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US 2019/0055699 A1Published application
Methods, materials and apparatus for mobile additive manufacturing of advanced structures and roadways
OwnerRobert A. Flitsch, Frederick A. Flitschinventors
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Abstract
The present disclosure provides various aspects for mobile and automated processing utilizing additive manufacturing and the methods for their utilization. In some examples, discrete material formats for use in an Additive Manufacturing Array are disclosed. Methods of using the additive manufacturing robot, discrete materials, and the roadways produced with the additive manufacturing robot are provided. A combined function Addibot, with Additive Manufacturing capabilities, cleaning capabilities, line painting capabilities and seal coating capabilities which may be used in concert with a camera equipped aerial drone for design and characterization function is described.
Claims23
An apparatus for roadway repair and building comprising:
- a discrete material element, wherein the discrete material element comprises:
- an inner core;
- a first coating layer comprising an adhesive, wherein the first coating layer surrounds the inner core;
- and
- a second coating layer surrounding the first coating layer, wherein the second coating layer prevents the discrete material element from binding to surrounding material while it is in storage;
- and
- an additive manufacturing system which processes the discrete material element, wherein a signal causes the additive manufacturing system to release the discrete material element over a location on a surface.
4 more elements
An additive material array device comprising:
- an array of deposition elements;
- a storage element that feeds the array of deposition elements;
- a thermal control element that maintains a temperature of the storage element;
- and
- a local heating system that provides energy to a discrete material element while the discrete material element is released by an element of the array of deposition elements, and wherein the discrete material element comprises an inner core, a first coating layer comprising an adhesive, and a second coating layer surrounding the first coating layer, wherein the second coating layer prevents the discrete material element from binding to surrounding material while it is in storage.
2 more elements
An apparatus for roadway repair and building comprising:
- a filament material element, wherein the filament material element comprises:
- an inner core;
- and
- a coating layer surrounding the inner core, wherein the coating layer prevents the filament material element from binding to surrounding material while it is in storage, and wherein the coating layer keeps a structure of the filament material element stable as it is fed into a three-dimensional printing head;
- a first mobility frame comprising:
- a controller capable of executing algorithms and providing control signals;
- and
- an additive manufacturing system to form a deposit of at least a first material in prescribed locations across a surface according to a first digital model processed by the controller;
- a drive system operative to transport the additive manufacturing system along the surface;
- wherein the drive system is located in a second mobility frame connected to the first mobility frame;
- a vision system;
- wherein the vision system views the roadway surface and converts captured image data into a model of surface topography;
- a navigation system to determine a location of the additive manufacturing system and guide the drive system;
- a power system capable of providing power to operate at least the drive system, navigation system, control system and additive manufacturing system;
- and
- wherein the first material is added to the additive manufacturing system as the filament material element.
13 more elements
A method for forming and repairing a roadway comprising:
- transmitting a control signal to an apparatus, wherein the apparatus is a mobile additive manufacturing apparatus comprising:
- a drive system operative to move the apparatus along a surface,
- a navigation system to determine location,
- a controller capable of executing algorithms and providing control signals,
- an additive manufacturing system to deposit at least a first material in prescribed locations across the surface according to a digital model processed by the controller, and
- a power system capable of providing power to operate at least the drive system, navigation system, controller and additive manufacturing system;
- forming a first deposit of a first material on the surface, wherein the first material is deposited by dropping a discrete material element from an additive material array device of the additive manufacturing system, wherein the discrete material element comprises an inner core, a first coating layer comprising an adhesive, and a second coating layer surrounding the first coating layer, wherein the second coating layer prevents the discrete material element from binding to surrounding material while it is in storage;
- moving the apparatus to a different location;
- and
- forming a second deposit of the first material on the different location.
7 more elements
A method for forming and repairing a roadway comprising:
- transmitting a control signal to an apparatus, wherein the apparatus is a mobile additive manufacturing apparatus comprising:
- a drive system operative to move the apparatus along a surface,
- a navigation system to determine location,
- a controller capable of executing algorithms and providing control signals,
- an additive manufacturing system to deposit at least a first material in prescribed locations across the surface according to a digital model processed by the controller, and
- a power system capable of providing power to operate at least the drive system, navigation system, controller and additive manufacturing system;
- forming a first deposit of a first material on the surface, wherein the first material is deposited by forcing a filament material through a three-dimensional printing head wherein the filament material comprises an inner core and a coating layer surrounding the inner core, wherein the coating layer prevents the filament material from binding to surrounding material while it is in storage, and wherein the coating layer keeps a structure of the filament material stable as it is fed into the three dimensional printing head;
- moving the apparatus to a different location;
- and
- forming a second deposit of the first material on the different location.
7 more elements
A method of using an additive manufacturing robot the method comprising:
- depositing from an additive manufacturing element of the additive manufacturing robot a conductive material upon a roadway bed, wherein the deposit is controlled to be located in a pattern that will emit energy towards a vehicle passing over the conductive material, wherein the conductive material is extruded from an extrusion element fed by a filament form of a composite material, wherein the filament form comprises a metal mesh surrounded by a thermoplastic coating layer.
A mobile additive manufacturing apparatus comprising:
- a first mobility frame comprising:
- a controller capable of executing algorithms and providing control signals;
- and
- an additive manufacturing system to deposit at least a first material in prescribed locations across a surface according to a first digital model processed by the controller;
- a drive system operative to transport the additive manufacturing system along the surface;
- wherein the drive system is located in a second mobility frame connected to the first mobility frame;
- a vision system;
- wherein the vision system views the roadway surface and converts capture image data into a model of surface topography;
- a navigation system to determine a location of the additive manufacturing system and guide the drive system;
- and
- a power system capable of providing power to operate at least the drive system, navigation system, control system and additive manufacturing system.
8 more elements
A method of using an additive manufacturing robot, the method comprising:
- depositing from an additive manufacturing element of the additive manufacturing robot a paint;
- wherein a location of the paint is controlled by a navigation system of the additive manufacturing robot operating in concert with a controller controlling an array of additive manufacturing elements to emit such that the paint is located in a pattern;
- and
- wherein the additive manufacturing robot comprises:
- a first mobility frame;
- a controller capable of executing algorithms and providing control signals;
- and
- an additive manufacturing system to form a deposit of at least a first material in prescribed locations across a surface according to a first digital model processed by the controller;
- a drive system operative to transport the additive manufacturing system along the surface;
- wherein the drive system is located in a second mobility frame connected to the first mobility frame;
- a vision system;
- wherein the vision system views the roadway surface and converts captured image data into a model of surface topography;
- a navigation system to determine a location of the additive manufacturing system and guide the drive system;
- a power system capable of providing power to operate at least the drive system, navigation system, control system and additive manufacturing system;
- and
- one or more of a routing or grinding head, a pressurized washing head, a sealcoat dispersal head, or a brushing element.
13 more elements
A method of using a roadway constructed with an Addibot comprising:
- establishing a communication link between a vehicle and an antenna embedded within the roadway, wherein the antenna was added to the roadway surface by the Addibot, and wherein a communication signal continues from the antenna through a conductive element in the roadway, wherein the conductive element in the roadway was added with an Addibot.
Dependencies are inferred from the claim text.