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Title:
THREE-DIMENSIONAL PRINTING SYSTEM
Document Type and Number:
WIPO Patent Application WO/2020/097299
Kind Code:
A4
Abstract:
A vat polymerization apparatus configured with a resin circulatory system that includes pumps (104,106) arranged to extract used photo-curing resin from a tank (102) and refresh or replace it with new resin, another fluid, or a combination of new resin and the fluid. Resin flow is regulated using a plurality of valves (113,114,116,118) which are opened and closed to achieve a desired circulation process. Additional aspects of the apparatus include a membrane assembly in which a radiation-transparent flexible membrane is supported in a frame that stretches the membrane. A lip of the frame is secured to a bottom rim of the tank; thus, when the membrane assembly is in place it forms a bottom of the tank. A tension adjustment mechanism may be employed to adjust the tension of the membrane within the frame. The frame may be aligned with the tank with the aid of magnetized alignment aids distributed about the frame.

Inventors:
BARKER NATHAN (US)
BARKER STEVE (US)
MEDALSY IZHAR (US)
TRINGALI LUCIANO (US)
Application Number:
PCT/US2019/060219
Publication Date:
September 24, 2020
Filing Date:
November 07, 2019
Export Citation:
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Assignee:
NEXA3D INC (US)
International Classes:
B29C64/124; B29C64/129; B29C64/245; B29C64/314; B29C64/35
Attorney, Agent or Firm:
FAHMI, Tarek, N. (US)
Download PDF:
Claims:
AMENDED CLAIMS

received by the International Bureau on 1 1 August 2020 (1 1.08.2020)

CLAIMS

What is claimed is:

1. An apparatus, comprising:

a tank configured to contain a resin, the tank including an entrance port and an exit port; and

a resin circulatory system comprising:

a first pump configured to extract the resin from the tank through the exit port of the tank, and flow the resin towards a branch point, the branch point fluidly coupled to the first pump, a first valve, and a second valve, wherein the first valve regulates a flow of the resin from the first branch point to an inlet of a first reservoir and the second valve regulates a flow of the resin from the first branch point to a first of the confluence points;

a third valve regulating a flow of the resin from an outlet of the first reservoir to a second confluence point, and a fourth valve regulating a flow of the resin from the first confluence point to a second of the confluence point;

a second reservoir configured to supply a fluid to the first confluence point, wherein the fluid comprises at least one of fresh resin or an additive; and a second pump is configured to extract the resin, the fluid or a

combination of the resin and the fluid from the second confluence point and flow the resin, the fluid, or the combination of the resin and the fluid, as applicable, into the tank via the entrance port of the tank.

2. (Canceled)

3. The apparatus of claim 1, further comprising a membrane assembly that includes:

a radiation-transparent flexible membrane; and

a frame affixed to a perimeter of the radiation-transparent flexible membrane and configured to stretch the radiation-transparent flexible membrane along a first plane, wherein the frame comprises a lip extending perpendicular to the first plane, the lip configured to be secured to a bottom rim of a sidewall of the tank, wherein the membrane assembly, when secured to the sidewall, forms a bottom of the tank.

4. The apparatus of claim 3, wherein the membrane assembly further comprises a tension adjustment mechanism coupled to the radiation-transparent flexible membrane and configured to adjust a tension of the radiation-transparent flexible membrane.

5. The apparatus of claim 3, wherein the membrane assembly further comprises a tension sensor affixed to a surface of the radiation-transparent flexible membrane and configured to measure a tension of the radiation-transparent flexible membrane.

6. The apparatus of claim 5, wherein the tension sensor comprises a strain gauge affixed to the surface of the radiation-transparent flexible membrane.

7. The apparatus of claim 3, wherein the membrane assembly further comprises a tension sensor embedded within the radiation-transparent flexible membrane and configured to measure a tension of the radiation-transparent flexible membrane.

8. The apparatus of claim 7, wherein the tension sensor comprises a conductive strip embedded within the radiation-transparent flexible membrane.

9. The apparatus of claim 7, wherein the tank includes a sidewall having a bottom rim that includes a groove; a tension sensor is coupled to the tank sidewall; and a first frame which supports a radiation-transparent flexible membrane at a perimeter of the membrane and which includes a lip is secured to the tank by engagement of the groove of the bottom rim of the tank sidewall with the lip, said tension sensor being configured to detect movement of the radiation-transparent flexible membrane upon a loss of tension of the radiation-transparent flexible membrane.

10. The apparatus of claim 9, further comprising a lighting assembly having a glass plate secured within a second frame, and a liquid crystal display (LCD) secured within a third frame, wherein the second frame is secured to the third frame, and is configured to displace a portion of the radiation-transparent flexible membrane away from a first plane into a second plane parallel to the first plane, said first plane defining a region in which the radiation-transparent flexible membrane lies absent the displacement of the portion

25 of the radiation-transparent flexible membrane by the second frame.

11. The apparatus of claim 10, further comprising a base portion configured to support at least one of the third frame or the LCD, and a height adjustment mechanism disposed between the first frame and the base portion, the height adjustment mechanism configured to adjust a vertical position of the first frame with respect to the base portion and, in turn, adjust the displacement of the portion of the radiation-transparent flexible membrane with respect to the first plane.

12. The apparatus of claim 10, further comprising a base portion configured to support the first frame, and a height adjustment mechanism disposed between the base portion and at least one of the third frame or the LCD, the height adjustment mechanism configured to adjust a vertical position of the LCD with respect to the base portion and, in turn, adjust the displacement of the portion of the radiation-transparent flexible membrane with respect to the first plane.

13. The apparatus of claim 1, further comprising:

a frame assembly comprising a first frame supporting a glass plate and/or a radiation-transparent flexible membrane, the first frame including a first plurality of through holes and a first plurality of magnetized portions distributed about a surface of the first frame; and

a liquid crystal display (LCD) assembly comprising a second frame and an LCD, wherein the second frame is configured to hold the LCD, the second frame including a second plurality of through holes and a second plurality of magnetized portions distributed about a surface of the second frame,

wherein (i) a pattern in which the first plurality of through holes are distributed about the surface of the first frame is a mirror image of a pattern in which the second plurality of through holes are distributed about the surface of the second frame, (ii) a pattern in which the first plurality of magnetized portions are distributed about the surface of the first frame is a mirror image of a pattern in which the second plurality of magnetized portions are distributed about the surface of the second frame, and (iii) each one of the first plurality of magnetized portions is attracted to a corresponding one of the second plurality of magnetized portions such that when the first frame is disposed in a

26 proximity of the second frame, (I) the surface of the first frame automatically contacts the surface of the second frame, and (II) each one of the first plurality of through holes automatically aligns with a corresponding one of the second plurality of through holes.

14. The apparatus of claim 13, further comprising:

a gasket disposed within or near a boundary region between the surface of the first frame and the surface of the second frame.

15. A method to operate an apparatus comprising a tank configured to contain a resin, the tank including an entrance port and an exit port; and a resin circulatory system comprising (i) a first pump configured to extract the resin from the tank through the exit port of the tank, and flow the resin towards a branch point, (ii) the branch point fluidly coupled to the first pump, a first valve and a second valve, (iii) the first valve regulating a flow of the resin from the first branch point to an inlet of a first reservoir, (iv) the second valve regulating a flow of the resin from the first branch point to a first confluence point, (v) a third valve regulating a flow of the resin from an outlet of the first reservoir to a second confluence point, (vi) a fourth valve regulating a flow of the resin from the first confluence point to the second confluence point, (vii) a second reservoir configured to supply a fluid to the first confluence point, wherein the fluid comprises at least one of fresh resin or an additive, and (viii) a second pump configured to extract the resin, the fluid or a combination of the resin and the fluid from the second confluence point and flow the resin, the fluid or the combination of the resin and the fluid towards the entrance port of the tank, the method comprising:

during a first time period, opening the first and third valves, and closing the second and fourth valves so as to flow resin from the tank through the first reservoir and back into the tank; and

during a second time period, closing the first and third valves, and opening the second and fourth valves so as to flow resin from the tank to the first confluence point attached to the second reservoir, and flow the combination of the resin and the fluid into the tank.

27