System and process for using a conductive, non-stick coating for automating tool touch-off

Patent metadata

Field	Value
Publication number	US-12103234-B2
Application number	US-202117381944-A
Country	US
Kind code	B2
Filing date	Jul 21, 2021
Priority date	Jul 21, 2021
Publication date	Oct 1, 2024
Grant date	Oct 1, 2024

Abstract

Systems and methods for using a non-stick conductive material to automate tool touch-off in an additive manufacturing process are provided. A substrate comprises a first conductive layer, an intermediate binder layer, and a second non-stick conductive layer. The non-stick conductive layer may comprise perfluoroalkoxy alkanes and carbon nanotubes. An electrical connection may be made between the first conductive layer and the second non-stick conductive layer. When used with an additive manufacturing device, when the nozzle of the device contacts the substrate, a circuit may close resulting in a detectable voltage drop. When the voltage drop is detected, a reference point for the additive manufacturing device may be set.

First claim

Having thus described various embodiments of the invention, what is claimed as new and desired to be protected by Letters Patent includes the following:

1. A system for automating tool touch-off in an additive manufacturing process, the system comprising:
a substrate, comprising:
a bottom layer comprising a conductive material;
a middle layer disposed directly on the bottom layer, the middle layer comprising a binding material; and
a top layer disposed on the middle layer, the top layer comprising a non-stick conductive material,
wherein the non-stick conductive material comprises a fluoropolymer and carbon nanotubes, and
wherein print material is configured to be deposited onto the top layer; and

at least one conductive object extending through the top layer, the middle layer, and at least partially into the bottom layer, the at least one conductive object providing an electrical connection between the bottom layer and the top layer; and
a circuit comprising the substrate and a nozzle of an additive manufacturing device,
wherein the circuit is configured to close when the nozzle contacts the top layer of the substrate and the electrical connection is created between the top layer and the bottom layer by current passing from the top layer, through the at least one conductive object and to the bottom layer.

2. The system of claim 1 , further comprising:
at least one non-transitory computer-readable media comprising computer-executable instructions that, when executed by at least one processor, cause the at least one processor to perform a method of automating tool touch-off in the additive manufacturing process, the method comprising:
causing the additive manufacturing device to decrease a distance between the nozzle of the additive manufacturing device and the substrate;
determining a voltage drop resulting from the nozzle coming into contact with the top layer of the substrate; and
responsive to determining the voltage drop, setting a reference value associated with a coordinate system of the additive manufacturing device, wherein the reference value corresponds to a position of the nozzle upon determining the voltage drop.

3. The system of claim 1 , wherein the fluoropolymer comprises perfluoroalkoxy alkanes.

4. The system of claim 1 , wherein the at least one conductive object comprises a mechanical connector.

5. The system of claim 1 , wherein the at least one conductive object comprises at least one of: a screw, a bolt, a nail, a shaft, a plug, or a wire.

6. The system of claim 1 , wherein the at least one conductive object comprises an electrical contact disposed upon the top layer.

7. The system of claim 1 , wherein a concentration of the carbon nanotubes in the non-stick conductive material is from 0.5% to 2.5% by weight.

8. The system of claim 1 , wherein the substrate is non-planar.

9. The system of claim 1 , further comprising a sensor operably coupled to the circuit, the sensor configured to detect a voltage drop when the circuit closes.

10. The system of claim 1 , wherein the top layer is disposed directly on the middle layer.

11. A method of automating tool touch-off in an additive manufacturing process, the method comprising:
causing an additive manufacturing device to decrease a distance between a nozzle of the additive manufacturing device and a substrate,
wherein the substrate comprises:
a bottom layer comprising a conductive material;
a middle layer disposed directly on the bottom layer, the middle layer comprising a binding material; and
a top layer disposed on the middle layer, the top layer comprising a non-stick conductive material, the non-stick conductive material comprising a fluoropolymer and carbon nanotubes;

wherein print material is configured to be deposited on the top layer,
wherein the substrate defines a hole extending at least partially into the bottom layer, through the middle layer, and through the top layer, and
wherein a conductive object extends through the hole and provides an electrical connection between the bottom layer and the top layer;

determining a voltage drop resulting from a circuit closing due to the nozzle coming into contact with the top layer of the substrate, thereby creating the electrical connection between the top layer and the bottom layer by current passing from the top layer, through the conductive object and to the bottom layer,
wherein the circuit comprises the nozzle and the substrate; and
responsive to determining the voltage drop, setting a reference value associated with a coordinate system of the additive manufacturing device, wherein the reference value corresponds to a position of the nozzle upon determining the voltage drop.

12. The method of claim 11 , wherein the fluoropolymer comprises perfluoroalkoxy alkanes.

13. The method of claim 11 , wherein the conductive object comprises at least one electrical lead line.

14. The method of claim 11 ,
wherein the conductive object comprises a mechanical connector, and wherein the method further comprises:
inserting the mechanical connector into the hole prior to causing the additive manufacturing device to decrease the distance between the nozzle of the additive manufacturing device and the substrate.

15. The method of claim 11 , wherein determining the voltage drop comprises:
monitoring, with a voltmeter, a voltage of a circuit defined at least in part by the nozzle, the top layer, the conductive object, and the bottom layer, wherein the circuit closes when the nozzle contacts the top layer.

16. The method of claim 11 , further comprising:
responsive to determining the voltage drop, causing the additive manufacturing device to stop decreasing the distance between the nozzle and the substrate.

Assignees

• Honeywell Federal Mfg & Tech Llc

Inventors

• Laplant Steven Todd
• Trimmer Matthew Wayne
• Ogden Nicholas Christopher
• Smith Mark Douglas
• Pino Ruben Arturo

Classifications

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B29K2827/12

  containing fluorine · CPC title

• B29K2907/04

  Carbon · CPC title

• B29K2995/0005

  Conductive · CPC title

• H01B1/24

  the conductive material comprising carbon-silicon compounds, carbon or silicon · CPC title