US20190263066A1 - Additive manufacturing system with heater configured for improved interlayer adhesion in a part formed by the system - Google Patents
Additive manufacturing system with heater configured for improved interlayer adhesion in a part formed by the system Download PDFInfo
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- US20190263066A1 US20190263066A1 US16/412,883 US201916412883A US2019263066A1 US 20190263066 A1 US20190263066 A1 US 20190263066A1 US 201916412883 A US201916412883 A US 201916412883A US 2019263066 A1 US2019263066 A1 US 2019263066A1
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- United States
- Prior art keywords
- heater
- material applicator
- applicator
- manufacturing system
- platform
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/115—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by spraying molten metal, i.e. spray sintering, spray casting
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- 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
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/295—Heating elements
-
- 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
- B29C64/118—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
-
- 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
- B29C64/30—Auxiliary operations or equipment
- B29C64/386—Data acquisition or data processing for additive manufacturing
- B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
-
- 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
- B29C64/40—Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
-
- 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
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/245—Platforms or substrates
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2101/00—Use of unspecified macromolecular compounds as moulding material
- B29K2101/12—Thermoplastic materials
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- 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
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
-
- 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
Definitions
- the system and method disclosed in this document relate to printers that produce three-dimensional objects and, more particularly, to a device and method for improving interlayer adhesion in parts printed by such printers.
- Digital three-dimensional manufacturing also known as digital additive manufacturing, is a process of making a three-dimensional solid object of virtually any shape from a digital data model.
- Three-dimensional printing is distinguishable from traditional object-forming techniques, which mostly rely on the removal of material from a work piece by a subtractive process, such as cutting or drilling.
- Fused Filament Fabrication (FFF) printing for example, is an additive process in which one or more material applicators extrude polymer filament to form successive layers of material on a substrate in different shapes.
- the polymer filament includes fillers, such as metal particles or fibers, or the polymer filament comprises a metal wire coated with a polymer.
- the extrudable material 26 After being heated by the melter 42 , the extrudable material 26 is deposited on the member 18 by a nozzle 46 of the at least one material applicator 14 . After being deposited by the nozzle 46 , the material 26 cools on the member 18 to a temperature below the transition temperature such that the layer 22 becomes less pliable and more viscous and acts as a solid.
- the at least one material applicator 14 is driven in the z-dimension relative to the member 18 to re-position the at least one material applicator 14 at the height H above the layer 22 .
- Re-positioning the at least one material applicator 14 in the z-dimension accommodates the thickness T of the layer 22 atop the member 18 to prevent the at least one material applicator 14 from contacting the layer 22 during subsequent passes in the x-dimension.
- the at least one material applicator 14 is again driven in the x-dimension to deposit another layer 30 of the object 34 on top of the layer 22 .
- the at least one material applicator 14 can be driven in the x-dimension to pass the member 18 in the same direction or in the opposite direction as the previous pass. If the at least one material applicator 14 is driven in the same direction, the at least one material applicator 14 is also re-positioned in the x-dimension before depositing the further layer 30 .
- FIG. 6B shows a top view of the prior art three-dimensional object printer of FIG. 6A after a first portion of the process to form the object has been completed.
- FIG. 6D shows a side view of the prior art three-dimensional object printer of FIG. 6A after a third portion of the process to form the object has been completed.
- the actuator 122 can include one actuator configured to selectively move the material applicator 112 relative to the member 104 , one actuator configured to selectively heat material 116 within the melter 128 , one actuator configured to selectively expel material 116 from the nozzle 132 , and another actuator configured to selectively heat the heater 120 .
- the material applicator 112 of the printing system 100 is movable in the x-, y-, and z-dimensions.
- the z-dimension (shown in FIG. 1A ) is perpendicular to the planar surface 108 of the member 104
- the x-dimension (shown in FIGS. 1A and 1B ) is parallel to the planar surface 108 of the member 104
- the y-dimension (shown in FIG. 1B ) is parallel to the planar surface 108 of the member 104 .
- the actuator 122 moves the material applicator 112 in the first and second directions without changing the orientation of the material applicator 112 .
- the material applicator 112 does not rotate about a longitudinal axis 140 (shown in FIG. 1B ) of the material applicator 112 , which extends in the z-dimension.
- the material applicator 112 may be rotatable about the longitudinal axis 140 .
- the heater 120 is coupled to the material applicator 112 in such a way that the heater 120 does not interfere with the filament 130 being fed into the material applicator 112 , the melter 128 , the nozzle 132 , or the extrudable material 116 being extruded from the nozzle 132 .
- the heater 120 is further arranged to direct heat toward the planar surface 108 of the member 104 . Accordingly, when the object 136 is present on the member 104 , the heater 120 directs heat toward an uppermost layer 144 of the object 136 .
- the heater 120 is also configured to heat the material 116 to a temperature above the transition temperature of the material 116 . Thus, the heater 120 weakens the intermolecular bonds of the material 116 on the uppermost layer 144 of the object 136 .
- the controller 118 operates the actuator 122 to selectively heat the heater 120 to heat the material 116 above its transition temperature. More specifically, the heater 120 increases the pliability and reduces the viscosity of the material 116 , but does not heat the material 116 to a temperature at which it becomes completely liquid. Because the material 116 is not heated to a temperature at which it becomes completely liquid and runs, the object 136 is not significantly distorted or deformed by the heat from the heater 120 .
- the controller 118 could be configured to operate the actuator 122 to adjust the power of the heater 120 based on the duration of movements of the material applicator 112 . Accordingly, when the material applicator 112 makes small movements and remains above a small area of the object 136 , the power of the heater 120 is adjusted to heat the uppermost layer 144 of the object 136 more slowly to prevent overheating the smaller area of the uppermost layer 144 . In contrast, when the material applicator 112 makes large movements and moves above a large area of the object 136 , the power of the heater 120 is adjusted to heat the uppermost layer 144 of the object 136 more quickly to sufficiently heat the larger area of the uppermost layer 144 to a temperature above the transition temperature of the material 116 .
- the controller 118 could be configured to operate the actuator 122 to adjust the power of the heater 120 based on an elapsed time since the heater 120 last heated an area of material 116 . If the heater 120 has recently heated an area of the object 136 , the material 116 in that area may still be above the transition temperature and may not benefit from additional heating or may become overheated. Accordingly, the controller 118 could be configured to obtain data from the model of the object 136 being printed to determine how recently an area of the object 136 was heated and adjust the power of the heater 120 to direct less heat to areas that were more recently heated.
- the power of the heater 120 is adjusted to heat the uppermost layer 144 of the object 136 more slowly to prevent overheating the recently heated area of the uppermost layer 144 .
- the power of the heater 120 is adjusted to heat the uppermost layer 144 of the object 136 more quickly to sufficiently heat the less recently heated area of the uppermost layer to a temperature above the transition temperature of the material 116 .
- the printing system 100 can include a temperature measuring device, for example an infrared thermocouple 150 , as shown in FIG. 2 , operatively connected to the controller 118 .
- the controller 118 is configured to operate the actuator 122 to adjust the power of the heater 120 based on a measured temperature of the object 136 received from the infrared thermocouple 150 .
- the infrared thermocouple 150 can be embodied as more than one infrared thermocouple operatively connected to the same controller or to different controllers.
- the heater 120 is coupled to the material applicator 112 so as to be always ahead of the material applicator 112 when the material applicator 112 moves in both the first direction and the second direction.
- the heater 120 is always positioned in front of the nozzle 132 of the material applicator 112 in the direction of movement.
- the actuator 122 maintains the rotational position of the material applicator 112 relative to the longitudinal axis 140 when moving the material applicator 112 in the first direction and the second direction. Therefore, to maintain its position in front of the nozzle 132 , the heater 120 is either rotated about the material applicator 112 or is positioned to surround the material applicator 112 .
- the heater 120 includes a hot wire 152 within a reflector 156 (shown in FIG. 1A ).
- the reflector 156 is configured to direct the heat generated by the hot wire 152 toward the planar surface 108 of the member 104 .
- the heater 120 encircles the material applicator 112 , and the hot wire 152 and the reflector 156 are arranged parallel to the planar surface 108 .
- the hot wire 152 and the reflector 156 are positioned in front of the nozzle 132 .
- the hot wire 152 and the reflector 156 are still positioned in front of the nozzle 132 .
- the actuator 122 when the material applicator 112 moves in a direction indicated by the arrow A in the x-dimension, the actuator 122 selectively operates only the heating elements 164 positioned along the direction A.
- the heating elements 164 that are heated by the actuator 122 heat the uppermost layer 144 of material 116 in front of and behind the nozzle 132 .
- the heater 120 ′ does not expend energy to emit heat from portions of the heater 120 ′ which are not arranged in front of and behind the nozzle 132 in the direction of movement.
- FIG. 4 depicts a top view of another alternative embodiment of a heater 120 ′′ for use with the printing system 100 .
- the heater 120 ′′ is substantially similar in structure and function to the heater 120 shown in FIGS. 1A and 1B and described above. However, the heater 120 ′′ does not include a hot wire and a reflector. Instead, the heater 120 ′′ includes a single heating element 168 which is rotatable about the material applicator 112 .
- the heater 120 ′′ also includes a motor 172 configured to selectively rotate the single heating element 168 based on the direction of movement of the material applicator. In this embodiment, the actuator 122 is operatively coupled to the motor 172 to enable the motor 172 to selectively rotate the single heating element 168 . As shown in FIG.
- the motor 172 rotates the single heating element 168 from an initial position (indicated by dashed lines) to a position aligned with the direction B.
- the single heating element 168 is selectively positioned to heat the uppermost layer 144 of material 116 in front of the nozzle 132 .
- the heater 120 ′′ only expends energy to emit heat from a single heating element 168 in the direction of movement B.
Abstract
A three-dimensional object printing system improves the interlayer adhesion of an object. The printing system includes a platform on which a three-dimensional object is built. A material applicator in the printing system expels material to form layers of the object on the platform. The material applicator also includes a heater mounted to an arm that is configured to rotate about the material applicator to position the heater so the heater heats the layer of the object ahead of the material applicator as the material applicator moves relative to the platform.
Description
- This application is a divisional application of co-pending U.S. patent application Ser. No. 15/156,366, which is entitled “Improved Interlayer Adhesion In A Part Printed By Additive Manufacturing,” which was filed on May 17, 2016, and which issued as U.S. Pat. No. ______ on ______.
- The system and method disclosed in this document relate to printers that produce three-dimensional objects and, more particularly, to a device and method for improving interlayer adhesion in parts printed by such printers.
- Digital three-dimensional manufacturing, also known as digital additive manufacturing, is a process of making a three-dimensional solid object of virtually any shape from a digital data model. Three-dimensional printing is distinguishable from traditional object-forming techniques, which mostly rely on the removal of material from a work piece by a subtractive process, such as cutting or drilling. Fused Filament Fabrication (FFF) printing, for example, is an additive process in which one or more material applicators extrude polymer filament to form successive layers of material on a substrate in different shapes. In some embodiments, the polymer filament includes fillers, such as metal particles or fibers, or the polymer filament comprises a metal wire coated with a polymer.
- The polymer filament is typically unwound from a coil and fed into the material applicator to provide material for a layer. As described in further detail below, in the material applicator, the filament is heated to a temperature that increases the pliability of the material, enabling the material to be extruded selectively through a nozzle onto the platform at a controlled rate. The substrate is typically supported on a platform, and one or more material applicators are operatively connected to one or more actuators for controlled movement of the one or more material applicators relative to the platform to produce the layers that form the object. The material applicators are typically moved vertically and horizontally relative to the platform via a numerically controlled mechanism to position the nozzle at x-, y-, and z-dimension coordinates before depositing the material on the substrate. In alternative embodiments, the platform is moved relative to the material applicators.
- One process for producing three-dimensional objects with a
FFF printing system 10 is illustrated inFIGS. 6A-6D . As shown inFIG. 6A , during a printing operation, at least onematerial applicator 14 is positioned relative to amember 18 to space the at least onematerial applicator 14 vertically above themember 18 in the z-dimension by a height H. As the at least onematerial applicator 14 is driven in the x-dimension relative to themember 18, the at least onematerial applicator 14 deposits alayer 22 ofmaterial 26 having a length L (shown inFIG. 6B ) on themember 18. - The
material 26 is fed into the at least onematerial applicator 14 as afilament 38 that is heated by amelter 42 of the at least onematerial applicator 14. As mentioned above, themelter 42 heats thefilament 38 to a temperature that increases the pliability of the polymer of thefilament material 26. Typically, the polymer of thefilament material 26 is a thermoplastic, which is a material that is pliable above a certain temperature, referred to hereinafter as a “transition temperature,” and acts as a solid below the transition temperature. Furthermore, some thermoplastics have an amorphous crystal structure, which prevents the material from “solidifying,” or forming a crystalline structure, even below the transition temperature. - When the
melter 42 heats the thermoplastic polymer of thefilament material 26 above the transition temperature, the intermolecular forces of thematerial 26 weaken, and thematerial 26 becomes more pliable and less viscous. At this elevated temperature, thematerial 26 is selectively extrudable and is hereinafter referred to as being “extrudable” or in “an extrudable state.” Themelter 42 does not heat thefilament 38 to a temperature which causes thematerial 26 to become completely liquid and run. Instead, themelter 42 heats thefilament 38 to a temperature above the transition temperature at which thematerial 26 is soft and malleable, but not completely liquid. After being heated by themelter 42, theextrudable material 26 is deposited on themember 18 by anozzle 46 of the at least onematerial applicator 14. After being deposited by thenozzle 46, thematerial 26 cools on themember 18 to a temperature below the transition temperature such that thelayer 22 becomes less pliable and more viscous and acts as a solid. - As shown in
FIG. 6B , after thelayer 22 ofmaterial 26 is deposited on themember 18, the at least onematerial applicator 14 is driven in the z-dimension relative to themember 18 to re-position the at least onematerial applicator 14 at the height H above thelayer 22. Re-positioning the at least onematerial applicator 14 in the z-dimension accommodates the thickness T of thelayer 22 atop themember 18 to prevent the at least onematerial applicator 14 from contacting thelayer 22 during subsequent passes in the x-dimension. After re-positioning in the z-dimension, the at least onematerial applicator 14 is again driven in the x-dimension to deposit anotherlayer 30 of theobject 34 on top of thelayer 22. The at least onematerial applicator 14 can be driven in the x-dimension to pass themember 18 in the same direction or in the opposite direction as the previous pass. If the at least onematerial applicator 14 is driven in the same direction, the at least onematerial applicator 14 is also re-positioned in the x-dimension before depositing thefurther layer 30. - As shown in
FIGS. 6C and 6D , the at least onematerial applicator 14 is also driven in the y-dimension in the same manner as described above with respect to the x-dimension. Accordingly, the at least onematerial applicator 14 also depositsmaterial 26 to define a width W of theobject 34 on themember 18. The at least onematerial applicator 14 can define the width W of theobject 34 either by depositing thematerial 26 on themember 18 in layers with each layer having the width W in the y-dimension (shown inFIG. 6C ) or by depositing multiple layers on themember 18 in the x-dimension to make up the width W in the y-dimension (shown inFIG. 6D ). In some printing systems, the at least onematerial applicator 14 can be driven in a direction having components in both the x-dimension and the y-dimension. Since the three-dimensional object printing process is an additive process,material 26 is repeatedly added to theobject 34, and the thickness T of theobject 34 increases throughout the process. This process can be repeated as many times as necessary to form theobject 34. - One issue that arises in the production of three-dimensional objects with a FFF printing system is the possibility of inconsistent material strength throughout the object. In particular, objects may have inconsistent material strength in the height along the z-dimension. This inconsistency may arise due to weak bonding between the layers of material forming the object, resulting in low and inconsistent interlayer strength throughout the object. A printing system that builds the layers with stronger adhesion between layers would be beneficial.
- A three-dimensional object printing system includes a platform, a material applicator, and a heater. The platform defines a planar surface, and the material applicator and the platform are configured to move relative to one another in at least a first direction and a second direction. The first direction and the second direction are parallel to the planar surface. The material applicator is configured to expel material to form a layer of an object on the platform. The heater is coupled to the material applicator and is configured to heat a portion of the layer before the material applicator expels material onto the portion of the layer when the material applicator moves in the first and second directions. The heater is configured to heat the layer to a temperature greater than a transition temperature of the material forming the object on the platform.
- A method of printing an object in a three-dimensional printing system includes expelling material from a material applicator to form a layer of an object on a platform positioned opposite the material applicator. The method further includes moving the material applicator in at least a first direction and a second direction. The first direction and the second direction are parallel to a planar surface of the platform. The method also includes heating a first portion of the layer ahead of the material applicator to a temperature greater than a transition temperature of the material forming the object on the platform when the material applicator is moving in the first direction. The method also includes heating a second portion of the layer ahead of the material applicator to the temperature greater than the transition temperature of the material forming the object on the platform when the material applicator is moving in the second direction.
- The foregoing aspects and other features of a three-dimensional object printer and method for forming an object with the printer to correct for inconsistent interlayer strength of the object are explained in the following description, taken in connection with the accompanying drawings.
-
FIG. 1A shows a side view of a printing system including a material applicator and a heater. -
FIG. 1B shows a top view of a part of the printing system ofFIG. 1A . -
FIG. 2 shows a top view of the printing system ofFIG. 1A including a temperature measuring device. -
FIG. 3 shows a top view of another alternative embodiment of a heater for use with the printing system ofFIG. 1A . -
FIG. 4 shows a top view of another alternative embodiment of a heater for use with the printing system ofFIG. 1A . -
FIG. 5A shows a top view of another alternative embodiment of a heater for use with the printing system ofFIG. 1A . -
FIG. 5B shows a side view of the heater ofFIG. 5A for use with the printing system ofFIG. 1A . -
FIG. 6A shows a top view of a prior art three-dimensional object printer prior to performing a first portion of a process to form an object. -
FIG. 6B shows a top view of the prior art three-dimensional object printer ofFIG. 6A after a first portion of the process to form the object has been completed. -
FIG. 6C shows a side view of the prior art three-dimensional object printer ofFIG. 6A after a second portion of the process to form the object has been completed. -
FIG. 6D shows a side view of the prior art three-dimensional object printer ofFIG. 6A after a third portion of the process to form the object has been completed. - For a general understanding of the environment for the system and method disclosed herein as well as the details for the system and method, reference is made to the drawings. In the drawings, like reference numerals have been used throughout to designate like elements.
- A three-dimensional
object printing system 100 is shown inFIGS. 1A and 1B . Theprinting system 100 operates in a manner that is similar to the operation of theprinting system 10 described above and shown inFIGS. 6A-6D . Like the priorart printing system 10, theprinting system 100 includes a substrate or amember 104 having aplanar surface 108 and at least onematerial applicator 112 configured to depositmaterial 116 on theplanar surface 108 and subsequently formed layers. Theprinting system 100 differs from the priorart printing system 10, however, in that theprinting system 100 also includes aheater 120 coupled to thematerial applicator 112 and configured to heatmaterial 116 previously deposited on theplanar surface 108 and subsequently formed layers. - As shown in
FIG. 1A , theprinting system 100 further includes acontroller 118 and anactuator 122, and thematerial applicator 112 includes at least onemelter 128 and at least onenozzle 132. Theactuator 122 is operatively connected to thematerial applicator 112 and to theheater 120. Thecontroller 118 is operatively connected to theactuator 122 to operate theactuator 122 to selectively move thematerial applicator 112 relative to themember 104, to selectively heatmaterial 116 within themelter 128, to selectively expel material 116 from thenozzle 132, and to selectively heat theheater 120. It is noted that theactuator 122 can be embodied as more than one actuator operatively connected to the same controller or to different controllers. For example, theactuator 122 can include one actuator configured to selectively move thematerial applicator 112 relative to themember 104, one actuator configured to selectively heatmaterial 116 within themelter 128, one actuator configured to selectively expel material 116 from thenozzle 132, and another actuator configured to selectively heat theheater 120. - As shown in
FIG. 1A , like theprinting system 10, theprinting system 100 is also a FFF printing system. Themelter 128 receives afilament 130 of thematerial 116, and theactuator 122 selectively heats thefilament 130 to a temperature above the transition temperature of the material 116 to bring thematerial 116 to its extrudable state. Theextrudable material 116 is delivered to thenozzle 132, which has an orifice 134 that faces toward themember 104. Theactuator 122 selectively expels the material 116 through the orifice 134 and onto theplanar surface 108 of themember 104 or onto a previously formed layer to build anobject 136. To enable this building of the object, theactuator 122 also positions thematerial applicator 112 at a location above themember 104 that enables thenozzle 132 and thematerial applicator 112 to pass over theobject 136 and themember 104 without contacting theobject 136 or themember 104. - In alternative embodiments, the
printing system 100 can be another type of additive printing system. For example, thenozzle 132 can be replaced with another material expulsion element, such as a printhead, and themelter 128 can be replaced with another melting element configured to receivematerial 116 from a source, heat the material to its extrudable state, and deliver the extrudable material to the printhead. The printhead can include an ejector, which, like thenozzle 132, is configured to deposit theextrudable material 116 on theplanar surface 108 of themember 104. - As shown in
FIGS. 1A and 1B , as in theprinting system 10, thematerial applicator 112 of theprinting system 100 is movable in the x-, y-, and z-dimensions. In the same manner, the z-dimension (shown inFIG. 1A ) is perpendicular to theplanar surface 108 of themember 104, the x-dimension (shown inFIGS. 1A and 1B ) is parallel to theplanar surface 108 of themember 104, and the y-dimension (shown inFIG. 1B ) is parallel to theplanar surface 108 of themember 104. - The
controller 118 is configured to operate the actuator 122 (shown inFIG. 1A ) to selectively move thematerial applicator 112 in the x-, y-, and z-dimensions and to selectively expel the material 116 from thenozzle 132 of thematerial applicator 112. Thematerial applicator 112 is movable in at least a first direction and a second direction in the x- and y-dimensions, each of the first direction and the second direction being parallel to theplanar surface 108. The first direction and the second direction can be opposite directions along a common line. For example, as shown inFIG. 1B , thematerial applicator 112 is movable rightwardly and leftwardly, or back and forth, along a common line in the x-dimension. However, the first direction and the second direction can also be directions that are not opposite along a common line. For example, as shown inFIG. 1B , thematerial applicator 112 is movable leftwardly and rightwardly, in directions in the x-dimension, and upwardly and downwardly, in directions the y-dimension. These directions are not opposite along a common line. Furthermore, in some embodiments, thematerial applicator 112 is also movable in directions that have components in both the x-dimension and the y-dimension. For example, as shown inFIG. 1B , thematerial applicator 112 is movable diagonally in directions having an upward or downward component and having a leftward or rightward component. - The
actuator 122 moves thematerial applicator 112 in the first and second directions without changing the orientation of thematerial applicator 112. In other words, thematerial applicator 112 does not rotate about a longitudinal axis 140 (shown inFIG. 1B ) of thematerial applicator 112, which extends in the z-dimension. In alternative embodiments, however, thematerial applicator 112 may be rotatable about thelongitudinal axis 140. - The
heater 120 is coupled to thematerial applicator 112 in such a way that theheater 120 does not interfere with thefilament 130 being fed into thematerial applicator 112, themelter 128, thenozzle 132, or theextrudable material 116 being extruded from thenozzle 132. Theheater 120 is further arranged to direct heat toward theplanar surface 108 of themember 104. Accordingly, when theobject 136 is present on themember 104, theheater 120 directs heat toward anuppermost layer 144 of theobject 136. Like thematerial applicator 112, theheater 120 is also configured to heat thematerial 116 to a temperature above the transition temperature of thematerial 116. Thus, theheater 120 weakens the intermolecular bonds of thematerial 116 on theuppermost layer 144 of theobject 136. - The
controller 118 operates theactuator 122 to selectively heat theheater 120 to heat thematerial 116 above its transition temperature. More specifically, theheater 120 increases the pliability and reduces the viscosity of thematerial 116, but does not heat thematerial 116 to a temperature at which it becomes completely liquid. Because thematerial 116 is not heated to a temperature at which it becomes completely liquid and runs, theobject 136 is not significantly distorted or deformed by the heat from theheater 120. - In at least one embodiment, the
controller 118 operates theactuator 122 to adjust the power of theheater 120 based on the speed of movement of thematerial applicator 112. Accordingly, when thematerial applicator 112 moves more slowly, the power of theheater 120 is adjusted to heat theuppermost layer 144 of theobject 136 more slowly to prevent overheating theuppermost layer 144. In contrast, when thematerial applicator 112 moves more quickly, the power of theheater 120 is adjusted to heat theuppermost layer 144 of theobject 136 more quickly to sufficiently heat theuppermost layer 144 to a temperature above the transition temperature of thematerial 116. - Similarly, the
controller 118 could be configured to operate theactuator 122 to adjust the power of theheater 120 based on the duration of movements of thematerial applicator 112. Accordingly, when thematerial applicator 112 makes small movements and remains above a small area of theobject 136, the power of theheater 120 is adjusted to heat theuppermost layer 144 of theobject 136 more slowly to prevent overheating the smaller area of theuppermost layer 144. In contrast, when thematerial applicator 112 makes large movements and moves above a large area of theobject 136, the power of theheater 120 is adjusted to heat theuppermost layer 144 of theobject 136 more quickly to sufficiently heat the larger area of theuppermost layer 144 to a temperature above the transition temperature of thematerial 116. - Additionally, the
controller 118 could be configured to operate theactuator 122 to adjust the power of theheater 120 based on an elapsed time since theheater 120 last heated an area ofmaterial 116. If theheater 120 has recently heated an area of theobject 136, thematerial 116 in that area may still be above the transition temperature and may not benefit from additional heating or may become overheated. Accordingly, thecontroller 118 could be configured to obtain data from the model of theobject 136 being printed to determine how recently an area of theobject 136 was heated and adjust the power of theheater 120 to direct less heat to areas that were more recently heated. When thematerial applicator 112 is moved to an area that it has recently heated, the power of theheater 120 is adjusted to heat theuppermost layer 144 of theobject 136 more slowly to prevent overheating the recently heated area of theuppermost layer 144. In contrast, when thematerial applicator 112 is moved to an area that has not been recently heated, the power of theheater 120 is adjusted to heat theuppermost layer 144 of theobject 136 more quickly to sufficiently heat the less recently heated area of the uppermost layer to a temperature above the transition temperature of thematerial 116. - Additionally, or alternatively, the
printing system 100 can include a temperature measuring device, for example aninfrared thermocouple 150, as shown inFIG. 2 , operatively connected to thecontroller 118. In such embodiments, thecontroller 118 is configured to operate theactuator 122 to adjust the power of theheater 120 based on a measured temperature of theobject 136 received from theinfrared thermocouple 150. It is noted that theinfrared thermocouple 150 can be embodied as more than one infrared thermocouple operatively connected to the same controller or to different controllers. Theinfrared thermocouple 150 is positioned so as to be always ahead of theheater 120 to measure the temperature of theobject 136 at a position ahead of the position of theheater 120 and thematerial applicator 112. Theinfrared thermocouple 150 measures a temperature at the surface of an area of theobject 136 and transmits the temperature measurement information to thecontroller 118. Thecontroller 118 is configured to adjust the power of theheater 120 based on the temperature measurement information received from theinfrared thermocouple 150. - For example, if the
controller 118 receives temperature measurement information from theinfrared thermocouple 150 indicating a temperature at the surface of an area of theobject 136 that is at or above the transition temperature, thematerial 116 in that area may not benefit from additional heating or may become overheated. Accordingly, the power of theheater 120 is adjusted to direct no heat toward that area of theobject 136. If thecontroller 118 receives temperature measurement information from theinfrared thermocouple 150 indicating a temperature at the surface of an area of theobject 136 that is below the transition temperature, the power of theheater 120 is adjusted to direct sufficient heat toward that area of theobject 136 to raise the temperature of the surface of that area of theobject 136 to the transition temperature of thematerial 116. In various embodiments, thecontroller 118 can use temperature measurement information from theinfrared thermocouple 150 independently or in conjunction with elapsed time and object model data to adjust the power of theheater 120. -
FIGS. 1A and 1B , theheater 120 is coupled to thematerial applicator 112 so as to be always ahead of thematerial applicator 112 when thematerial applicator 112 moves in both the first direction and the second direction. For example, when thematerial applicator 112 moves in a direction of movement, indicated by the arrow A inFIG. 1A , relative to themember 104, theheater 120 is always positioned in front of thenozzle 132 of thematerial applicator 112 in the direction of movement. - Accordingly, the
heater 120 is configured to heat theuppermost layer 144 of theobject 136 before thematerial applicator 112 applies anotherlayer 148 atop theuppermost layer 144. Because theuppermost layer 144 is heated above the transition temperature by theheater 120 and thenext layer 148 is heated above the transition temperature by themelter 128 before being extruded through thenozzle 132, both are made up ofmaterial 116 that has weakened intermolecular bonds. The weakened intermolecular bonds of the material 116 enable thematerial 116 of theuppermost layer 144 and of thenext layer 148 to intermingle upon contact. In particular, polymer strands of the polymer of the material 116 at the interface between theuppermost layer 144 and thenext layer 148 rearrange and interact with one another. When thematerial 116 cools below its transition temperature, the intermingledmaterial 116 of theuppermost layer 144 and thefurther layer 148 improves the interlayer strength of theobject 136. - As mentioned above, the
actuator 122 maintains the rotational position of thematerial applicator 112 relative to thelongitudinal axis 140 when moving thematerial applicator 112 in the first direction and the second direction. Therefore, to maintain its position in front of thenozzle 132, theheater 120 is either rotated about thematerial applicator 112 or is positioned to surround thematerial applicator 112. In the embodiment shown inFIGS. 1A and 1B , theheater 120 includes ahot wire 152 within a reflector 156 (shown inFIG. 1A ). Thereflector 156 is configured to direct the heat generated by thehot wire 152 toward theplanar surface 108 of themember 104. - The
heater 120 encircles thematerial applicator 112, and thehot wire 152 and thereflector 156 are arranged parallel to theplanar surface 108. Thus, when thematerial applicator 112 moves in the first direction parallel to theplanar surface 108, thehot wire 152 and thereflector 156 are positioned in front of thenozzle 132. Additionally, when thematerial applicator 112 moves in the second direction parallel to theplanar surface 108, thehot wire 152 and thereflector 156 are still positioned in front of thenozzle 132. Because theheater 120 encircles thematerial applicator 112, no matter in which direction thematerial applicator 112 moves parallel to theplanar surface 108, theheater 120 is positioned to lead thematerial applicator 112. In this embodiment,hot wire 152 and thereflector 156 are also positioned behind thenozzle 132. - As shown in
FIG. 1B , from a top view, in a plane parallel to theplanar surface 108, thematerial applicator 112 defines aperimeter 160. In the embodiment shown, theperimeter 160 is circular. However, in alternative embodiments, theperimeter 160 can have other shapes. In the embodiment shown inFIGS. 1A and 1B , theheater 120 is substantially cylindrically shaped and defines acentral axis 162 that is coaxial with thelongitudinal axis 140 of thematerial applicator 112. Thus, theheater 120 is positioned concentrically about thematerial applicator 112. As shown inFIG. 1B , from the top view, theheater 120 completely surrounds thematerial applicator 112. In other embodiments, theheater 120 can have other shapes and can be positioned to completely surround thematerial applicator 112, but have thecentral axis 162 not coaxially located with thelongitudinal axis 140. -
FIG. 3 depicts a top view of an alternative embodiment of aheater 120′ for use with theprinting system 100. Theheater 120′ is substantially similar in structure and function to theheater 120 shown inFIGS. 1A and 1B and described above. However, theheater 120′ does not include a hot wire and a reflector. Instead, theheater 120′ includesseparate heating elements 164 positioned around thematerial applicator 112. In this embodiment, theactuator 122 is configured to selectively heat theseparate heating elements 164 based on the direction of movement of thematerial applicator 112. As shown inFIG. 3 , when thematerial applicator 112 moves in a direction indicated by the arrow A in the x-dimension, theactuator 122 selectively operates only theheating elements 164 positioned along the direction A. Thus, theheating elements 164 that are heated by theactuator 122 heat theuppermost layer 144 ofmaterial 116 in front of and behind thenozzle 132. In this embodiment, theheater 120′ does not expend energy to emit heat from portions of theheater 120′ which are not arranged in front of and behind thenozzle 132 in the direction of movement. -
FIG. 4 depicts a top view of another alternative embodiment of aheater 120″ for use with theprinting system 100. Theheater 120″ is substantially similar in structure and function to theheater 120 shown inFIGS. 1A and 1B and described above. However, theheater 120″ does not include a hot wire and a reflector. Instead, theheater 120″ includes asingle heating element 168 which is rotatable about thematerial applicator 112. Theheater 120″ also includes amotor 172 configured to selectively rotate thesingle heating element 168 based on the direction of movement of the material applicator. In this embodiment, theactuator 122 is operatively coupled to themotor 172 to enable themotor 172 to selectively rotate thesingle heating element 168. As shown inFIG. 4 , when thematerial applicator 112 moves in a direction indicated by the arrow B in the x-dimension and the y-dimension, themotor 172 rotates thesingle heating element 168 from an initial position (indicated by dashed lines) to a position aligned with the direction B. Thus, thesingle heating element 168 is selectively positioned to heat theuppermost layer 144 ofmaterial 116 in front of thenozzle 132. In this embodiment, theheater 120″ only expends energy to emit heat from asingle heating element 168 in the direction of movement B. -
FIGS. 5A and 5B depict a top view and a side view, respectively, of another alternative embodiment of aheater 120′″ for use with theprinting system 100. Theheater 120′″ is substantially similar in structure and function to theheater 120 shown inFIGS. 1A and 1B and described above. However, theheater 120′″ does not include a hot wire and a reflector. Instead, theheater 120′″ includes aheating element 174, a pressurized air source, such as a fan orblower 176, aduct 180, (each shown inFIG. 5A ) and aheat distributor 184. In this embodiment, as shown inFIG. 5A , theactuator 122 is operatively connected to theheating element 174 and the fan orblower 176 and is configured to heat theheating element 174 and actuate the fan orblower 176. Theduct 180 is coupled to theheating element 174 and to theheat distributor 184, and the fan orblower 176 is actuated to blow hot air generated by theheating element 174 into and through theduct 180 to theheat distributor 184. The hot air is then expelled from theheat distributor 184 around thematerial applicator 112 to heat theuppermost layer 144 ofmaterial 116. In the embodiment shown, theheat distributor 184 is substantially cylindrically shaped and surrounds thematerial applicator 112. Because, like the embodiment of theheater 120 shown in FIGS. 1A and 1B, theheater 120′″ emits heat in every direction in a circle around thematerial applicator 112, when thematerial applicator 112 is moved in any direction parallel to theplanar surface 108, theheater 120′″ heats theuppermost layer 144 ofmaterial 116 in front of and behind thenozzle 132. An additional advantage of theheater 120′″ is that the hot air generated by theheating element 174 can also carry moisture away from theuppermost layer 144 of theobject 136, which may further aid in adhesion of the further layer 148 (shown inFIG. 5B ) to theuppermost layer 144. - The
heaters printing system 100. Further alternative embodiments can include other types of heaters and arrangements of heaters to emit heat toward theplanar surface 108 of themember 104 in other ways not specifically discussed herein. For example, in alternative embodiments, theprinting system 100 can include other heaters that use a hot radiant metal filament, a ceramic heating element, and/or a heated flow of air to heat thematerial 116. Additionally, theprinting system 100 can include other heaters that use other elements and/or procedures to heat thematerial 116. - In all embodiments, the heater is configured to heat the
uppermost layer 144 ahead of thematerial applicator 112 when thematerial applicator 112 moves in a first direction and moves in a second direction to a temperature above the transition temperature of the material to enable thematerial 116 of afurther layer 148, extruded from thenozzle 132 of thematerial applicator 112 atop theuppermost layer 144, to intermingle with theheated material 116 of theuppermost layer 144. - It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems, applications or methods. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art, which are also intended to be encompassed by the following claims.
Claims (20)
1. A three-dimensional (3D) object manufacturing system comprising:
a platform defining a planar surface;
a material applicator configured to expel material to form a layer of an object on the platform;
a first actuator operatively connected to one of the platform and the material applicator to move the platform and material applicator relative to one another in at least a first direction and a second direction that are orthogonal to one another in a plane that is parallel to the planar surface; and
a heater mounted to an arm that is configured to rotate about the material applicator to position the heater relative to the material applicator so the heater heats a portion of the layer of the object before the material applicator expels material onto the portion of the layer of the object as the material applicator moves in the first and second directions.
2. The 3D object manufacturing system of claim 1 wherein the heater is further configured to heat the expelled material ahead of the material applicator to a temperature greater than a transition temperature of the material forming the object on the platform but less than a temperature at which the material becomes liquid.
3. The 3D object manufacturing system of claim 2 further comprising:
a second actuator operatively connected to the arm to which the heater is mounted, the actuator being configured to rotate the arm about the material applicator.
4. The 3D object manufacturing system of claim 3 further comprising:
a controller operatively connected to the first actuator and the second actuator, the controller being configured to operate the second actuator to rotate the arm and position the heater to lead the material applicator as the material application moves relative to the platform.
5. The 3D object manufacturing system of claim 4 wherein the controller is further configured to adjust an electrical power delivered to the heater with reference to a speed at which the material applicator moves.
6. The 3D object manufacturing system of claim 4 wherein the controller is further configured to adjust an electrical power delivered to the heater with reference to a size of an area over which the material applicator moves while expelling material.
7. The 3D object manufacturing system of claim 4 wherein the controller is further configured to adjust an electrical power delivered to the heater with reference to an elapsed time since the heater heated the area in which the material applicator is expelling material.
8. The 3D object manufacturing system of claim 4 further comprising:
a sensor for generating a signal indicative of a temperature of an area opposite the sensor, the sensor being mounted proximate to the heater; and
the controller is operatively connected to the sensor, the controller being further configured to adjust an electrical power delivered to the heater with reference to the temperature indicated by the signal received from the sensor.
9. The 3D object manufacturing system of claim 8 wherein the sensor is mounted to precede the heater as the material applicator moves relative to the platform.
10. The 3D object manufacturing system of claim 9 wherein the sensor is an infrared thermocouple.
11. The 3D object manufacturing system of claim 4 wherein the material applicator is an extruder.
12. The 3D object manufacturing system of claim 4 wherein the material applicator is a printhead.
13. The 3D object manufacturing system of claim 4 wherein the heater is a single heating element.
14. The 3D object manufacturing system of claim 14 , the heater further comprising:
a source of pressurized air positioned to direct air heated by the single heating element away from the heating element.
15. The 3D object manufacturing system of claim 4 , the material applicator further comprising:
a heater within the material applicator to heat material to be expelled from the material applicator to a transition temperature of the material before expelling the material.
16. A three-dimensional (3D) object manufacturing system comprising:
a platform defining a planar surface;
a material applicator configured to expel material to form a layer of an object on the platform;
a first actuator operatively connected to one of the platform and the material applicator to move the platform and material applicator relative to one another in at least a first direction and a second direction that are orthogonal to one another in a plane that is parallel to the planar surface;
a heater mounted to an arm that is configured to rotate about the material applicator to position the heater relative to the material applicator so the heater heats a portion of the layer of the object before the material applicator expels material onto the portion of the layer of the object as the material applicator moves in the first and second directions, the heater being further configured to heat the expelled material ahead of the material applicator to a temperature greater than a transition temperature of the material forming the object on the platform but less than a temperature at which the material becomes liquid; and
a second actuator operatively connected to the arm to which the heater is mounted, the actuator being configured to rotate the arm about the material applicator.
17. The 3D object manufacturing system of claim 16 further comprising:
a controller operatively connected to the first actuator and the second actuator, the controller being configured to operate the second actuator to rotate the arm and position the heater to lead the material applicator as the material application moves relative to the platform.
18. The 3D object manufacturing system of claim 17 wherein the controller is further configured to adjust an electrical power delivered to the heater with reference to a speed at which the material applicator moves.
19. The 3D object manufacturing system of claim 18 further comprising:
a sensor for generating a signal indicative of a temperature of an area opposite the sensor, the sensor being mounted proximate to the heater; and
the controller is operatively connected to the sensor, the controller being further configured to adjust an electrical power delivered to the heater with reference to the temperature indicated by the signal received from the sensor.
20. The 3D object manufacturing system of claim 19 , the material applicator further comprising:
a heater within the material applicator to heat material to be expelled from the material applicator to a transition temperature of the material before expelling the material.
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2016
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2017
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- 2017-04-28 JP JP2017090132A patent/JP6832223B2/en active Active
-
2019
- 2019-05-15 US US16/412,883 patent/US20190263066A1/en not_active Abandoned
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
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US10960606B2 (en) * | 2016-07-22 | 2021-03-30 | Hewlett-Packard Development Company, L.P. | Controlling heating in additive manufacturing |
US20210162671A1 (en) * | 2019-11-29 | 2021-06-03 | Canon Kabushiki Kaisha | Method of manufacturing three-dimensionally shaped object, and additive manufacturing apparatus |
US11826962B2 (en) | 2020-12-24 | 2023-11-28 | Seiko Epson Corporation | Three-dimensional shaping apparatus |
US11712854B2 (en) | 2021-09-07 | 2023-08-01 | Xerox Corporation | System and method for detecting errors during 3D printing |
Also Published As
Publication number | Publication date |
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JP2017206011A (en) | 2017-11-24 |
CN107379517A (en) | 2017-11-24 |
CN107379517B (en) | 2020-09-22 |
US10328637B2 (en) | 2019-06-25 |
JP6832223B2 (en) | 2021-02-24 |
US20170334137A1 (en) | 2017-11-23 |
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