US5281789A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method and apparatus for depositing molten metal
Assignee: Individual
•
Filing: 1992-07-24
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Granted: 1994-01-25
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Expires: 2012-07-24
Abstract
Abstract A collector electrode and adjacent electric weld torch are placed at a selected distance from a work surface or substrate. An electric welding current is generated so that a welding current arc forms between the collector electrode and the weld torch. A feed metal is then fed into the welding current arc and is melted into molten metal adjacent to the collector electrode. The molten metal is then deposited onto a work surface. The collector electrode and weld torch are positioned so that the welding current arc between the weld torch and the collector electrodes does not penetrate the work surface or the already-deposited metal.
Inventors
- 👤 Robert Merz
- 👤 Fritz B. Prinz
- 👤 Lee E. Weiss
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 23:30
CPC Classifications
B; B23; B23K; B23K9/00; B23K9/04; B22; B22F; B22F3/00; B22F3/115; B33; B33Y; B33Y10/00; B33Y30/00; B22F9/00; B22F9/02; B22F9/06; B22F9/08; B22F9/082; B22F2009/0848; B22F2998/00; B22F2998/10; Y; Y02; Y02P; Y02P10/00; Y02P10/25; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/4998; Y10T29/49982; Y10T29/49986
Claims Analysis
Total Claims: 35
Claim 1
Independent Claim
119 words
An apparatus for depositing molten metal to form a three-dimensional object, comprising: a rotatable collector electrode located a selected distance above a work surface; a weld torch located a selected distance from the collector electrode, wherein an electric welding current travels between the collector electrode and the weld torch, the relative position of the welding current to the collector electrode and the weld torch remaining fixed; and means for feeding a feed metal into the welding current so that the welding current can melt the feed metal into molten metal and transfer the molten metal towards the collector electrode so that the molten metal is deposited onto the work surface below the collector electrode to form a three-dimensional object.
Claim 2
Independent Claim
119 words
An apparatus for depositing molten metal to form a three-dimensional object, comprising: a rotatable collector electrode located a selected distance above a work surface; a weld torch located a selected distance from the collector electrode, wherein an electric welding current travels between the collector electrode and the weld torch, the relative position of the welding current to the collector electrode and the weld torch remaining fixed; and means for feeding a feed metal into the welding current so that the welding current can melt the feed metal into molten metal and transfer the molten metal towards the collector electrode so that the molten metal is deposited onto the work surface below the collector electrode to form a three-dimensional object.
Claim 3
Dependent Claim
23 words
The apparatus of claim 1 wherein the welding current between the weld torch and the collector electrode does not penetrate the work surface.
Claim 4
Dependent Claim
20 words
The apparatus of claim 1 further comprising a passage located within the collector electrode for a coolant to pass therethrough.
Claim 5
Dependent Claim
19 words
The apparatus of claim 1 wherein the collector electrode is made of one of copper and a copper alloy.
Claim 6
Dependent Claim
22 words
The apparatus of claim 1 wherein one of the collector electrode and the work surface are movable in at least one direction.
Claim 7
Dependent Claim
25 words
The apparatus of claim 1 wherein the collector electrode and the weld torch and the work surface are mounted to a computer numerically controlled machine.
Claim 8
Dependent Claim
15 words
The apparatus of claim 1 wherein the work surface is comprised of a nonconductive material.
Claim 9
Dependent Claim
15 words
The apparatus of claim 1 wherein the work surface is comprised of a conductive material.
Claim 10
Dependent Claim
23 words
The apparatus of claim 1 wherein the weld torch and the collector electrode are positioned above the work surface during the depositing operation.
Claim 11
Dependent Claim
18 words
The apparatus of claim 1 wherein the work surface and the feed metal are comprised of dissimilar materials.
Claim 12
Dependent Claim
16 words
The apparatus of claim 1 also comprising means for applying mechanical energy to the feed metal.
Claim 13
Dependent Claim
18 words
The apparatus of claim 11 wherein the means for applying mechanical energy causes the feed metal to vibrate.
Claim 14
Independent Claim
129 words
An apparatus for depositing molten metal to form a three-dimensional object, comprising: a collector electrode located a selected distance above a work surface; a weld torch located a selected distance from the collector electrode, wherein an electric welding current travels between the collector electrode and the weld torch, the relative position of the welding current to the collector electrode and the weld torch remaining fixed; means for feeding a feed metal into the welding current so that the welding current can melt the feed metal into molten metal and transfer the molten metal towards the collector electrode so that the molten metal is deposited onto the work surface below the collector electrode to form a three-dimensional object; and a cleaning brush that is in contact with the collector electrode.
Claim 15
Independent Claim
129 words
An apparatus for depositing molten metal to form a three-dimensional object, comprising: a collector electrode located a selected distance above a work surface; a weld torch located a selected distance from the collector electrode, wherein an electric welding current travels between the collector electrode and the weld torch, the relative position of the welding current to the collector electrode and the weld torch remaining fixed; means for feeding a feed metal into the welding current so that the welding current can melt the feed metal into molten metal and transfer the molten metal towards the collector electrode so that the molten metal is deposited onto the work surface below the collector electrode to form a three-dimensional object; and a cleaning brush that is in contact with the collector electrode.
Claim 16
Independent Claim
110 words
A method for depositing molten metal to form a three-dimensional object, comprising: positioning a collector electrode a selected distance above a work surface; positioning a weld torch a selected distance from the collector electrode, wherein an electric welding current travels between the collector electrode and the weld torch; placing sufficient feed metal into the welding current so that the welding current can melt the feed metal into molten metal adjacent the collector electrode which molten metal is deposited onto the work surface below the collector electrode to form a three-dimensional object consisting of a plurality of deposited layers of feed metal; and removing the three-dimensional object from the work surface.
Claim 17
Independent Claim
110 words
A method for depositing molten metal to form a three-dimensional object, comprising: positioning a collector electrode a selected distance above a work surface; positioning a weld torch a selected distance from the collector electrode, wherein an electric welding current travels between the collector electrode and the weld torch; placing sufficient feed metal into the welding current so that the welding current can melt the feed metal into molten metal adjacent the collector electrode which molten metal is deposited onto the work surface below the collector electrode to form a three-dimensional object consisting of a plurality of deposited layers of feed metal; and removing the three-dimensional object from the work surface.
Claim 18
Dependent Claim
20 words
The method of claim 14 wherein a passage is located within the collector electrode for a coolant to pass therethrough.
Claim 19
Dependent Claim
14 words
The method of claim 14 further comprising the step of rotating said collector electrode.
Claim 20
Dependent Claim
18 words
The method of claim 14 wherein the collector electrode is made of one of copper and copper alloy.
Claim 21
Dependent Claim
47 words
The method of claim 14 further comprising the step of selectively moving one of the collector electrode and the work surface during the depositing of the molten metal so that the molten metal will be released onto selected locations of the work surface and metal deposited thereon.
Claim 22
Dependent Claim
15 words
The method of claim 14 wherein the work surface is comprised of a nonconductive material.
Claim 23
Dependent Claim
15 words
The method of claim 14 wherein the work surface is comprised of a conductive material.
Claim 24
Dependent Claim
23 words
The method of claim 14 wherein the weld torch and the collector electrode are positioned above the work surface during the depositing operation.
Claim 25
Dependent Claim
25 words
The method of claim 14 wherein the weld torch and the collector electrode and the work surface are mounted to a computer numerically controlled machine.
Claim 26
Dependent Claim
18 words
The method of claim 14 wherein the work surface and the feed metal are composed of dissimilar materials.
Claim 27
Dependent Claim
17 words
The method of claim 14 also comprising the step of applying mechanical energy to the feed metal.
Claim 28
Dependent Claim
15 words
The method of claim 24 wherein applying mechanical energy causes the feed metal to vibrate.
Claim 29
Dependent Claim
38 words
The method of claim 14 also comprising the steps of: a) measuring a temperature of at least one droplet of deposited metal; and b) adjusting a rate at which subsequent droplets are deposited based upon a measured temperature.
Claim 30
Independent Claim
156 words
An apparatus for depositing molten metal onto a work surface to form a three-dimensional object thereon, comprising: a collector electrode located a selected distance above the work surface, the collector electrode being rotatable about an axis, the axis of rotation being generally parallel with the work surface; a weld torch located a selected distance above the collector electrode, wherein an electric welding current travels between the collector electrode and the weld torch, the relative position of the welding current to the collector electrode and the weld torch remaining fixed; and means for feeding a feed metal into the welding current so that the welding current can melt the feed metal into molten metal and transfer the molten metal onto the collector electrode, wherein the molten metal then drops onto the work surface ad the molten metal's drop from the collector electrode onto the work surface is accelerated by the centrifugal force at the rotating collector electrode.
Claim 31
Independent Claim
156 words
An apparatus for depositing molten metal onto a work surface to form a three-dimensional object thereon, comprising: a collector electrode located a selected distance above the work surface, the collector electrode being rotatable about an axis, the axis of rotation being generally parallel with the work surface; a weld torch located a selected distance above the collector electrode, wherein an electric welding current travels between the collector electrode and the weld torch, the relative position of the welding current to the collector electrode and the weld torch remaining fixed; and means for feeding a feed metal into the welding current so that the welding current can melt the feed metal into molten metal and transfer the molten metal onto the collector electrode, wherein the molten metal then drops onto the work surface ad the molten metal's drop from the collector electrode onto the work surface is accelerated by the centrifugal force at the rotating collector electrode.
Claim 32
Independent Claim
157 words
A method for depositing molten metal onto a work surface to form a three-dimensional object, comprising: providing a collector electrode a selected distance above the work surface, the collector electrode being rotatable about an axis, the axis of rotation being generally parallel with the work surface; providing a weld torch a selected distance above the collector electrode, wherein an electric welding current travels between the collector electrode and the weld torch, the relative position of the welding current to the collector electrode and the weld torch remaining fixed; and feeding sufficient feed metal into the welding current so that the welding current can melt the feed metal into molten metal and transfer the molten metal onto the collector electrode, wherein the molten metal then drops onto the work surface to form a three-dimensional object and the molten metal's drop from the collector electrode onto the work surface is accelerated by centrifugal force at the rotating collector electrode.
Claim 33
Independent Claim
157 words
A method for depositing molten metal onto a work surface to form a three-dimensional object, comprising: providing a collector electrode a selected distance above the work surface, the collector electrode being rotatable about an axis, the axis of rotation being generally parallel with the work surface; providing a weld torch a selected distance above the collector electrode, wherein an electric welding current travels between the collector electrode and the weld torch, the relative position of the welding current to the collector electrode and the weld torch remaining fixed; and feeding sufficient feed metal into the welding current so that the welding current can melt the feed metal into molten metal and transfer the molten metal onto the collector electrode, wherein the molten metal then drops onto the work surface to form a three-dimensional object and the molten metal's drop from the collector electrode onto the work surface is accelerated by centrifugal force at the rotating collector electrode.
Claim 34
Independent Claim
109 words
A method for depositing molten metal to form a three-dimensional object, comprising: positioning a first electrode a selected distance above a work surface; positioning a second electrode a selected distance from the first electrode, wherein an electric welding current travels between the electrodes and above the work surface; placing sufficient feed metal into the welding current so that the welding current can melt the feed metal into discrete molten metal droplets adjacent the first electrode which molten metal is dropped onto the work surface below the first electrode to form a three-dimensional object comprised of a plurality of incremental layers; and removing the three-dimensional object from the work surface.
Claim 35
Independent Claim
109 words
A method for depositing molten metal to form a three-dimensional object, comprising: positioning a first electrode a selected distance above a work surface; positioning a second electrode a selected distance from the first electrode, wherein an electric welding current travels between the electrodes and above the work surface; placing sufficient feed metal into the welding current so that the welding current can melt the feed metal into discrete molten metal droplets adjacent the first electrode which molten metal is dropped onto the work surface below the first electrode to form a three-dimensional object comprised of a plurality of incremental layers; and removing the three-dimensional object from the work surface.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1997-01-24 | 1997-07-26 | 1998-01-25 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2001-01-24 | 2001-07-26 | 2002-01-25 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2005-01-24 | 2005-07-26 | 2006-01-25 | $7700.00 | Window Closed / Lapsed |