公开(公告)号：US11370166B2

公开(公告)日：2022-06-28

申请号：US16711313

申请日：2019-12-11

Applicant: Impossible Objects Inc.

Inventor： Robert Swartz ,  Eugene Gore ,  Buckley Crist

IPC: B29C64/147 ,  B29C65/48 ,  B32B5/22 ,  G03G15/22 ,  B32B5/02 ,  B32B7/14 ,  B32B5/26 ,  B32B5/30 ,  B29C64/153 ,  B32B9/04 ,  B32B27/36 ,  B32B29/00 ,  B32B9/06 ,  B32B27/14 ,  B32B29/02 ,  B32B27/08 ,  B32B27/10 ,  B32B5/16 ,  B32B29/04 ,  B32B27/06 ,  B32B18/00 ,  B32B27/12 ,  B32B5/12 ,  B32B9/00 ,  B29C64/30 ,  B29C64/20 ,  B29C64/141 ,  B29K101/12 ,  B29K105/00 ,  B33Y40/00 ,  B33Y10/00

Abstract: A three-dimensional object comprises substantially planar or flat substrate layers that are folded and stacked in a predetermined order and infiltrated by a hardened material. The object is fabricated by positioning powder on all or part of multiple substrate layers. On each layer, the powder is selectively deposited in a pattern that corresponds to tiles that each have a slice of the object. For each slice, powder is deposited in positions that correspond to positions in the slice where the object exists, and not deposited where the object does not exist. The tiles of each substrate layer are folded and aligned in a predetermined order. Multiple folded substrate layers mat be combined into a single stack. The powder is transformed into a substance that flows and subsequently hardens into the hardened material in a spatial pattern that infiltrates positive regions, and does not infiltrate negative regions, in the substrate layers.

公开(公告)号：US20210229359A1

公开(公告)日：2021-07-29

申请号：US17156541

申请日：2021-01-23

Applicant: Impossible Objects, Inc.

Inventor： Robert Swartz ,  Eugene Gore

IPC: B29C64/321 ,  B22F12/50 ,  B33Y30/00

Abstract: A powder refill system for a CBAM process that makes changing a powder container simple and maintains the smallest possible distribution change during the print process. The system automates a constantly low trough powder level during a print and reduces the number of times the powder is recirculated. The system uses a sensor to sense the amount of powder in a tray and a compressed air powder application system to force powder into the system. Powder enters the system from a powder bottle mounted upside-down on a plate with an orifice and mixing chamber and a stainless-steel “aeration stone” This is a fitting with porous walls, where porosity is finer than most of particulate matter of the powder being used. Air can enter through the fitting, broken down into microscopic streams, but powder cannot enter back into the air supplying line. The powder aerosol is then used in the printing/flooding process. A mounting plate allows easy replacement of the powder bottle.

公开(公告)号：US20210229347A1

公开(公告)日：2021-07-29

申请号：US17156538

申请日：2021-01-23

Applicant: Impossible Objects, Inc.

Inventor： Robert Swartz ,  James Brough ,  Eugene Gore

IPC: B29C64/147 ,  B29C64/321 ,  B29C64/314 ,  B29C64/245 ,  B29C64/232

Abstract: A system and method for lifting substrate sheets off of a stack of porous sheets one at a time, even though the sheets tend to stick together. A felt tamp is lowered onto the stack of sheets, and as the tamp is raised, a set of edge flickers create a downward force on the corners of the top sheet. This causes the edges of the top sheet to bend downward slightly just enough to pry the second sheet loose from the top sheet. The tamp can then be further raised with only the top sheet adhering to the felt, and the lifted sheet can be deposited at the next station in the process. Periodically, a brush is used to renew the surface of the felt to prevent matting of the felt fibers.

公开(公告)号：US10377106B2

公开(公告)日：2019-08-13

申请号：US15722653

申请日：2017-10-02

Applicant: Impossible Objects, Inc.

Inventor： Robert Swartz ,  Buckley Crist ,  Eugene Gore ,  Joseph M. Jacobson

IPC: B32B5/26 ,  B29C64/153 ,  B29C64/141 ,  G03G15/22 ,  B29C70/22 ,  B33Y70/00 ,  B32B5/02 ,  B32B1/00 ,  B32B7/14 ,  B29L9/00

Abstract: A 3D object according to the invention involves substrate layers infiltrated by a hardened material. The 3D object may be fabricated by a method comprising the following steps: Flatten a substrate layer. Position powder on all or part of a substrate layer. Repeat this step for the remaining substrate layers. Stack the substrate layers. Transform the powder into a substance that flows and subsequently hardens into the hardened material. The hardened material solidifies in a spatial pattern that infiltrates positive regions in the substrate layers and does not infiltrate negative regions in the substrate layers. In a preferred embodiment, the substrate is carbon fiber and excess substrate is removed by abrasion. Flattening a substrate layer involves reducing planar inconsistencies or imperfections, and comprises applying heat to each substrate layer, cooling the substrate layers, and optionally applying tension and/or pressure to the heated and cooled substrate layers.

公开(公告)号：US20180022065A1

公开(公告)日：2018-01-25

申请号：US15722653

申请日：2017-10-02

Applicant: Impossible Objects, Inc.

Inventor： Robert Swartz ,  Buckley Crist ,  Eugene Gore ,  Joseph M. Jacobson

IPC: B32B5/26 ,  B32B7/14 ,  B32B1/00 ,  B29C70/22 ,  G03G15/22 ,  B29C64/141 ,  B29C64/153 ,  B32B5/02 ,  B33Y70/00

CPC classification number: B32B5/26 ,  B29C64/141 ,  B29C64/153 ,  B29C70/22 ,  B29L2009/00 ,  B32B1/00 ,  B32B5/022 ,  B32B5/024 ,  B32B7/14 ,  B32B2260/021 ,  B32B2260/023 ,  B32B2260/04 ,  B32B2260/046 ,  B32B2262/106 ,  B33Y70/00 ,  G03G15/224 ,  G03G15/225 ,  Y10T428/24479 ,  Y10T428/2481 ,  Y10T428/24826 ,  Y10T428/24843 ,  Y10T442/60 ,  Y10T442/67

Abstract: A 3D object according to the invention involves substrate layers infiltrated by a hardened material. The 3D object may be fabricated by a method comprising the following steps: Flatten a substrate layer. Position powder on all or part of a substrate layer. Repeat this step for the remaining substrate layers. Stack the substrate layers. Transform the powder into a substance that flows and subsequently hardens into the hardened material. The hardened material solidifies in a spatial pattern that infiltrates positive regions in the substrate layers and does not infiltrate negative regions in the substrate layers. In a preferred embodiment, the substrate is carbon fiber and excess substrate is removed by abrasion. Flattening a substrate layer involves reducing planar inconsistencies or imperfections, and comprises applying heat to each substrate layer, cooling the substrate layers, and optionally applying tension and/or pressure to the heated and cooled substrate layers.