FIELD

[0001] The present disclosure relates generally to a support strap for supporting a filament tube in a three-dimensional printer.

BACKGROUND

[0002] The statements in this section merely provide background information related to the present disclosure and may or may not constitute prior art.

[0003] In three-dimensional printing, a three-dimensional object is formed by sequentially depositing layers of a material. Each layer of the material is supported by the layer of material underneath it and where it may not be possible to fully support the material, support structures are incorporated into the design that may be removed after printing is completed. Within the printer, the material is deposited on a build plate by a printhead supported on an x,y-gantry. The x,y-gantry is configured to move the printhead in an x- direction and in a y-direction. The material deposited on the build plate is generally in the form of an elongated filament. The filament is typically stored in a roller adjacent the 3D printer and must be routed to and within the 3D printer and ultimately to the printhead. Typically, the filament will travel within a filament tube to be directed to the printhead. The filament and filament tube must be supported within the 3D printer until the filament reaches the printhead where the filament is extruded on to the build plate. Importantly, the filament and filament tube must be supported to accommodate the movement of the printhead in the x and y directions. Additionally, the printhead requires electrical control signals and power to operate.

[0004] Accordingly, while current solutions for routing electrical control signals and power, a filament and a filament tube of a three-dimensional printer are useful for their intended purpose, there is room in the art for an improved printer design and method for supporting a filament tube and electrical cables in the three-dimensional printer.

SUMMARY

[0005] According to several aspects, a three-dimensional printer is provided. The three-dimensional printer includes a frame for supporting an X- car for movement in an x-direction and a Y-car for movement in a y-direction. The printer also includes a printhead supported for movement on one of the X- car and Y-car. The printer further includes a support strap secured at a first end to the support frame and at a second end to the Y-car, where the support strap is stiff in a first direction and damping in a second direction, where the second direction is perpendicular to the first direction.

[0006] In another aspect of the present disclosure, the first end of the support strap is secured to and is electrically grounded to the support frame.

[0007] In another aspect of the present disclosure, the three- dimensional printer further includes a filament tube for guiding filament to the printhead, where the filament tube is affixed to the support strap.

[0008] In another aspect of the present disclosure, the three- dimensional printer further includes a plurality of clips attached to the support strap for affixing the filament tube to the support strap. [0009] In another aspect of the present disclosure, the support strap includes a laminate structure including a metal sheet material layer and a polymer sheet material layer.

[0010] In another aspect of the present disclosure, the metal sheet material layer of the support strap is attached to the polymer sheet material layer by an adhesive.

[0011] In another aspect of the present disclosure, the first end of the support strap includes a plurality of apertures for securing to the support frame and the second end of the support strap includes a plurality of apertures for securing to the Y-car.

[0012] In another aspect of the present disclosure, the three- dimensional printer further includes a preventer affixed to the Y-car, where the preventer is configured to provide a force on the support strap to reduce resonant oscillations of the support strap.

[0013] In another aspect of the present disclosure, the preventer includes an elastically deformable material including a V-shaped portion in contact with a surface of the support strap, where an end of the preventer is angled away from the support strap.

[0014] In another aspect of the present disclosure, the preventer is made of elastically deformable metal.

[0015] In another aspect of the present disclosure, the threedimensional printer further includes a first set of flat flexible cables for communicating control signals from a controller to the printhead. [0016] In another aspect of the present disclosure, the three- dimensional printer further includes a second set of flat flexible cables for communicating electrical power to the printhead.

[0017] In another aspect of the present disclosure, the first set of flat flexible cables are disposed on a first side of the support strap and the second set of flat flexible cables are disposed on a second side of the support strap.

[0018] In another aspect of the present disclosure, the metal sheet material layer of the support strap electrically shields the first set of flat flexible cables from the second set of flat flexible cables.

[0019] In another aspect of the present disclosure, the first set of flat flexible cables includes two flat flexible cables disposed on a first side of the support strap and the second set of flat flexible cables includes two flat flexible cables disposed on the second side of the support strap.

[0020] In another aspect of the present disclosure, the three- dimensional printer further includes a clamp for attaching the support strap to the Y-car.

[0021] In another aspect of the present disclosure, the clamp includes a first plate and a second plate, where the first plate is affixed to the second plate by a plurality of fasteners, where the second plate is affixed to a structural member the Y-car by a plurality of fasteners.

[0022] In another aspect of the present disclosure, the support strap is disposed between the first plate and the second plate.

[0023] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

[0024] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

[0025] FIG. 1 is a perspective view of a three-dimensional printer illustrated according to an exemplary embodiment;

[0026] FIG. 2 is a perspective top view of a support frame disposed inside the enclosure for supporting an x,y gantry for movement above the process chamber illustrated according to an exemplary embodiment;

[0027] FIG. 3 is a perspective view of a support strap made of a laminate structure of a metal sheet material layer and a polymer sheet material layer illustrated according to an exemplary embodiment; and

[0028] FIG. 4 is a first perspective view of the support frame and the X,Y cars illustrated according to an exemplary embodiment

[0029] FIG. 5 is a second perspective view of the support frame and the X,Y cars illustrated according to an exemplary embodiment.

DETAILED DESCRIPTION

[0030] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.

[0031] An aspect of a three-dimensional printer 100 is illustrated in FIG. 1 . The three-dimensional printer 100 generally includes an enclosure 102 defining a process chamber 104 and a support bed 106 supported within the process chamber 104. The support bed 106 includes a support surface 108 onto which a build plate 110 is placed. The three-dimensional printer 100 further includes a printhead 112, which deposits filament 114 onto the build plate 110 to form the three-dimensionally printed object 116. The printhead 112 is supported relative to the build plate 110 on an x,y gantry 118 allowing the printhead 112 to move in a plane defined by a first axis A1 and a second axis A2. The support bed 106 is moved relative to the printhead 112 by a z- axis gantry 120 allowing the support bed 106 to move along a third axis A3 orthogonal to the plane defined by the first axis A1 and second axis A2. In further aspects, the printhead 112 may be moved along the z-axis and the support bed 106 may be moved along the x,y-axis. Filament 114 is stored in one or more canisters 122 and provided to the printhead 112 by a filament drive system 124. A controller 128 is provided to control the various functions of the three-dimensional printer 100.

[0032] Referring to FIG. 2, a perspective view of a support frame 150 is illustrated disposed inside the enclosure 102 for supporting x,y gantry 118 for movement above the process chamber 104. Support frame 150 is generally rectangular and includes a pair of side support brackets 152 and 154. Side support brackets 152 and 154, have linear motors configured to interact with an X-car 156 of x,y gantry 118. X-car 156 is a bracket that includes ends that interact with the linear motors attached to side support brackets 152 and 154 to propel the X-car along the second axis A2. A Y-car 158 of x,y gantry 118 interacts with a linear motor attached to X-car 156. Y-car 158 is a bracket that includes an end that interacts with the linear motor attached to X-car 156 to propel the Y-car 158 along the first axis A1. Additional rigidity is imparted to the support frame 150 by a first and second end support brackets 160 and 162. Side support brackets 152 and 154 are each attached to first and second end support brackets 160 and 162 by fasteners such as screws and the like.

[0033] A support strap 164 is attached at a first end 166 to support frame 150 and at a second end 168 to Y-car 158. Support strap 164 is made of a laminate structure of a metal sheet material layer 170 (e.g., steel sheet material) and a polymer sheet material layer 172, as shown in FIG. 3. Moreover, with continuing reference to FIG. 3, support strap 164 is formed by adhering the metal sheet material layer 170 to the polymer sheet material layer 172. The laminate structure of metal and polymer of support strap 164 provides stiffness in a vertical direction plus damping in the X,Y direction (i.e., perpendicular to the vertical direction).

[0034] A plurality of apertures 174 are disposed at a first end 176 and a second end 178 of the metal sheet material layer 170. A plurality of apertures 180 are disposed at a first end 182 and a second end 184 of the polymer sheet material layer 172. When metal sheet material layer 170 and polymer sheet material layer 172 are joined to form the layered support strap 164, apertures 174 and 180 align so that first end 166 formed by first end 176 of the metal sheet material layer 170 and first end 176 of the polymer sheet material layer 172 may be secured to support frame 150. Similarly, when metal sheet material layer 170 and polymer sheet material layer 172 are joined to form the layered support strap 164, apertures 174 and 180 align so that second end 168 formed by second end 178 of the metal sheet material layer 170 and second end 184 of the polymer sheet material layer 172 may be secured to Y-car 158.

[0035] Referring now to FIGS. 4 and 5, perspective views of support frame 150 and X,Y cars 156,158 are illustrated. Further, a preventer 200 is attached to Y-car 158. Preventer 200 contacts and provides a biasing force F on the support strap 164 in one direction (F direction) to stiffen the support strap 164 and reduce resonant oscillations during repetitive movement of the Y-car 158. Preventer 200 is a plate made of a metal or other material that elastically deforms when contacted by the support strap 164. Preventor has a V-shaped portion 201 for evenly contacting a surface of the support strap 164. An end 203 of the preventer 200 is angled away from the support strap 164 to avoid contacting the support strap 164 during operation of the printhead.

[0036] Additionally, a pair of flat flexible cables (FFC) 202 and 204 are connected at a first end 206 to a circuit board 208 mounted to Y-car 158. FFCs 202 and 204 are attached by clips 210 to support strap 164. For example, FFC 202 may carry control signals from controller 128 to the circuit board 208 mounted to Y-car 158 and FFC 204 may carry power to circuit board 208. To prevent interference from the power carrying FFC 204, the control signal carrying FFC 202 is mounted on a first side surface 212 and the FFC 204 is mounted on the opposite side surface 214. The metal sheet material layer 170 shields FFC 202 from FFC 204 thereby preventing electrical interference from one FFC to the other. [0037] Clips 210 further include a pair of apertures 218, 220. Apertures 218, 220 are configured to secure a pair of filament tubes 222, 224 to the support strap 164. Filament tubes 222, 224 each contain filaments that may be made of the same material or different material. Filament tubes 222 and 224 contain and guide the filaments from the filament canisters to the printhead.

[0038] With continuing reference to FIG. 5, a plate clamp 300 is illustrated. Plate clamp 300 includes a first plate 302 and a second plate 304. First plate 302 is mounted or attached to second plate 304 by a plurality of fasteners 306 such as screws or bolts or the like. Second plate 304 is mounted or attached to a structural member 310 of Y-car 158 by a plurality of fasteners 312 such as screws or bolts or the like. Plate clamp 300 functions to secure the support strap 164 to the Y-car 158 for secure movement with the Y-car.

[0039] The description of the present disclosure is merely exemplary in nature and variations that do not depart from the gist of the present disclosure are intended to be within the scope of the present disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure.