLC

发明人： Vlastimil Kunc ,  Craig A. Blue ,  Chad E. Duty ,  Randall F. Lind ,  John M. Lindahl ,  Peter D. Lloyd ,  Lonnie J. Love ,  Matthew R. Love ,  Brian K. Post ,  Orlando Rios

IPC分类号： B29C67/00

CPC分类号： B29C64/295 ,  B29C64/106 ,  B29C64/209 ,  B29C70/222 ,  B33Y10/00 ,  B33Y30/00

摘要： Several examples of additive manufacturing machines and methods for depositing a bead of composite polymer material having continuous fiber reinforcement are disclosed. A length of fiber reinforcement is provided to a nozzle. The fiber reinforcement is embedded into a stream of a base polymer material at the nozzle and deposited as a bead of composite polymer material having fiber reinforcement. The fiber reinforcement may be dry or pre-impregnated with a reinforcing polymer. The additional strength of the composite polymer material having fiber reinforcement allows for true, three-dimensional printing of articles having unsupported regions.

公开(公告)号：US11518073B2

公开(公告)日：2022-12-06

申请号：US16953425

申请日：2020-11-20

申请人： UT-Battelle, LLC

发明人： Vlastimil Kunc ,  Ahmed A. Hassen ,  John M. Lindahl ,  Seokpum Kim

IPC分类号： B29C45/00 ,  B29C45/54 ,  B29K309/08 ,  B29K105/12 ,  B29K77/00

摘要： An improved method for obtaining high fiber volume fraction, long fiber injection molded articles is provided. According to one embodiment, the method includes forming an injection molding feedstock by cutting pre-impregnated fiber-reinforced tape into platelets. The platelets can be coated with a thin layer of polymer to allow sliding of the platelets with respect to each other at the early stages of plastication, rather than forcing relative motion of fibers with respect to each other. The method can further include the dispersion of material only in the final stages of the injection molding screw to promote gentle motion of the feedstock at the earlier stages of the plastication process. The method allows improvement of mechanical properties of articles manufactured with equipment and techniques that are prevalent in high volume automotive and consumer industries.

公开(公告)号：US20220157499A1

公开(公告)日：2022-05-19

申请号：US17529588

申请日：2021-11-18

申请人： UT-Battelle, LLC ,  University of Tennessee Research Foundation

发明人： Uday Kumar Vaidya ,  Mariappan Parans Paranthaman ,  Vlastimil Kunc ,  Ahmed A. Hassen

IPC分类号： H01F1/147 ,  H01F1/057 ,  H01F41/02 ,  B22F1/00 ,  B22F3/02

摘要： A method for producing a bonded magnet, comprising: (i) low-shear compounding of a thermoplastic polymer and magnetic particles to form an initial homogeneous mixture thereof; (ii) feeding the initial homogeneous mixture into a plasticator comprising a low-shear single screw rotating unidirectionally toward a die orifice and housed within a heated barrel to result in heating of the initial homogeneous mixture until the thermoplastic polymer melts and forms a further homogeneous mixture, wherein said further homogeneous mixture is transported within threads of the single screw towards the die orifice and exits the die orifice as a solid pellet; (iii) conveying the solid pellet into a mold and compression molding the pellet in the mold, to form the bonded magnet, wherein the bonded magnet possesses a magnetic particle loading of at least 80 vol % and exhibits one or more magnetic properties varying by less than 5% throughout the bonded magnet.