AT526676B1 - Pressure hull - Google Patents

Abstract

The invention relates to a method for integrating electrical components into a printing body (2), wherein a band (1) comprising at least three electrical lines is placed on an already printed first layer (5) of the printing body (2) during the 3D printing process, wherein at least one free end of the band (1) is guided by a movable device (4) so that when printing a subsequent second layer (6), it can be moved away from the location at which a layer build-up is taking place, wherein after the subsequent second layer (6) or several subsequent second layers (6) have been applied, the band (1) is placed on the one subsequent second layer (6) or the uppermost subsequent second layer (6) so that the band (1) on the second layer (6) runs at a higher level of the printing body (2) than on the first layer (5).

Description

Description

[0001] The invention relates to a method for integrating a tape comprising electrical lines in 3D printing.

[0002] The method in question is applicable to 3D printing processes in which printing bodies are built up layer by layer.

[0003] US2016271876A1 discloses several different devices for embedding a round wire in a printing process, wherein the print head and a wire feed device are moved together over the surface of a body. The print head and the wire feed device are connected via device components, so that only a rotary relative movement and/or a relative movement in the Z direction of the device appears to be possible between them.

[0004] EP 3664989 B1 and DE 102020215625 A1 show general state of the art.

[0005] The object of the invention is to provide a simple and efficient embedding of electrical cables in a pressure vessel.

[0006] According to the invention, this is achieved by a method according to claim 1.

[0007] In one embodiment, a method is provided for integrating electrical components into a printing body while the latter is being produced in a 3D printing process with layer-by-layer material application, wherein a band which comprises at least three electrical lines is placed on an already printed first layer of the printing body during the 3D printing process, wherein at least one free end of the band protrudes from the already printed layer of the printing body and the free end is guided by a movable device so that when printing a subsequent second layer, it can be moved away from the point at which a layer build-up is taking place, wherein the band lying on the already printed first layer of the printing body is at least partially overprinted by the subsequent second layer and wherein the subsequent second layer also at least partially covers the already printed first layer,

wherein after application of the subsequent second layer or of several subsequent second layers, the tape is placed on the one subsequent second layer or the uppermost subsequent second layer so that the tape on the second layer runs in a higher plane of the printing body than on the first layer.

[0008] The band is deformable. The band can be stretchable. The band can be elastic.

[0009] In this context, deformable means a deformation transverse to the plane of an element, for example bending or folding the element, in particular the band. Stretchable means a deformability in the longitudinal or transverse direction of the element, which is accompanied by a change in dimensions in the plane of the element. In this context, stretchable means an element whose length or width can be extended by a tensile force. Elastic means that the element returns to its original extension after the tensile force is removed.

[0010] Due to the elasticity of the tape, it can be laid in curves without the formation of wrinkles.

[0011] The at least three conductors preferably comprise a supply conductor, a ground conductor and at least one data conductor. In addition, an address conductor may be present.

[0012] Preferably, the band comprises an elastic insulating material which electrically insulates the multiple electrical conductors from each other and preferably also from the outside. However, the electrical conductors can also be present uninsulated on the surface of a substrate in the form of a band. The electrical conductors themselves can consist of elastic conductive material. However, the electrical conductors can also be arranged on or in the band in such a way that they can be pulled apart due to a winding or folded course. The conductors can

printed on a substrate of the tape. The conductors may be in the form of wires or stranded cables. The conductors may be in the form of elastic conductive fibers, for example by winding a metallic wire around an elastic fiber. The conductors may each have insulation and be attached to a substrate of the tape.

[0013] It is preferred that the tape is fixed to the subsequent second layer or the uppermost subsequent second layer by overprinting with at least one subsequent third layer.

[0014] It is preferred that the movable device for moving the tape comprises a winding head from which the tape is unwound.

[0015] The movable device is preferably movable around the printing volume and over the height of the printing volume of the printing body. The movement around the printing volume can be realized by rotation or by a pivoting movement. The movement in the direction of height by a linear unit or by pivoting around a horizontal axis. The device can preferably pivot the band by 180° so that it can always lie flat. This is necessary if the course of the band is changed by rotation around the height of the printing body.

[0016] In some cases, however, it may be sufficient for the device to be movable only linearly in the printing plane and perpendicular to it, namely when the path of the belt only runs along or against a single direction. In this case, the print head of the 3D printer can be raised or moved sideways to make room for the device to move past in the direction of the belt.

[0017] It is preferred that at least one circuit board is attached to the band, which is integrated into the printing body during the 3D printing process.

[0018] It is preferred that at least one surface of the circuit board or of a component attached to the circuit board is exposed on an outer side of the finished printing body.

[0019] It is preferred that the circuit board has at least one thinner edge region and a thicker central region, wherein the thinner edge region is overprinted with at least one layer in the 3D printing process. A circuit board is a flat element.

[0020] The circuit board can be deformable. The circuit board can be stretchable. The circuit board can be elastic.

[0021] It is preferred that the band is stretchable, wherein the band comprises stretchable conductors or conductor tracks and an insulating material of the band surrounding the stretchable conductors or conductor tracks is elastic.

[0022] It is preferred that the pressure body is deformable. It is preferred that the pressure body is stretchable. It is preferred that the pressure body is elastic.

[0023] It is preferred that the pressure body is a planar element (the width and length are greater, in particular a multiple, of the thickness), wherein the surface of the pressure body, the surface of at least one plate and the surface of at least a partial region of the strip are parallel.

[0024] It is preferred that there is a central electronics unit on the belt, which is integrated into the printing body during the printing process, wherein the central electronics unit is connected to at least one circuit board via the belt and communicates with the latter via the belt.

[0025] It is preferred that there are several circuit boards on the strip, which are attached to the strip at a distance from one another.

[0026] The invention makes it possible to obtain freely shaped objects in a continuous process that can have electronic functions distributed over the entire object. An example is an individually shaped orthosis with integrated sensors for monitoring pressure, temperature and humidity.

[0027] The invention is illustrated by drawings:

[0028] Fig. 1: Schematically illustrates the embedding of a tape between two printed layers.

[0029] Fig. 2: Schematically illustrates a first deflection of the tape to clear an area for printing.

[0030] Fig. 3: Schematically illustrates a second deflection of the belt in order to place it on a second level.

[0031] Fig. 4: Illustrates the overprinting of the band on the second level. [0032] Fig. 5: Illustrates a first variant of a possible course of the band. [0033] Fig. 6: Illustrates a second variant of a possible course of the band. [0034] Fig. 7: Illustrates the embedding of the band in a view from above.

[0035] Fig. 8: Illustrates the deflection of the belt in a top view.

[0036] Fig. 9: Illustrates the overprinting of the area previously covered by the tape in a top view.

[0037] Fig. 10: Illustrates a variant with a pre-printed recess for the tape.

[0038] Fig. 11: Illustrates a variant with a pre-printed registration feature for the tape.

[0039] Fig. 12: Illustrates a variant of a cross section of the band.

[0040] Fig. 13: Illustrates a variant of a circuit board on a strip. [0041] Fig. 14: Illustrates the embedding of the circuit board in the pressure body.

[0042] Fig. 15: Illustrates an oblique change of direction of the belt.

[0043] Fig. 16: Illustrates an oblique change of direction with a change of plane of the belt.

[0044] Fig. 17: Illustrates an exemplary print body with integrated electronics. [0045] Fig. 18: Illustrates a level change of the tape back to a lower level.

[0046] Fig. 19: Schematically illustrates a first variant of a movable device for positioning the belt.

[0047] Fig. 20: Schematically illustrates a second variant of a movable device for positioning the belt.

[0048] The embodiments shown in the figures merely show possible embodiments, whereby it should be noted at this point that the invention is not restricted to these specifically illustrated embodiments thereof, but combinations of the individual embodiments with one another and a combination of an embodiment with the general description given above are also possible. These further possible combinations do not have to be mentioned explicitly, since these further possible combinations are within the skill of the person skilled in this technical field due to the teaching of technical action through the present invention.

[0049] Fig. 1 illustrates a first part of the method for integrating electrical components into a printing body 2 while the latter is being manufactured in a 3D printing process with layer-by-layer material application. The layers can be applied by a print head 3. Fig. 7 illustrates the step shown in Fig. 1 in a view from above. In this case, tape 1, which comprises at least three electrical lines, is placed on an already printed first layer 5 of the printing body 2 during the 3D printing process. A free end of the tape 1 is guided or directed with a movable device 4. The free end protrudes from the printing body 2, i.e. from its already printed layer 5. This means that not

the entire tape 1 is placed on the layer 5, but only a partial length of the tape 1. Since the tape 1 is held by the device 4 and can be moved by it, the free end of the tape can be positioned so that it does not run in the area in which a layer build-up is currently taking place.

[0050] The band 1 lying on the already printed first layer 5 of the printing body 2 is at least partially overprinted by the subsequent second layer 6, whereby the subsequent second layer 6 also at least partially covers the already printed first layer 5. As a result, a partial area of the band 1 is fixed between the layers 6 and 5.

[0051] As shown in Fig. 2 and 8, the free end of the tape 1 can subsequently be moved or pivoted by the device 4 so that that area of the first layer 5 which was previously covered by the tape 1 can be printed with a second layer 6. The tape 1 is thereby deformed at the transition between its already fixed area and its free area, for example by 180°.

[0052] In Fig. 9, the pressure body 2 is shown with a layer 6 which completely covers the layer 5. Of course, it is also possible for the layer 5 and the layer 6 to be present with a structure, for example as a lattice structure.

[0053] In Fig. 3, a subsequent, further movement or pivoting of the band 1 is illustrated before it is placed on the second layer 6. By again deflecting it by 180°, the band 1 on the second layer 6 can run in the same direction as the band 1 on the first layer 5.

[0054] In another embodiment, the band 1 can be placed on the second layer 6 in the orientation shown in Fig. 9, so that the band 1 on the layer 6 runs opposite to the direction of the band 1 on the layer 5. However, as described further below, the band 1 on the layer 6 can also run obliquely to the band 1 on the layer 5.

[0055] Fig. 4 illustrates the overprinting of the tape 1 with a third layer 7 in order to fix the tape 1 to the second layer 6. The third layer 7 covers at least a partial area of the tape 1 and a partial area of the second layer 6.

[0056] In Fig. 5 and 6 it is illustrated that several second layers 6 can be provided in order to be able to place the free end of the tape 1 on a higher level. In Fig. 5 it is illustrated again that the tape 1 in the higher level can run in the opposite direction to the tape 1 in the lower level. In Fig. 5 it is illustrated again that the tape 1 in the higher level can run in the same direction as the tape 1 in the lower level. As can be seen from Figs. 7-9, any number of second layers 6 can be printed if the tape 1 is pivoted back and forth between the positions of the device 4 shown in Figs. 7 and 8 in order to make the two sides of the printing body 1 alternately accessible for printing.

[0057] Fig. 10 shows a variant in which the first layer 5 has a recess 8 into which the tape 1 can be inserted. The tape 1 is preferably flush in this recess 8. It should be noted that the first layer 5 does not have to be the first layer of the printing body 2. The designations first layer 5, second layer 6 and third layer 7 serve to make the different layers distinguishable for the reader. The task of one or more first layers 5 is to create a support surface for a first section of the tape 1. The task of one or more second layers 6 is to fix the tape 1 on the first layer 5 and to create a raised support surface for a second section of the tape 1. The task of one or more third layers 7 is to fix the tape 1 on the second layer 6.

[0058] The at least one third layer 7 can in turn provide an increased support surface for a third section of the band 1. A fourth layer (not shown) can fix the band 1 on the third layer 7. The at least one fourth layer can in turn provide an increased support surface for a fourth section of the band 1. This can of course be done in

any number of times, so that band 1 can run on any number of levels and any chosen levels of the pressure hull.

[0059] As illustrated in Fig. 18, the band 1 can also run back down to a lower level after changing to a higher level. As illustrated in Fig. 18, this can be achieved by the second layer 6 or at least one of several second layers 6 not completely covering the underlying first layer 5 or second layer 6.

[0060] Fig. 11 shows a variant in which the printing body 2 is provided with three-dimensional first registration features 9. The first registration features 9 can be depressions or elevations on the first layer 5. The band 1 has second registration features 10 corresponding to the first registration features 9, which are present as depressions or elevations on the band 1 opposite to the first registration features 9. When the band 1 is placed on the printing body 2, at least one first registration feature 9 of the printing body 2 and at least one second registration feature 10 of the band 1 engage with one another. This ensures in particular that the band 1 finds a hold on the first layer 5, so that the band 1 can be unwound from the device 4 against resistance. Alternatively, the second end of the band 1 can be held by a second movable device 4 so that both ends can be placed at different levels. Alternatively, the second end of the band 1 can be held or clamped by a stationary element. Alternatively, a component can be present at the second end of the band 1, which is placed in a recess of the pressure body 2, as illustrated in Fig. 17.

[0061] The registration features 10 of the band 1 can also be present at its two edge regions, for example in the form of serrations or indentations.

[0062] The band 1 can optionally be porous or perforated so that it is permeable to the material of the 3D printing process. As a result, the material of the second layer 6 partially penetrates the band 1 to connect to the first layer 5.

[0063] Fig. 12 shows an optional cross-sectional shape of a band 1, which can have a thicker base body and a thinner widening 13 on each side. The widenings 13 can have a thickness equal to the layer thickness of the 3D printing process. The base body can have a thickness equal to an integer multiple, for example double, of the layer thickness of the 3D printing process. However, the band can basically have any cross-section, with a rectangular cross-section being preferred. The band 1 is preferably a flat band. The thickness of the rectangular cross-section or the flat band is preferably equal to the layer thickness of the printing process or an integer multiple of the layer thickness.

[0064] Fig. 13 shows a preferred embodiment in which at least one circuit board 11 is attached to the strip 1. The circuit board 11 contacts the lines of the strip 1. This can be done by soldering. Any SMD components (surface-mounted device SMD) can be attached to the circuit boards.

[0065] These are preferably cast into the circuit board 11 so that the thickness of the circuit board decreases towards the edge. The circuit board 11 preferably comprises at least two edge regions 12 which are less thick than the central region of the circuit board. The thinner edge or edge regions 12 allow the circuit board to be overprinted at the edge or edge regions 12 so that the circuit board 11 is secured in the layer structure of the printing body 2. The thickness of the edge or edge regions 12 is preferably equal to the layer thickness of the printing process or an integer multiple of the layer thickness.

[0066] Preferably, the central surface of the board 11, which is raised relative to the edge regions 12, is finally open on the surface of the pressure body 2, as is illustrated in Fig. 14. The surface of the board 11 and the surrounding surface of the pressure body 2 can be flush as shown, or offset from one another. As already mentioned, it is preferred that the components which are present on the board 11 are already sealed by a casting

are surrounded by a compound when the strip 1 is placed with one or more circuit boards 11 on the pressure body 2. Alternatively, the circuit board 11 can be in a recess in the pressure body 2 and a potting compound can then be introduced into this recess. Contact surfaces, sensor surfaces, actuators and/or display elements on the circuit board 11 can protrude from the potting compound or be flush with it.

[0067] As illustrated in Fig. 17, a central electronics unit 14 is preferably attached to one end of the band, which can communicate with ICs (integrated circuits) on all circuit boards 11 via the electrical lines of the band 1. The ICs on the circuit boards 11 are preferably a combination of sensors, actuators, display elements, ADCs, DACs, analog signal processing elements and microcontrollers, which can take over measurement, control and/or display functions at the position of the circuit boards 11, which are controlled or read out by the central electronics unit 14. An interface 15 can optionally be present on the central electronics unit 14. The interface 15 can provide energy and/or data transmission with the central electronics unit 14. The energy and/or data transmission can take place contactlessly, so that the interface 15 can be completely enclosed in the pressure body 2. The interface 15 can be in the form of a socket in order to be able to transmit energy and/or data via cable. The central electronics 14 can comprise a battery or another energy storage device.

[0068] As illustrated in Fig. 17, the central electronics 14 can be enclosed in the printing body 2. The central electronics 14 can already be integrated into the printing body 2 during the printing process.

[0069] Alternatively, the central electronics 14 can also be inserted into a recess in the printing body. This can also be done after the printing process, whereby the central electronics 14 is placed on or in the finished printing body and is connected to the band 1 integrated in the printing body 2.

[0070] Less preferably, the central electronics 14 can also be located outside the pressure hull 2.

[0071] An interface 15, in particular in the form of a socket or a plug, can also be present at one or both ends of the band 1. In one embodiment, there is a socket at one or both ends of the band 1 and a plug at the other. The contacts of the plug preferably protrude from the pressure body 2.

[0072] Fig. 15 shows that an oblique course or a kink can also be produced in the course of the band 1. After the first partial area of the band 1 has been overprinted with the at least one second layer 6 and thus fixed to the first layer 5, the device 4 can be pivoted in order to cause a curve in the band 1 at the transition from the fixed area to the free area.

[0073] In a first embodiment, the free area of the band 1 can now be overprinted in order to fix the curve and at least part of the further inclined area of the band 1 to the first layer 5 in order to produce a bend in the band without changing the plane.

[0074] In a second embodiment (Fig. 16), in addition to the bend in the course of the band, a change of level takes place. Advantageously, an area 16 of the band 1 and the first layer 5 is additionally overprinted, which includes at least the curve of the band 1. After the curve has been fixed to the layer 5, the band can be pivoted by 180° in the diagonal area adjacent to the curve in order to expose the previously hidden area of the first layer 5. As shown in Fig. 16, the first layer 5 can now be further overprinted. The band 1 can now be fixed to the second layer 6 in the position shown in Fig. 16 by a third layer 7. Alternatively, the band can first be pivoted back by 180° from the position shown in Fig. 16 and then fixed to the second layer 6 by a third layer 7. Of course, it is also possible in this embodiment to apply several layers 6 before the tape 1 is applied to the uppermost of these two

ten layers 6 are fixed by a third layer 7.

[0075] The invention can also include software that plans the printing process in advance from CAD data and controls the printer and winding head accordingly. The volumes occupied by the tape 1 and the circuit boards 11 and/or the central electronics 14 and/or an interface 15 are planned accordingly and left out in the printing process. The thickness of the tape 1 and the circuit boards 11 is preferably adapted to the height of the printing layer. Preferably, the software also includes planning of the tape so that the position of the circuit boards and/or the central electronics 14 on the tape is calculated by the software.

[0076] Preferably, in a first step, the printing body with the positions of the circuit boards 11 and the course of the band 1 in the printing body 2 is created by a user in a CAD software, wherein in a further step the software automatically creates the printing process and outputs instructions for the production of the band 1 with the positions of the circuit boards 11. The production of the band 1 can be carried out manually by soldering the circuit boards 11 to the band 1. Automated production of the band 1 with the circuit boards 11 is also conceivable.

[0077] The strip 1 can already be provided with circuit boards 11 when it is fed into the 3D printing process. The strip 1 can, for example, be rolled up with the circuit boards 11 on a spool of the device 4.

[0078] In one embodiment, the circuit boards 11 are attached to the tape 1 during the 3D printing process, in particular soldered to the tape 1. For this purpose, the tape 1 can be present without circuit boards 11 on a spool of the device 4, wherein the circuit boards 11 are attached to a part of the tape 1 which has already been unwound or is accessible on the outside of the spool but has not yet been overprinted. The circuit boards 11 can also be placed and attached by a second device to a section of the tape 1 which is already resting on the 3D printing body 2. The advantage of this method is that the tape 1 with circuit boards 11 does not have to be manufactured in advance and that the circuit boards 11 are attached to the tape 1 in the 3D printing process at the required and freely selectable positions.

[0079] Fig. 19 illustrates a first variant of a movable device 4, which can be sufficient in cases where the path of the band 1 only takes place along or against a single direction. The device 4 is linearly movable in the printing plane and perpendicular to it. The print head 3 of the 3D printer is raised or moved sideways to make room for the device 4 moving past in the direction of the band 1. The band 1 lies on a spool body of the device 4 that can rotate about its longitudinal axis. The device 4 is shown in Fig. 19 in the two end positions and an intermediate position. Not shown is the vertical adjustment of the device 4, by means of which the not yet fixed band 1 can be placed on the printing body 2 or lifted off it. If the linear unit can be pivoted by the height of the printing body 2, for example by 90°, areas of the band 1 that run at an angle to one another can also be realized in the printing body 2.

[0080] Fig. 19 illustrates a second variant of a movable device, wherein the movable device 4 is movable around the pressure volume and over the height of the pressure volume of the pressure body. The movement around the pressure volume can be realized by rotation or by a pivoting movement. The movement in the direction of height by a linear unit or by pivoting around a horizontal axis. Preferably, the device 4 can pivot the band by 180° so that it can always lie flat. This is necessary if the course of the band 1 is changed by rotation around the height of the pressure body 2. The device 4 is shown in Fig. 20 in the two end positions and an intermediate position. The arrow on the spool body of the device serves for illustration, namely to show that it was also pivoted by 180° during the pivoting movement of the device 4 around the pressure body 2. This pivoting is schematically illustrated in the intermediate position by the inclined spool body. Not shown is the vertical adjustment of the device 4, by means of which the not yet fixed band 1 can be placed on the pressure body 2 or lifted off therefrom.

Claims (13)

Patent claims 1. Method for integrating electrical components into a printing body (2) while the latter is being produced in a 3D printing process with layer-by-layer material application, characterized in that a band (1) which comprises at least three electrical lines is placed on an already printed first layer (5) of the printing body (2) during the 3D printing process, wherein at least one free end of the band (1) protrudes from the already printed layer (5) of the printing body (2) and the free end is guided by a movable device (4) so that when printing a subsequent second layer (6), it can be moved away from the location at which a layer build-up is taking place, wherein the band (1) lying on the already printed first layer (5) of the printing body (2) is at least partially overprinted by the subsequent second layer (6) and wherein the subsequent second layer (6) also at least partially covers the already printed first layer (5), wherein after the application of the subsequent second layer (6) or several subsequent second layers (6), the Band (1) is placed on the one subsequent second layer (6) or the uppermost subsequent second layer (6), so that the band (1) on the second layer (6) runs in a higher level of the printing body (2) than on the first layer (5). 2. Method according to claim 1, characterized in that the tape (1) is fixed on the subsequent second layer (6) or the uppermost subsequent second layer (6) by overprinting with at least one subsequent third layer (7). 3. Method according to one of claims 1 or 2, characterized in that the movable device (4) for moving the tape (1) comprises a winding head from which the tape (1) is unwound. 4. Method according to one of claims 1 to 3, characterized in that at least one circuit board (11) is attached to the strip (1), which is integrated into the printing body (2) during the 3D printing process. 5. Method according to claim 4, characterized in that at least one surface of the circuit board or of a component fastened to the circuit board (11) is exposed on an outer side of the finished printing body (2). 6. Method according to claim 4 or 5, characterized in that the circuit board (11) has at least one thinner edge region (12) and a thicker central region, wherein the thinner edge region (12) is overprinted with at least one layer in the 3D printing process. 7. Method according to one of claims 1 to 6, characterized in that the band (1) is stretchable, wherein the band (1) comprises stretchable conductors or conductor tracks and an insulating material of the band surrounding the stretchable conductors or conductor tracks is elastic. 8. Method according to one of claims 1 to 7, characterized in that the pressure body (2) is deformable. 9. Method according to one of claims 1 to 8, characterized in that the pressure body (2) is elastic. 10. Method according to one of claims 1 to 9, characterized in that a central electronics unit (14) is present on the belt (1), which is integrated into the printing body (2) during the printing process, wherein the central electronics unit (14) is connected to a plurality of circuit boards (11) via the belt (1) and communicates with them via the belt (1) in order to control and/or read them. 11. Method according to one of claims 1 to 10, characterized in that several circuit boards (11) are present on the strip (1), which are attached to the strip (1) at a distance from one another. 12. Method according to one of claims 1 to 11, characterized in that several circuit boards (11) are attached to the belt (1) during the 3D printing process. 13. Method according to claim 12, characterized in that the tape (1) without circuit boards (11) is present on a reel of the movable device (4), wherein the circuit boards (11) are attached to a part of the tape (1) which has already been unwound or is accessible on the outside of the reel, but has not yet been overprinted. 9 sheets of drawings