U.S. patent application number 16/179546 was filed with the patent office on 2020-10-08 for method and system for in situ cross-linking of materials to produce three-dimensional features via electron beams from mobile accelerators.
The applicant listed for this patent is Fermi Research Alliance, LLC. Invention is credited to Robert Kephart, Aaron Sauers.
Application Number | 20200316853 16/179546 |
Document ID | / |
Family ID | 1000005104284 |
Filed Date | 2020-10-08 |
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United States Patent
Application |
20200316853 |
Kind Code |
A2 |
Sauers; Aaron ; et
al. |
October 8, 2020 |
METHOD AND SYSTEM FOR IN SITU CROSS-LINKING OF MATERIALS TO PRODUCE
THREE-DIMENSIONAL FEATURES VIA ELECTRON BEAMS FROM MOBILE
ACCELERATORS
Abstract
A method and system for in situ cross-linking of polymers,
Bitumen, and other materials to produce arbitrary functional or
ornamental three-dimensional features using electron beams provided
by mobile accelerators comprises defining a desired pattern for
imparting on a target area, mapping the target area, defining at
least one discrete voxel in the target area according to the
desired pattern to be imparted on the target area, assigning an
irradiation value to each of the at least one discrete voxels, and
delivering a dose of irradiation to each of the at least one
discrete voxels according to the assigned irradiation value.
Inventors: |
Sauers; Aaron; (Aurora,
IL) ; Kephart; Robert; (Pioneer, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Fermi Research Alliance, LLC |
BATAVIA |
IL |
US |
|
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20200139620 A1 |
May 7, 2020 |
|
|
Family ID: |
1000005104284 |
Appl. No.: |
16/179546 |
Filed: |
November 2, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01J 37/305 20130101;
B29K 2105/24 20130101; B33Y 10/00 20141201; B29C 64/135 20170801;
E01C 11/005 20130101; H01J 37/1472 20130101; B29C 64/264 20170801;
E01C 23/14 20130101; H01J 37/06 20130101 |
International
Class: |
B29C 64/135 20060101
B29C064/135; H01J 37/305 20060101 H01J037/305; H01J 37/06 20060101
H01J037/06; H01J 37/147 20060101 H01J037/147; E01C 23/14 20060101
E01C023/14; E01C 11/00 20060101 E01C011/00; B29C 64/264 20060101
B29C064/264; B33Y 10/00 20060101 B33Y010/00 |
Goverment Interests
STATEMENT OF GOVERNMENT RIGHTS
[0001] The invention described in this patent application was made
with Government support under the Fermi Research Alliance, LLC,
Contract Number DE-AC02-07CH11359 awarded by the U.S. Department of
Energy. The Government has certain rights in the invention.
Claims
1. A fabrication method comprising: defining a desired pattern for
imparting on a target area; mapping said target area; defining at
least one discrete voxel in said target area, according to said
desired pattern to be imparted on said target area; assigning an
irradiation value to each of said at least one discrete voxels; and
delivering a dose of irradiation to each of said at least one
discrete voxels according to said assigned irradiation value.
2. The method of claim 1 further comprising: delivering said dose
of irradiation with an accelerator.
3. The method of claim 2 further comprising: adjusting a duty
factor of said accelerator according to said assigned irradiation
value for each of said at least one discrete voxels.
4. The method of claim 2 wherein said accelerator comprises an
electron beam accelerator mounted to a vehicle.
5. The method of claim 2 wherein delivering the dose of irradiation
further comprises at least one of: directing an electron beam
accelerator, mounted to a vehicle, through said target area; and
sweeping an electron beam over said target area.
6. The method of claim 5 further comprising: directing said vehicle
in a predefined path, wherein said predefined path is selected
according to said desired pattern for imparting on said target
area.
7. The method of claim 4 further comprising: determining a position
of said vehicle in said target area with at least one sensor.
8. The method of claim 1 further comprising: depositing a
cross-linking material in said target area.
9. The method of claim 1 wherein said target area is at least one
of: two-dimensional; and three-dimensional.
10. The method of claim 1 further comprising: iteratively creating
a plurality of layers, said plurality of layers forming a
three-dimensional structure.
11. A fabrication system comprising: a mobile accelerator system;
and a control system configured for: defining a desired pattern for
imparting on a target area; mapping said target area; defining at
least one discrete voxel in said target area, according to said
desired pattern to be imparted on said target area; and assigning
an irradiation value to each of said at least one discrete voxels;
wherein said mobile accelerator system delivers a dose of
irradiation to each of said at least one discrete voxels according
to said assigned irradiation value.
12. The system of claim 1 wherein said mobile accelerator system
further comprises: a mobile unit; an accelerator; and a beam
bending assembly, said beam bending assembly adjusting a terminal
position of a beam provided by said accelerator.
13. The system of claim 12 wherein said beam bending assembly
comprises: at least one beam bending magnet.
14. The system of claim 12 wherein said beam bending assembly
comprises: a beam bending snout.
15. The system of claim 12 wherein said beam bending assembly is
configured to direct an electron beam from said accelerator through
said target area.
16. The system of claim 11 further comprising: a vehicle for moving
said mobile accelerator system in a predefined path, said
predefined path selected according to said desired pattern for
imparting on said target area.
17. The system of claim 11 further comprising: at least one
position sensor configured for determining a position of said
mobile accelerator assembly in said target area.
18. A fabrication method comprising: designing a structure;
defining at least one discrete voxel in said structure assigning an
irradiation value to each of said at least one discrete voxels;
covering a build surface with material; and delivering a dose of
irradiation to each of said at least one discrete voxels according
to said assigned irradiation value.
19. The method of claim 18 further comprising: preparing said build
surface for fabrication.
20. The method of claim 18 further comprising: iteratively creating
a plurality of layers associated with said structure.
Description
TECHNICAL FIELD
[0002] Embodiments are generally related to the field of control
systems. Embodiments are also related to the field of
manufacturing. Embodiments are further related to the field of
electron beam manufacturing. Embodiments are also related to
electron accelerators. Embodiments are also related to the
cross-linking of materials such as synthetic polymer. Embodiments
additionally relate to methods and systems for rapid and deep
pre-heating of surfaces, surface preparation, treating, and
strengthening materials. Embodiments are also related to the field
of mobile accelerators. Embodiments are further related to methods,
systems, and apparatuses for in situ cross-linking of polymers,
Bitumen, and other materials to produce arbitrary functional or
ornamental three-dimensional features using electron beams provided
by mobile accelerators.
BACKGROUND
[0003] Accelerators originally developed for scientific
applications are currently used for broad industrial, medical, and
security applications. Over 30,000 accelerators find some use in
producing over $500 billion per year in products and services,
creating a major impact on the economy. Industrial accelerators
must be cost effective, simple, versatile, efficient, and
robust.
[0004] An electron accelerator refers generally to a type of
apparatus capable of accelerating electrons generated from an
electron gun in a vacuum condition through a high voltage generator
or RF structure to impart increased energy to the electron, and
diffusing the electrons so as to emit electron beams having high
energy close to the speed of light through a beam extraction device
so that the electrons are extracted from the vacuum condition and
can impinge on a target object. The electron accelerator
accelerates the electrons generated from the electron gun and emits
the electron beams having a regular width while scanning in a scan
coil in the beam extraction device so as to cause the electron
beams to irradiate a target object in a controlled fashion.
[0005] Many industrial applications for electron accelerators
require high-average beam power. Recent developments have
dramatically reduced the size of electron accelerators, paving the
way for a number of new associated technologies.
SUMMARY
[0006] The following summary is provided to facilitate an
understanding of some of the innovative features unique to the
embodiments disclosed and is not intended to be a full description.
A full appreciation of the various aspects of the embodiments can
be gained by taking the entire specification, claims, drawings, and
abstract as a whole.
[0007] It is, therefore, one aspect of the disclosed embodiments to
provide a method, system, and apparatus for control systems.
[0008] It is an aspect of the disclosed embodiments to provide
methods and systems for manufacturing.
[0009] It is an aspect of the disclosed embodiments to provide
methods and systems for electron beam manufacturing.
[0010] It is an aspect of the disclosed embodiments to provide
methods and systems for electron accelerator manufacturing.
[0011] It is an aspect of the disclosed embodiments to provide
methods and systems for cross-linking of materials.
[0012] It is an aspect of the disclosed embodiments to provide
methods and systems for rapid and deep pre-heating of surfaces,
surface preparation, treating, and strengthening materials.
[0013] It is an aspect of the disclosed embodiments to provide
methods and systems for in situ cross-linking of polymers, Bitumen,
and other materials to produce arbitrary functional or ornamental
three-dimensional features using electron beams provided by mobile
accelerators.
[0014] In an exemplary embodiment, a method for fabrication
includes defining a desired pattern for imparting on a target area,
mapping the target area, defining at least one discrete voxel in
the target area, according to the desired pattern to be imparted on
the target area, assigning an irradiation value to each of the at
least one discrete voxels, and delivering a dose of irradiation to
each of the at least one discrete voxels according to the assigned
irradiation value. In an embodiment, the method further comprises
delivering the dose of irradiation with an accelerator. In an
embodiment the method comprises adjusting a duty factor of the
accelerator according to the assigned irradiation value for each of
the at least one discrete voxels. In an embodiment delivering the
dose of irradiation further comprises at least one of: directing an
electron beam accelerator mounted to a vehicle through the target
area, and sweeping an electron beam over the target area. The
method further comprises directing the vehicle in a predefined
path, wherein the predefined path is selected according to the
desired pattern for imparting on the target area. In an embodiment
the method further comprises determining a position of the vehicle
in the target area with at least one sensor. In an embodiment the
method further comprises depositing a cross-linking material in the
target area. In an embodiment the accelerator comprises an electron
beam accelerator mounted to a vehicle. In an embodiment the target
area is at least one of: two-dimensional, and three-dimensional. In
another embodiment the method further comprises iteratively
creating a plurality of layers, the plurality of layers forming a
three-dimensional structure.
[0015] In an embodiment a fabrication system comprises a mobile
accelerator system, and a control system configured for: defining a
desired pattern for imparting on a target area, mapping the target
area defining at least one discrete voxel in the target area,
according to the desired pattern to be imparted on the target area,
and assigning an irradiation value to each of the at least one
discrete voxels; wherein the mobile accelerator system delivers a
dose of irradiation to each of the at least one discrete voxels
according to the assigned irradiation value. In an embodiment the
mobile accelerator system further comprises a mobile unit, an
accelerator, and a beam bending assembly, the beam bending assembly
adjusting a terminal position of a beam provided by the
accelerator. In an embodiment the beam bending assembly comprises
at least one beam bending magnet. In an embodiment the beam bending
assembly comprises a beam bending snout. In an embodiment the beam
bending assembly is configured to direct an electron beam from the
accelerator through the target area. In an embodiment the system
further comprises a vehicle for moving the mobile accelerator
system in a predefined path, the predefined path selected according
to the desired pattern for imparting on the target area. The system
can further comprise at least one position sensor configured for
determining a position of the mobile accelerator assembly in the
target area.
[0016] In another embodiment a fabrication method comprises
designing a structure, defining at least one discrete voxel in the
structure, assigning an irradiation value to each of the at least
one discrete voxels, covering a build surface with material, and
delivering a dose of irradiation to each of the at least one
discrete voxels according to the assigned irradiation value. In an
embodiment the method further comprises preparing the build surface
for fabrication. In an embodiment the method further comprises
iteratively creating a plurality of layers associated with the
structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The accompanying figures, in which like reference numerals
refer to identical or functionally-similar elements throughout the
separate views and which are incorporated in and form a part of the
specification, further illustrate the embodiments and, together
with the detailed description, serve to explain the embodiments
disclosed herein.
[0018] FIG. 1 depicts a block diagram of a computer system which is
implemented in accordance with the disclosed embodiments;
[0019] FIG. 2 depicts a graphical representation of a network of
data-processing devices in which aspects of the present embodiments
may be implemented;
[0020] FIG. 3 depicts a computer software system for directing the
operation of the data-processing system depicted in FIG. 1, in
accordance with an embodiment;
[0021] FIG. 4 depicts a perspective cut-away view of RF structures
that can form elements of an electron accelerator that can be
adapted for use in accordance with a preferred embodiment;
[0022] FIG. 5 depicts a perspective cut-away view of a
superconducting RF structure that can also form elements of an
electron accelerator adapted for use in accordance with an
embodiment. The figure indicates the operating principles of such
an elliptical RF cavity;
[0023] FIG. 6 depicts a system for treating and strengthening a
material, in accordance with an embodiment;
[0024] FIG. 7 depicts a system for fabricating structures in
accordance with the disclosed embodiments;
[0025] FIG. 8A depicts a method for fabricating structures in
accordance with the disclosed embodiments;
[0026] FIG. 8B depicts a method for fabricating structures in
accordance with the disclosed embodiments;
[0027] FIG. 9 depicts a beam bending system in accordance with the
disclosed embodiments;
[0028] FIG. 10 depicts a system for controlling duty factor in
accordance with the disclosed embodiments;
[0029] FIG. 11 depicts a system for fabricating three-dimensional
structures in accordance with the disclosed embodiments;
[0030] FIG. 12 depicts a method for fabricating three-dimensional
structures in accordance with the disclosed embodiments;
[0031] FIG. 13A depicts an electrified road in accordance with the
disclosed embodiments;
[0032] FIG. 13B depicts a method for fabricating an electrified
road in accordance with the disclosed embodiments;
[0033] FIG. 14A depicts an induced electrified road in accordance
with the disclosed embodiments; and
[0034] FIG. 14B depicts a method for fabricating an induced
electrified road in accordance with the disclosed embodiments.
DETAILED DESCRIPTION
[0035] The particular values and configurations discussed in the
following non-limiting examples can be varied, and are cited merely
to illustrate one or more embodiments and are not intended to limit
the scope thereof.
[0036] Example embodiments will now be described more fully
hereinafter with reference to the accompanying drawings, in which
illustrative embodiments are shown. The embodiments disclosed
herein can be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein; rather,
these embodiments are provided so that this disclosure will be
thorough and complete, and will fully convey the scope of the
embodiments to those skilled in the art. Like numbers refer to like
elements throughout.
[0037] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting. As
used herein, the singular forms "a", "an", and "the" are intended
to include the plural forms as well, unless the context clearly
indicates otherwise. It will be further understood that the terms
"comprises" and/or "comprising," when used in this specification,
specify the presence of stated features, integers, steps,
operations, elements, and/or components, but do not preclude the
presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof.
[0038] Throughout the specification and claims, terms may have
nuanced meanings suggested or implied in context beyond an
explicitly stated meaning. Likewise, the phrase "in one embodiment"
as used herein does not necessarily refer to the same embodiment
and the phrase "in another embodiment" as used herein does not
necessarily refer to a different embodiment. It is intended, for
example, that claimed subject matter include combinations of
example embodiments in whole or in part.
[0039] In general, terminology may be understood at least in part
from usage in context. For example, terms, such as "and", "or", or
"and/or," as used herein may include a variety of meanings that may
depend at least in part upon the context in which such terms are
used. Typically, "or" if used to associate a list, such as A, B or
C, is intended to mean A, B, and C, here used in the inclusive
sense, as well as A, B or C, here used in the exclusive sense. In
addition, the term "one or more" as used herein, depending at least
in part upon context, may be used to describe any feature,
structure, or characteristic in a singular sense or may be used to
describe combinations of features, structures or characteristics in
a plural sense. In addition, the term "based on" may be understood
as not necessarily intended to convey an exclusive set of factors
and may, instead, allow for existence of additional factors not
necessarily expressly described, again, depending at least in part
on context.
[0040] Unless otherwise defined, all terms (including technical and
scientific terms) used herein have the same meaning as commonly
understood by one of ordinary skill in the art. It will be further
understood that terms, such as those defined in commonly used
dictionaries, should be interpreted as having a meaning that is
consistent with their meaning in the context of the relevant art
and will not be interpreted in an idealized or overly formal sense
unless expressly so defined herein.
[0041] FIGS. 1-3 are provided as exemplary diagrams of
data-processing environments in which embodiments of the present
invention may be implemented. It should be appreciated that FIGS.
1-3 are only exemplary and are not intended to assert or imply any
limitation with regard to the environments in which aspects or
embodiments of the disclosed embodiments may be implemented. Many
modifications to the depicted environments may be made without
departing from the spirit and scope of the disclosed
embodiments.
[0042] A block diagram of a computer system 100 that executes
programming for implementing parts of the methods and systems
disclosed herein is shown in FIG. 1. A computing device in the form
of a computer 110 configured to interface with sensors, peripheral
devices, and other elements disclosed herein may include one or
more processing units 102, memory 104, removable storage 112, and
non-removable storage 114. Memory 104 may include volatile memory
106 and non-volatile memory 108. Computer 110 may include or have
access to a computing environment that includes a variety of
transitory and non-transitory computer-readable media such as
volatile memory 106 and non-volatile memory 108, removable storage
112 and non-removable storage 114. Computer storage includes, for
example, random access memory (RAM), read only memory (ROM),
erasable programmable read-only memory (EPROM) and electrically
erasable programmable read-only memory (EEPROM), flash memory or
other memory technologies, compact disc read-only memory (CD ROM),
Digital Versatile Disks (DVD) or other optical disk storage,
magnetic cassettes, magnetic tape, magnetic disk storage, or other
magnetic storage devices, or any other medium capable of storing
computer-readable instructions as well as data including image
data.
[0043] Computer 110 may include or have access to a computing
environment that includes input 116, output 118, and a
communication connection 120. The computer may operate in a
networked environment using a communication connection 120 to
connect to one or more remote computers, remote sensors, detection
devices, hand-held devices, multi-function devices (MFDs), mobile
devices, tablet devices, mobile phones, Smartphones, or other such
devices. The remote computer may also include a personal computer
(PC), server, router, network PC, RFID enabled device, a peer
device or other common network node, or the like. The communication
connection may include a Local Area Network (LAN), a Wide Area
Network (WAN), Bluetooth connection, or other networks. This
functionality is described more fully in the description associated
with FIG. 2 below.
[0044] Output 118 is most commonly provided as a computer monitor,
but may include any output device. Output 118 and/or input 116 may
include a data collection apparatus associated with computer system
100. In addition, input 116, which commonly includes a computer
keyboard and/or pointing device such as a computer mouse, computer
track pad, or the like, allows a user to select and instruct
computer system 100. A user interface can be provided using output
118 and input 116. Output 118 may function as a display for
displaying data and information for a user, and for interactively
displaying a graphical user interface (GUI) 130.
[0045] Note that the term "GUI" generally refers to a type of
environment that represents programs, files, options, and so forth
by means of graphically displayed icons, menus, and dialog boxes on
a computer monitor screen. A user can interact with the GUI to
select and activate such options by directly touching the screen
and/or pointing and clicking with a user input device 116 such as,
for example, a pointing device such as a mouse and/or with a
keyboard. A particular item can function in the same manner to the
user in all applications because the GUI provides standard software
routines (e.g., module 125) to handle these elements and report the
user's actions. The GUI can further be used to display the
electronic service image frames as discussed below.
[0046] Computer-readable instructions, for example, program module
or node 125, which can be representative of other modules or nodes
described herein, are stored on a computer-readable medium and are
executable by the processing unit 102 of computer 110. Program
module or node 125 may include a computer application. A hard
drive, CD-ROM, RAM, Flash Memory, and a USB drive are just some
examples of articles including a computer-readable medium.
[0047] FIG. 2 depicts a graphical representation of a network of
data-processing systems 200 in which aspects of the present
invention may be implemented. Network data-processing system 200 is
a network of computers or other such devices such as mobile phones,
smartphones, sensors, detection devices, controllers and the like
in which embodiments of the present invention may be implemented.
Note that the system 200 can be implemented in the context of a
software module such as program module 125. The system 200 includes
a network 202 in communication with one or more clients 210, 212,
and 214. Network 202 may also be in communication with one or more
device 204, servers 206, and storage 208. Network 202 is a medium
that can be used to provide communications links between various
devices and computers connected together within a networked data
processing system such as computer system 100. Network 202 may
include connections such as wired communication links, wireless
communication links of various types, fiber optic cables, quantum,
or quantum encryption, or quantum teleportation networks, etc.
Network 202 can communicate with one or more servers 206, one or
more external devices such as a controller, actuator, sensor, or
other such device 204, and a memory storage unit such as, for
example, memory or database 208. It should be understood that
device 204 may be embodied as a detector device, microcontroller,
controller, receiver, transceiver, or other such device.
[0048] In the depicted example, device 204, server 206, and clients
210, 212, and 214 connect to network 202 along with storage unit
208. Clients 210, 212, and 214 may be, for example, personal
computers or network computers, handheld devices, mobile devices,
tablet devices, smartphones, personal digital assistants,
microcontrollers, recording devices, MFDs, etc. Computer system 100
depicted in FIG. 1 can be, for example, a client such as client 210
and/or 212.
[0049] Computer system 100 can also be implemented as a server such
as server 206, depending upon design considerations. In the
depicted example, server 206 provides data such as boot files,
operating system images, applications, and application updates to
clients 210, 212, and/or 214. Clients 210, 212, and 214 and
external device 204 are clients to server 206 in this example.
Network data-processing system 200 may include additional servers,
clients, and other devices not shown. Specifically, clients may
connect to any member of a network of servers, which provide
equivalent content.
[0050] In the depicted example, network data-processing system 200
is the Internet with network 202 representing a worldwide
collection of networks and gateways that use the Transmission
Control Protocol/Internet Protocol (TCP/IP) suite of protocols to
communicate with one another. At the heart of the Internet is a
backbone of high-speed data communication lines between major nodes
or host computers consisting of thousands of commercial,
government, educational, and other computer systems that route data
and messages. Of course, network data-processing system 200 may
also be implemented as a number of different types of networks such
as, for example, an intranet, a local area network (LAN), or a wide
area network (WAN). FIGS. 1 and 2 are intended as examples and not
as architectural limitations for different embodiments of the
present invention.
[0051] FIG. 3 illustrates a software system 300, which may be
employed for directing the operation of the data-processing systems
such as computer system 100 depicted in FIG. 1. Software
application 305, may be stored in memory 104, on removable storage
112, or on non-removable storage 114 shown in FIG. 1, and generally
includes and/or is associated with a kernel or operating system 310
and a shell or interface 315. One or more application programs,
such as module(s) or node(s) 125, may be "loaded" (i.e.,
transferred from removable storage 114 into the memory 104) for
execution by the data-processing system 100. The data-processing
system 100 can receive user commands and data through user
interface 315, which can include input 116 and output 118,
accessible by a user 320. These inputs may then be acted upon by
the computer system 100 in accordance with instructions from
operating system 310 and/or software application 305 and any
software module(s) 125 thereof.
[0052] Generally, program modules (e.g., module 125) can include,
but are not limited to, routines, subroutines, software
applications, programs, objects, components, data structures, etc.,
that perform particular tasks or implement particular abstract data
types and instructions. Moreover, those skilled in the art will
appreciate that elements of the disclosed methods and systems may
be practiced with other computer system configurations such as, for
example, hand-held devices, mobile phones, smart phones, tablet
devices, multi-processor systems, printers, copiers, fax machines,
multi-function devices, data networks, microprocessor-based or
programmable consumer electronics, networked personal computers,
minicomputers, mainframe computers, servers, medical equipment,
medical devices, and the like.
[0053] Note that the term module or node as utilized herein may
refer to a collection of routines and data structures that perform
a particular task or implements a particular abstract data type.
Modules may be composed of two parts: an interface, which lists the
constants, data types, variables, and routines that can be accessed
by other modules or routines; and an implementation, which is
typically private (accessible only to that module) and which
includes source code that actually implements the routines in the
module. The term module may also simply refer to an application
such as a computer program designed to assist in the performance of
a specific task such as word processing, accounting, inventory
management, etc., or a hardware component designed to equivalently
assist in the performance of a task.
[0054] The interface 315 (e.g., a graphical user interface 130) can
serve to display results, whereupon a user 320 may supply
additional inputs or terminate a particular session. In some
embodiments, operating system 310 and GUI 130 can be implemented in
the context of a "windows" system. It can be appreciated, of
course, that other types of systems are possible. For example,
rather than a traditional "windows" system, other operation systems
such as, for example, a real time operating system (RTOS) more
commonly employed in wireless systems may also be employed with
respect to operating system 310 and interface 315. The software
application 305 can include, for example, module(s) 125, which can
include instructions for carrying out steps or logical operations
such as those shown and described herein.
[0055] The following description is presented with respect to
embodiments of the present invention, which can be embodied in the
context of, or require the use of a data-processing system such as
computer system 100, in conjunction with program module 125, and
data-processing system 200 and network 202 depicted in FIGS. 1-3.
The present invention, however, is not limited to any particular
application or any particular environment. Instead, those skilled
in the art will find that the systems and methods of the present
invention may be advantageously applied to a variety of system and
application software including database management systems, word
processors, and the like. Moreover, the present invention may be
embodied on a variety of different platforms including Windows,
Macintosh, UNIX, LINUX, Android, Arduino and the like. Therefore,
the descriptions of the exemplary embodiments, which follow, are
for purposes of illustration and not considered a limitation.
[0056] U.S. Pat. No. 9,186,645, titled "METHOD AND SYSTEM FOR
IN-SITU CROSS LINKING OF POLYMERS, BITUMEN AND SIMILAR MATERIALS TO
INCREASE STRENGTH, TOUGHNESS AND DURABILITY VIA IRRADIATION WITH
ELECTRON BEAMS FROM MOBILE ACCELERATORS," issued on Nov. 17, 2015
describes systems and methods for treating and strengthening a
material, the systems and methods comprising a mobile unit, an
electron gun that emits a beam of electrons, an electron
accelerator integrated with the mobile unit that is positioned to
accelerate the beam of electrons, and a beam extraction device
comprising a scan coil that emits the accelerated beam of
electrons, where the beam extracting device is positioned on the
mobile unit to irradiate the surface of, and treat in-situ, a
material located proximate to the mobile unit, wherein irradiation
of the material by the beam of electrons results in in-situ
cross-linking of the material and therefore a strengthening and
increased durability of the material. U.S. Pat. No. 9,186,645 is
herein incorporated by reference in its entirety.
[0057] U.S. Pat. No. 9,340,931, titled "METHOD AND SYSTEM FOR
IN-SITU CROSS LINKING OF POLYMERS, BITUMEN AND SIMILAR MATERIALS TO
INCREASE STRENGTH, TOUGHNESS AND DURABILITY VIA IRRADIATION WITH
ELECTRON BEAMS FROM MOBILE ACCELERATORS," issued on May 17, 2016
describes systems and methods for treating and strengthening a
material, the systems and methods comprising a mobile unit, an
electron gun that emits a beam of electrons, an electron
accelerator integrated with the mobile unit that is positioned to
accelerate the beam of electrons, and a beam extraction device
comprising a scan coil that emits the accelerated beam of
electrons, where the beam extracting device is positioned on the
mobile unit to irradiate the surface of, and treat in-situ, a
material located proximate to the mobile unit, wherein irradiation
of the material by the beam of electrons results in in-situ
cross-linking of the material and therefore a strengthening and
increased durability of the material. U.S. Pat. No. 9,340,931 is
herein incorporated by reference in its entirety.
[0058] U.S. Pat. No. 10,070,509, titled "COMPACT SRF BASED
ACCELERATOR," issued on Sep. 4, 2018, describes a particle
accelerator comprising an accelerator cavity, an electron gun, and
a cavity cooler configured to at least partially encircle the
accelerator cavity. A cooling connector and an intermediate
conduction layer are formed between the cavity cooler and the
accelerator cavity to facilitate thermal conductivity between the
cavity cooler and the accelerator cavity. The embodiments disclosed
therein teach a viable, compact, robust, high-power, high-energy
electron-beam, or x-ray source. The disclosed advances are
integrated into a single design, that enables compact, mobile,
high-power electron accelerators. U.S. Pat. No. 10,070,509 is
herein incorporated by reference in its entirety.
[0059] FIG. 4 illustrates a perspective cut-away view of an RF
structure 410 that can form elements of an electron accelerator
that can be adapted for use in accordance with embodiments
disclosed herein. Note that RF accelerator and electron gun
structures can be employed to produce electron beams of the
required energy for implementation of the disclosed embodiments. An
electron accelerator, for example, that employs the RF structure
410 can accelerate electrons generated from an electron gun with RF
electric fields in resonant cavities sequenced such that the
electrons are accelerated due to an electric field present in each
cavity as the electron traverses the cavity to reach a beam
extraction device.
[0060] FIG. 5 illustrates a perspective cut-away view of a four
cell elliptical superconducting RF structure 520 that can also form
elements of an electron accelerator adapted for use in accordance
with an embodiment. Note that varying embodiments can employ
alternative cavity geometries and/or cell numbers. FIG. 5 generally
indicates the operating principles of an elliptical RF cavity.
Advancements in SRF technology can enable even more compact and
efficient accelerators for this application.
[0061] The RF structure 520 of FIG. 5 demonstrates the principle of
operation in which alternating RF electric fields can be arranged
to accelerate groups of electrons timed to arrive in each cavity
when the electric field in that cavity causes the electrons to gain
additional energy. In the particular embodiment shown in FIG. 5, a
voltage generator 522 can induce an electric field within the RF
cavity. Its voltage can oscillate, for example, with a radio
frequency of 1.3 Gigahertz or 1.3 billion times per second. An
electron source 524 can inject particles into the cavity in phase
with the variable voltage provided by the voltage generator 522 of
the RF structure 520. Arrow(s) 526 shown in FIG. 5 indicate that
the electron injection and cavity RF phase is adjusted such that
electrons experience or "feel" an average force that accelerates
them in the forward direction, while arrow(s) 528 indicate that
electrons are not present in a cavity cell when the force is in the
backwards direction.
[0062] It can be appreciated that the example RF structures 410 and
520, respectively shown in FIGS. 4-5, represent examples only and
that electron accelerators of other types and
configurations/structures/frequencies may be implemented in
accordance with alternative embodiments. That is, the disclosed
embodiments are not limited structurally to the example electron
accelerator structures 410, 520, respectively shown in FIGS. 4-5,
but represent merely one possible type of structure that may be
employed with particular embodiments. Alternative embodiments may
vary in structure, arrangement, frequency, and type of utilized
accelerators, RF structures, and so forth.
[0063] FIG. 6 illustrates a system 660 for treating a material, in
accordance with a preferred embodiment. System 660 generally
includes a mobile unit 669 (e.g., a trailer, etc.) capable of being
pulled by, for example, a truck 667 or other vehicle. It should be
appreciated that the mobile unit 669 can comprise any
transportation device, including but not limited to, a sled, a
dolly, a cart, or other such transportation system. In other
embodiments, the mobile unit can comprise a driven and/or
autonomous vehicle. The truck 667 carries a mobile electrical
generator 666. One or more electron accelerators 662 can be
disposed within the trailer with respect to one or more RF sources
664. A cooling structure 676 can also be located within the trailer
or mobile unit 669 with respect to the RF source 664. In a
preferred embodiment, the accelerators 662, RF sources 664, and
cooling structure 676 can be integrated with the mobile unit
669.
[0064] A shielding 668 can be located at the rear of the mobile
unit 669 to enclose electron beams with respect to the electron
accelerator(s) 662. In addition, a structure 672 for EB bending and
sweeping magnets can also be located at the rear of the mobile unit
669. A mechanism can also be provided to follow the target surface
678 where pattern creation in a material 688 is desired. The
electron accelerators 662 can be positioned on the mobile unit 669
to irradiate (e.g. with X-rays, gamma rays, etc.) and treat
in-situ, a material 688, in or around, the target surface 678
(e.g., a road surface) where pattern creation is desired, located
proximate to the mobile unit 669, wherein irradiation of the
material 688 via the electron accelerators 662 results in in-situ
polymerization and/or cross-linking resulting in fabrication of a
pattern or structure 689 in the target surface 678.
[0065] In some embodiments, the material 688 to be irradiated may
constitute a polymer or a polymer composite. In other embodiments,
such material can be, for example, a bitumen or modified bitumen,
or an electron or x-ray cross-link capable bitumen product. In
still other embodiments, the material can be, for example, plastic
or plastic composite materials or any material capable of being
cross-linked or its materials properties modified with electron
beams or X-ray or by irradiation of the material to induce in-situ
cross-linking or curing of the material. In other embodiments, the
material can comprise pre-formed pavement (or other cross-linkable
material) tiles, of any shape, such that the tiles can be
distributed in a desired pattern and linked together.
[0066] In still other embodiments, the material 688 can be, for
example, asphalt, modified asphalt, or a cross-link capable
binder-stone mixture of a road surface. In a preferred embodiment,
material is such a road surface. In general, the mobile unit can be
configured as a vehicle-mounted unit that moves above and with
respect to the target area in the road surface/material filling.
The mobile unit moves with respect to the material filling that is
being treated.
[0067] In another embodiment, the system 660 can include a mobile
electron accelerator 662 that is used to accelerate electrons into
the surface of the target area 678 that has material 688. The
accelerated electrons rapidly raise the temperature of the repair
or fill material (e.g. asphalt) above the melting point of the
binder (e.g. bitumen) to a necessary depth below the surface of the
repair. This allows a lasting pattern or structure to be made in
the target area 678. The technique for imparting a pattern or
structure 689 can also be combined with a material that can be
electron beam cross-linked to provide extra strength.
[0068] One of the key aspects of the disclosed embodiments is based
on the realization that the material properties of polymers, for
example, can be improved (e.g., strength, toughness, heat
resistance, etc.) via cross-linking the material with radiation.
The mobile electron accelerators 662 and/or providing the electron
beams can provide such irradiation.
[0069] When a synthetic polymer is to be "cross-linked," this
refers to a process in which a portion of, or the entire bulk of
the polymer, has been exposed to the cross-linking method. The
disclosed approach exposes the polymer to radiation from the
electron accelerator(s). This resulting modification of mechanical
properties depends strongly on the cross-link density achieved. Low
cross-link densities decrease the viscosities of polymeric fluids.
Intermediate cross-link densities transform gummy polymers into
materials that have elastomeric properties and potentially high
strengths. Additional cross-linking makes the material more rigid
and eventually stiff and brittle. Radiation induced polymerization
allows in-situ adjustment of such materials' properties.
[0070] Numerous polymers can be added to bitumen to create mixtures
that, when cross-linked, alter their physical properties. Bitumen
mixtures of this type can be cross-linked, usually with the
addition of sulfur compounds. In addition, materials can be added
to the mixture to provide reflective, colorful, or other cosmetic
qualities of the mixture. All such methods can be performed
beforehand therefore coupling the handling properties of the
materials during fabrication to the eventual properties of the
completed item.
[0071] The disclosed embodiments, can employ electron beams from
mobile accelerators such as, for example, accelerators controlled
with a control system, to irradiate material in a specified manner
to achieve a desired pattern or structure, by adjusting the
properties of the binding materials (e.g., polymer) in-situ, and
after formation via radiation induced cross-linking. Such an
approach can be used to tailor the final materials' properties to
the intended application independent of the materials' properties
during formation of the surface. It should be appreciated, however,
that such an approach is not limited to road surfaces, and can be
adapted for use in irradiating other finished in-place materials to
achieve a desired pattern or structure from the material.
[0072] The embodiments described herein provide electron beams that
are very effective at depositing heat deep (several centimeters or
more) into a surface allowing its temperature to be raised to the
standard working temperatures for asphalt, even under conditions of
extreme winter cold. Electron beam heating described herein does
not depend on the thermal conductivity of an asphalt like material,
which is typically very poor, to heat subsurface material.
[0073] The embodiment depicted in FIG. 6 can be implemented in the
context of standard asphalt construction and repair involving the
use of gravel and bitumen, or in other fabrication methods.
Treatment of a target area is not limited to bulk road repair
applications. While pot hole repair, for example, can be achieved,
other more nuanced applications may also be desirable. For example,
a target area can be selected where a desired pattern or shape may
be necessary. The shape or pattern may range from something as
simple as ridges or grooves in the surface, to complex
three-dimensional structures. Such features can be functional. For
example, such features can be selected to increase lateral
stiffness, control directional friction, repair damage, or increase
draining efficiency.
[0074] The desired features to be imparted in or on the target area
can be expressed in a two dimensional or three dimensional
coordinate system. In the case of a three dimensional system, a
series of voxel elements can be defined in the target area. In such
an example, the adjacent rows of voxels in the accelerator's
direction of travel can define the length of the feature within the
target area. Adjacent rows of voxels in the beam scanning direction
can define the width of the feature in the target area. The energy
of the beam spot can define the vertical dimension of the feature.
The accelerator can then be moved through the target area while the
beam is scanned across the target area. The duty factor of the
accelerator can be adjusted so that each voxel element is properly
dosed with the required energy to achieve the desired
structure.
[0075] FIG. 7 illustrates a system 700 for fabricating structures
in a target area 678, in accordance with the disclosed embodiments.
In such embodiments, a control system 705 is operably connected to
the mobile accelerator assembly and/or the beam bending assembly
672. The control system can comprise a computer system, including a
specially configured or special purpose computer system with a
series of control modules. The control modules can comprise
instructions that can be implemented to control fabrication in
accordance with the disclosed embodiments. The operable
communication can be achieved via wired or wireless communication
over a network, or other such communication mode.
[0076] A user interface can be provided that allows the user to
control various aspects of designing a feature to be imparted in
the surface, and controlling the mobile accelerator. The user
interface can also provide the user instructions or notifications
as to the control of the mobile accelerator, etc. Thus, the user
interface can be provided on a computer system, mobile device,
heads-up display associated with a vehicle, or other such
device.
[0077] The control system 705 includes mapping module 730 which is
configured to interface with sensors, such as sensor 750 to
generate a map of the target area 678, and/or store a map of the
target area 678. The mapping module 730 can operate in conjunction
with a discretization module 734 configured to discretize the
target area 678 into discrete volumes or voxels. Design module 736
is configured to allow a user to prepare and/or store a desired
structural design for the target area 678. A dose module 738 is
configured to assign an irradiation dose to each voxel defined by
the discretization module 734, according to the design provided by
design module 736. Duty factor module 740 uses the speed of the
mobile unit 669 to control the duty factor of the accelerator so
that each voxel receives the proper dose of irradiation. It should
be understood that some or all of these modules can be automatic or
can allow a user to define certain parameters, such as fabrication
design, fabrication time, mobile unit speed, material
characteristics, etc.
[0078] It should be appreciated that the duty factor module 740 can
adjust the duty factor of the accelerator and/or can adjust the
sweep frequency of the electron beam 710 through the electron beam
bending assembly 672, to adjust the rate the electron beam 715 is
cycled back and forth as illustrated by arrow 720.
[0079] The duty factor module 740 can be configured to accept input
from on-board sensors such as sensors 750 or external sensors, such
as sensors 745. It should be understood that these sensors can
comprise, GPS receivers, locations sensors, sonic sensors, position
sensors, beacons, image sensors, and the like. External sensors 745
can be positioned around the target area 678, and serve to provide
the control system 705 reference location information on the
location of the accelerator and/or the target area 678. It should
be appreciated that location information may also be provided via a
GPS system, aerial drone system, or other such system.
[0080] For example, localization of the accelerator with respect to
its target may be achieved using both active and/or passive beacons
745 placed in or around the target area 678 with sensors 750 aboard
the mobile accelerator. In certain embodiments, physical barriers
755 may be erected such that the mobile unit 669 changes direction
when encountering the barrier 755. A barrier encounter could be
physical (e.g. the mobile unit 669 contacts the barrier) or virtual
(e.g. a sensor aboard the accelerator recognizes physical proximity
to a virtual or actual barrier 755).
[0081] In certain embodiments, the system, using beacons 745 to
provide barrier functionality (i.e. to confine the accelerator to a
specific area) as well as provide accelerator localization, can be
combined with an autonomously-driven mobile unit 669, configured to
impart specific irradiation values to specific voxel elements. The
mobile unit 669 can create specific designs by traveling an
arbitrary or optimized path through the target area 678. The
control system 705 can be programmed to traverse the space until
all voxel elements have been treated according to the design
created with the design module 736. The path can be optimized, or
can follow a pre-defined pattern, such as raster, spiral, or
wall-following pattern.
[0082] In a simple example embodiment, where pothole filling is
desired, the features of a roadway with one or more potholes can be
mapped. The mapped roadway, and the identified potholes, can be
discretized into voxel elements. Cross-linkable material 688 can be
inserted into the pothole(s). The mobile unit can then be moved
along the roadway over the pothole(s).
[0083] The control system 705 can be used to control irradiation of
each voxel of the pothole with cross-linkable material 688 therein,
and potentially, proximate areas surrounding the pothole, to
encourage cross-linking between the cross-linkable material and the
existing roadway. The proximate area can be a predetermined
distance (e.g. 2 inches surrounding the pothole circumference) or
can be defined by the user. The voxels can be irradiated with the
predefined dose provided by the dose module such that the
cross-linkable material 688 (and potentially, the surrounding
roadway) is irradiated. In such an embodiment, a significant
portion of the roadway will not be irradiated (i.e. will be
assigned a 0 value for irradiation) because it is not related to
the pothole, or other such area of interest.
[0084] This embodiment not only crosslinks the filler material and
surrounding pavement, but also provides more penetrating heat to
the filler material and surrounding pavement areas. The provision
of heat as well as crosslinking are characteristic of the exemplary
embodiment. Thus, the pothole in the roadway can be repaired in
this manner, even in extreme cold conditions, where prior art
pothole repair methods fail. It should be appreciated that the same
basic approach can be used on much larger target areas (e.g. a
highway, roadway, overpass, bridge, building pad, construction
site, etc.) where more specialized design parameters are
desired.
[0085] In certain embodiments the cross-linkable material 688,
which is intended to be targeted by the particle beam, can contain
a tracer element 760. An exemplary tracer element 760 can be a
unique color or reflective, such that it can be detected by a
low-cost sensor (e.g. sensor 750) mounted on the mobile unit 669.
In such embodiments, the sensor 750 can be fixed on the mobile unit
669 a known distance ahead of the beam outlet. The sensor 750 can
detect the tracer element 760. A signal indicative of the detection
of the tracer element 760 can be provided to the control system 705
to signify the presence of filler material 688. The control system
can then correctly activate the accelerator so that the beam outlet
traverses the target area according to the user defined irradiation
value necessary for fabrication of the desired structure. It should
be appreciated that tracer element 760 can include one or more of
magnetic particles embedded in the material, colorful particles
embedded in the material, and reflective particles embedded in the
material.
[0086] FIG. 8 illustrates a flow chart of steps associated with a
high level method 800 for fabricating a structure using the systems
disclosed herein, in accordance with the disclosed embodiments. The
method begins at 805. It should be appreciated that the order of
the steps illustrated in method 800 are exemplary but could be
implemented in alternative orders according to design
considerations.
[0087] A first step in the method is to select and map the target
area (or volume) as illustrated at step 810. Mapping of target
topography can be accomplished in any number of ways. In certain
embodiments, historical records or modern surveying methods can be
used. Mapping target topography can be achieved with a surveyor's
"traverse," whereby target (e.g. land, road, build platform, etc.)
positions are assigned to a plane coordinate system. Other direct
survey techniques which utilize position points, angle
measurements, and distances between them can also be used.
[0088] Passive sensor methodologies may be utilized to map the
target area, which can make use of aerial or satellite imagery to
delineate terrain features. Photogrammetry, whereby two or more
photographic images taken from different angles expose the
three-dimensional positions of common features are "triangulated"
from the intersection of rays, can be used to map target features.
Other technologies such as RADAR (Radio Direction And Ranging) and
LIDAR (Light Detection And Ranging) techniques may be employed to
map the target topography.
[0089] In other embodiments, drone systems, or other remote sensing
techniques can be used to map the target topography. Other
techniques include satellite or aircraft-borne sensor
techniques.
[0090] Once the target area is adequately mapped, the next step 815
is to discretize the target area or volume into voxel elements with
accompanying position values (e.g. GPS values, or other spatial
values). This may be most easily achieved with a computer system,
but other value assignment techniques can also be used.
[0091] The desired structure to be fabricated in, or on, the target
area can next be defined as illustrated at 820. As previously
noted, the desired structure can range in complexity and purpose.
In some cases, the desired structure may be as simple as a pothole
fill, or warning grooves or bumps formed in the edge of a roadway.
In other embodiments, complex two or three dimensional structures
can be selected, including but not limited to, patterns to improve
road traction, improve drainage, create varying sounds or tones,
and the like. In still further embodiments, the target area may not
be a roadway. In such cases, the target area can comprise a
manufacturing bed where fabrication of complex three-dimensional
structures is desired.
[0092] At step 825 irradiation values can be assigned to each voxel
element in the target area according to the desired structure to be
fabricated. The irradiation values can be assigned to each voxel
element with the computer system, or by other means. Irradiation
values for any given voxel will vary according to the level of
cross-linking necessary to impart the desired structure. Thus, the
irradiation values will range from 0 to essentially any value
greater than 0.
[0093] At this stage, the target area has been discretized into
voxel elements and each of those voxel elements has been assigned a
specific irradiation value necessary to fabricate the desired
structure in the target area. At step 830 the accelerator can begin
an initial pass over, or through, the target area. As the
accelerator progresses through the target area, the electron beam
can be swept, most commonly perpendicularly to the direction of
motion of the accelerator, although other sweep patterns or shapes
are also possible. According to the scaling described herein, the
duty factor of the accelerator can be adjusted according to the
accelerator speed so that each voxel is properly dosed.
Specifically, if the accelerator is moving slowly the control
system will adjust the duty factor of the accelerator so that each
voxel receives the required irradiation. If the accelerator is
moving faster, the accelerator will require a comparatively high
duty factor. Thus, the control system can use the speed of the
accelerator, and other such factors, to adjust the duty factor of
the accelerator as shown at 835.
[0094] It should be understood that, in certain cases, the target
area may exceed the width of the electron beam sweep, and/or
certain voxels in the target area may require additional
irradiation. In such cases, the accelerator may make multiple
passes over or through some or all of the target area to achieve
the desired irradiation of each voxel.
[0095] In other embodiments, the target area can be very precisely
targeted with a single pass. It is an aspect of the disclosed
embodiments to provide methods and systems for reducing
occupational exposure to the particle beam by precisely targeting
the materials to be irradiated, as illustrated in the method 800,
rather than uniformly irradiating a material without regard to
necessity. Irradiating only the materials that require irradiation
(e.g. a pothole filled with filling material, instead of the entire
roadway) dramatically reduces use of the beam and is consistent
with "ALARA" principles of radiation safety to keep potential
radiation doses "As Low As Reasonably Achievable." This can
significantly reduce the radiation dose to which the operator (e.g.
a road worker) is exposed.
[0096] In still other embodiments, after a first pass, new material
can be deposited in some or all of the target area, and the
accelerator can make an additional pass over the newly added
material, resulting in the fabrication of multiple layers of a
desired two or three dimensional structure. The method ends at step
840 when the desired structure has been fabricated.
[0097] FIG. 8B illustrates a method 850 for processing sensor data
in accordance with the disclosed embodiments. The method begins at
855. At step 860, one or more of the sensors associated with the
mobile unit detect the tracer material inserted in the
cross-linking material.
[0098] Upon detection of the tracer material, at step 865, the
sensor data can be provided as location data (i.e. cartesian
coordinates in one or more dimensions) to the controller. In
addition, the tracer material can trigger a "flag" in the
controller indicating that the tracer material has been identified.
The controller can then compare the location collected by the
sensor to the map data of the target volume, as illustrated at
870.
[0099] At step 875 the controller can verify the flag, based on the
sensor detection and the stored map data associated with the target
volume. Once the controller verifies that the sensor has correctly
identified a target volume with the tracer material, at step 880,
the coordinates of the location where the tracer material was
identified can be used by the controller to adjust the beam bending
assembly, so that the beam bending assembly can irradiate the
target area where the tracer has been identified. At step 885, the
controller can also scale the pulse rate of the accelerator to
provide the correct dose of irradiation for the identified voxel
with the tracer material.
[0100] It should be noted that this method can be continuously
implemented such that the sensors notify the controller anytime a
tracer material is identified, as illustrated by arrow 890. In this
way, the controller can use detection of the tracer material to
correctly irradiate one or more target locations in at or near real
time, as the mobile unit passes over the target. The method ends at
895.
[0101] A critical aspect of the system is the beam bending
assembly, which plays a crucial role in defining the width and
shape of the beam scan. The beam bending assembly 672 can be
controlled so that the desired pattern is imparted on the target
surface. The beam bending assembly can be embodied in variety of
ways. In some embodiments, the beam bending assembly can comprise a
set of one or more bending magnets 672, configured to bend the beam
710 along a predefined scanning direction, generally perpendicular
to the motion of the mobile unit 669, although other beam scanning
patterns are possible. In other embodiments, the beam bending
assembly can comprise an electromagnet, or deflection coil,
configured to bend the beam 710. The control system can adjust the
orientation of the beam bending assembly and/or the associated
magnetic field to achieve other more complex beam bending patterns,
or to spot treat one or more specific locations in the target
area.
[0102] For example, in one embodiment, the accelerator is advanced
in a desired direction along a surface. The magnet (e.g. an
electromagnet) serves to sweep the beam in a direction
perpendicular to that of the accelerator, thereby defining the
width of the scan pass. In certain embodiments, the electron gun
can be switched on and off at precisely defined intervals (i.e. a
desired duty factor) to impart the desired irradiation to each
voxel.
[0103] In other embodiments, a more sophisticated beam bending
assembly than 672 can include evacuated beam tubes, and beam
bending magnets, with a beam extraction window, configured with
rotatable vacuum seals. In this assembly, the beam can be directed
via the beam bending magnets such that an arbitrary pattern of high
energy charged particles can be delivered from the particle
accelerator to a desired target volume.
[0104] In one such embodiment a snout 900 as illustrated in FIG. 9,
can be employed. In such an embodiment, the particle beam 710
arrives vertically in a downward direction in an evacuated beam
transport tube 905, and passes through a rotatable vacuum seal 910.
The rotatable vacuum seal 910 can include a bending magnet 915.
[0105] The bending magnet 915 bends the beam 710 into a
substantially horizontal evacuated beam tube 920 with a horizontal
orientation in reference to the evacuated beam transport tube 905.
The evacuated beam tube 920 can rotate about the axis of the
downward traveling particle beam 710. The evacuated beam tube 920
extends a given length 945 from the center of rotation of the
rotatable vacuum seal 910. This length 945 thus defines the width
of the "scan pass". Specifically, the "scan pass" is twice the
length 945 of the evacuated beam tube 920 since the evacuated beam
tube 920 length 945 is the radius of the circle through which the
evacuated beam tube 920 can be rotated. It should be understood
that the "scan pass" can include a pass, or sweep of 0-360 degrees
along beam arc 940.
[0106] Rotation of the evacuated beam tube 920 can be controlled by
control system 705, and realized with a mechanical drive 925, such
as a motor, that is configured to rotate the evacuated beam tube
920 according to signals provide by the control system 705. In
certain embodiments, the evacuated beam tube 920 can be rotated at
a constant speed. In such a case the rotational speed can be
determined according to the pulsing rate of the accelerator (i.e.
duty factor). It should be understood that the rotational speed may
be relatively slow compared to the scanning speed of other
embodiments. However, by pulsing the accelerator (duty factor) a
wide range of irradiation doses can still be achieved, with the
added advantage that the control system 705 is only required to
control duty factor, when the rotational speed is constant.
[0107] The particle beam 710 transverse the horizontal beam tube
920 and then is bent downward by a second bending magnet 930. A
target 950 can be placed at the end of the movable snout 900 that
can convert the electron beam 710 to a beam of gamma-rays, x-rays,
etc. to create the desired pattern. The beam 710 then exits via a
beam window 935 and impinges on the desired target 678.
[0108] The snout 900 can impart arbitrary patterns of beam
irradiation along a beam arc 940. Using the snout 900, a desired
pattern can be achieved via variation of the rotation angle of the
horizontal beam tube 920, and/or on-off modulation of the beam 710,
coordinated with the rotation angle. In another embodiment, the
control system 705 can further control beam delivery via modulation
of the beam 710 energy, and/or the field strength of the bending
magnet 915, and/or bending magnet 930.
[0109] For example, when the control system includes control of
beam energy, field strength of the bending magnets, on-off
modulation of the beam, horizontal angle of the beam tube, and
speed of mobile unit 669 with respect to the target volume, very
precise patterns of material 688 irradiation in the target area can
be achieved. Such patterns may be useful for manufacturing
scenarios requiring complex patterns of irradiation like radiation
induced cross-linking, medical sterilization, waste treatment, and
in situ applications utilizing a mobile accelerator.
[0110] FIG. 10 illustrates an embodiment, of a system for managing
the duty factor and/or beam location according to the speed of the
mobile unit 669. The mobile unit 669 can include one or more
position sensors 750, and/or a GPS receiver 1010.
[0111] In an embodiment, the position sensors 750 can collect
position data 1005 indicative of a location of features on the
surface over which the mobile unit 669 is passing. The beam 710
output from the accelerator 662 and RF sources 664 can be a known
distance 1015 from the sensor 750. The sensor 750 can provide data
to the control system 705, which can in turn adjust the duty factor
of the accelerator 663 according to the data collected by the
sensor 750.
[0112] In another embodiment, the location, speed, and acceleration
of the mobile unit 669 can be recorded by a GPS unit 1010. The GPS
unit can provide such data to the control system 705. In such
embodiments, the control system 705 can be prepared with a desired
structural design for the target area 678, and an irradiation dose
assigned to each voxel. Alternatively, or in addition, the position
sensor 750 can collect data as the mobile unit 669 passes over the
underlying surface, and the necessary irradiation dose can be
determined at, or near, real time. In both cases, the control
system can adjust the duty factor of the accelerator 662 according
to the data collected from the GPS unit 1010 and/or the position
sensor 750.
[0113] In general, if the mobile unit 669 is moving faster, the
duty factor of the accelerator 662 will increase in order to
sufficiently dose each voxel in less time. By contrast, if the
mobile unit 669 is moving slower, the duty factor of the
accelerator 662 can decrease in order to properly dose each voxel.
In certain cases, the speed of the mobile unit 669 can be adjusted,
instead of, or in addition to, adjustment of duty factor of the
mobile accelerator 662, in order to ensure the proper dose of
irradiation is applied to each voxel. In certain cases, a driver of
the mobile unit can be provided a real time speed target, necessary
to properly dose each voxel. In other embodiments, the speed of the
mobile unit can be controlled autonomously by the control system
705.
[0114] In yet another embodiment, the speed of the mobile unit 669
can be used to adjust the duty factor of the accelerator 662. In
such cases, the speed of the mobile unit 669 can be collected with
an onboard speedometer, or other such device. The speed of the
mobile unit 669 can be provided to the control system 705. The
control system 705 can be preloaded with a desired structural
design for the target area 678, and an irradiation dose assigned to
each voxel, and/or the position sensor 750 can collect data as the
mobile unit 669 passes over the underlying surface, and the
necessary irradiation dose for each voxel can be determined at, or
near, real time. The control system 705 can use the speed of the
mobile unit to adjust the duty factor of the accelerator so that
the requisite dose of irradiation is applied to each voxel.
[0115] In an embodiment, the systems and methods disclosed herein
can be used to render three dimensional objects. Such embodiments
can include systems and methods for additive manufacturing of
objects of varying size and shape. For example, some embodiments
can include extreme-scale additive manufacturing applied over large
swaths of terrain.
[0116] In one such embodiment, illustrated in FIG. 11 a physical
barrier 1105 can be placed around a construction location 1110. In
certain embodiments, the construction location 1110 can be
excavated or raised as necessary for the desired project.
Cross-linkable liquid 1115 can be poured into the construction
location 1110, and a mobile unit 669 can pass through or over the
construction location 1110. The mobile unit accelerator can
irradiate select locations in the construction location 1110 with
the required irradiation dose. The location and dose of each voxel
in the construction location 1110 can be defined according to a
three dimensional design provided to the control system 705.
[0117] Position sensors 1120 can be situated along the barrier,
and/or in the construction location. Additional position sensors
1125 can be provided on the mobile accelerator. It should be
appreciated that the position sensors 1120 and position sensors
1125 can comprise GPS receivers, image sensors, sonic sensors,
beacons, location sensors, or other such sensors as disclosed
herein. The sensors can be used to accurately determine the
location of the beam in the construction location 1110. The control
system 705 can use this information to control one or more of the
position of the mobile unit, the duty factor of the accelerator,
and/or the speed of the mobile unit, such that a layer of the three
dimensional design is realized.
[0118] Once a layer of the three dimensional design is complete,
the remaining cross-linkable liquid 1115 can be drained away, for
example through drain 1130, and a new layer of cross-linkable
liquid can be introduced in the construction location 1110. The
process can be repeated multiple times to build multiple layers of
a three dimensional structure, until the desired three dimensional
structure is completed.
[0119] FIG. 12 illustrates a method 1200 for fabrication of three
dimensional structures in accordance with the disclosed
embodiments. The method begins at 1205.
[0120] At 1210, a three dimensional structure can be designed.
Features may be designed from scratch using a computer system
assuming an arbitrary target surface or according to a specific
target surface. Voxels of the design may be assigned irradiation
values as well as actual 2D or 3D dimensions. The desired dose for
each voxel will be imparted to the target surface via the mobile
accelerator. At 1215, the target surface can be prepared for
fabrication. In some cases, this can include any of, excavating
some or all areas of the surface, building mounds or other terrain
features in the surface, securing a barrier around the target
surface to contain cross-linking liquid, leveling the surface,
sloping the surface, etc.
[0121] The completed build surface can be covered with (or filled
with) cross-linking material as illustrated at 1220. The mobile
unit can then traverse the build surface to selectively irradiate
locations in the build surface with the required irradiation dose.
The location and dose of each voxel of the build surface can be
defined according to the three-dimensional design provided to the
control system. The mobile unit can be driven through the build
surface by an operator, can be remotely controlled by an operator,
or can be autonomously controlled by the control system. The mobile
unit can follow a pre-defined path, a random path, a most efficient
path, or a raster type path, through the build surface. Likewise,
the accelerator's duty factor can be controlled according to the
motion of the mobile unit as detailed above. Position sensors can
be situated along the barrier, and/or in the build surface and
additional position sensors can be provided on the mobile unit. The
sensors can be used to accurately determine the location of the
mobile unit in the construction location in order to control one or
more of the position of the mobile unit, the duty factor of the
accelerator, and/or the speed of the mobile unit.
[0122] Once the mobile unit has completed a pass over and/or
through the build surface, the remaining cross-linkable liquid can
be drained away or otherwise removed from the build surface at
1230. At this point, a single layer of the desired
three-dimensional structure is complete, as illustrated by
1235.
[0123] The process can be iterated according to decision block
1240. If the structure has not been completed as indicated at 1250,
the process is repeated from step 1220 where additional
crosslinking liquid is deposited on the build site. If the desired
three dimensional structure has been completed, as shown at step
1245, the fabrication of the desired three-dimensional structure is
done, and the method ends at 1255. It should be understood that the
method 1200 can be accomplished using one or more of the systems
illustrated herein.
[0124] In an embodiment, the methods and systems disclosed herein
can be implemented in the fabrication of electrified roads.
Electrified roads provide numerous advantages for electric vehicle
technology, by providing power to a vehicle as it travels along a
roadway. In some embodiments, the electrified road can be realized
by inserting a charging rail in a conduit formed in the road. FIG.
13A illustrates an electrified roadway system 1300 in accordance
with the disclosed embodiments. As illustrated, a channel 1305 is
cut in a roadway 1310. A conduit 1315 can be inserted in the
channel, and an electric rail 1320 is installed in the conduit
1315. The electric rail can be connected to an external power
source 1335, such as solar collectors, wind generators, batteries,
the existing power grid, a power plant, etc. An electric vehicle
1325 can be equipped with a coupler 1330 that contacts the electric
rail 1320, and draws a charge, such that batteries and/or the motor
associated with the electric vehicle 1325 receives power.
[0125] FIG. 13B illustrates a method 1350 for constructing an
electrified road in accordance with the embodiments disclosed
herein. The method begins at 1355. At 1360, a channel can be formed
in a roadway. In some cases, this can comprise forming a new
roadway, with a channel therein, or can comprise removing material
from an existing roadway to form the channel. At 1365, an electric
rail and conduit assembly can be installed in the channel. Voids
surrounding the electric rail and conduit assembly can next be
filled at step 1370. The void can be filled with cross-linkable
material, as described herein.
[0126] At step 1375, the cross-linkable material can be irradiated
according to the methods and systems disclosed herein. It is
important to note that this step can include a "tagging" process.
The tagging process includes irradiating cross-linkable material,
while strictly avoiding any irradiation of the electric rail and
conduit assembly. This can include identifying the electric rail
and conduit assembly based on characteristics such as, reflectivity
of the rail, color of the rail, etc. Tagging can include either an
instruction to irradiate the subject voxel element (because it has
been identified as cross-linkable material) provided by the control
system, or an instruction not to irradiate the subject voxel
element (because it is a part of the electric rail and conduit
assembly) provided by the control system. Tagging can thus include
using sensors to identify the rail assembly. When the rail assembly
is identified, the control system associated with the accelerator
can adjust one or both of the duty cycle of the accelerator and the
location of the accelerator beam, to ensure the cross-linkable
material is irradiated but the electric rail and conduit assembly
is not. The method ends at 1380.
[0127] Treatment, according to the method 1350, of the material
surrounding the electric rail and conduit assembly makes the
electrified roadway more resilient. This is important because it is
more expensive to construct sections of electrified roadways than
typical roadways. Thus, extending the life of electrified roadways,
even by relatively short amounts of time, yields significant cost
savings for the roadway lifecycle.
[0128] In another embodiment, the electric roadway can be
constructed using induction coils embedded in the roadway. FIG. 14A
illustrates an inductive charging roadway system 1400 in accordance
with the disclosed embodiments. The inductive charging roadway
system 1400 includes one or more inductive coils 1405 embedded in,
and buried completely (or partially) beneath the road surface 1410
in a void 1430. The inductive coil(s) 1405 can be connected to an
external power source 1415, such as solar collectors, wind
generators, batteries, the existing power grid, a power plant,
etc.
[0129] Inductive electric vehicle 1420 traveling along the road can
include one or more inductive coils 1425. The induced
electromagnetic field created by the inductive coil(s) 1405 induces
a current in the inductive coil 1425, as the electric vehicle 1420
passes. The induced current can be used to charge batteries and/or
provide current to the motor associated with the inductive electric
vehicle 1420.
[0130] In order to integrate the inductive coil in the pavement,
the surrounding material must be of a low-viscosity, in order to
flow around the coil's complex form. Method 1450 illustrated in
FIG. 14B provides a process for forming an inductive charging
roadway. The method begins at 1455.
[0131] At 1460, at least one void can be formed in a roadway. In
some cases, this can comprise forming a new roadway, with a void
therein. In other cases, this can comprise removing material from
an existing roadway to form the void. At 1465, an induction coil
can be installed in the void, and the induction coil can be
connected to a power source.
[0132] Cross-linkable material can next be used to fill the void at
1470. The cross-linkable material should be of a viscosity that
allows it to flow around, and cover, the induction coil form
factor. Thus, the cross-linkable material can be selected to have a
relatively low viscosity so that the completed fill is durable
while still conforming closely to the coil's shape. At step 1475,
the cross-linkable material can be irradiated according to the
methods and systems disclosed herein so that the roadway is
completed and smooth. The method ends at 1480.
[0133] Many other implementation and configurations are envisioned.
For example, the systems and methods disclosed herein can be
applied to create functional features in a surface (e.g. increase
lateral stiffness, control directional friction, repair damage, or
increase draining efficiency). Cracks of arbitrary shape can be
targeted, melted and re-rolled. Tiles of pre-formed pavement may be
placed and crosslinked together with treatment directed toward the
tile interfaces. Grooves can be formed in roads to create musical
roads, warning tones, and more descriptive tones that communicate
road conditions and locations via electronic interpretation of said
tones aboard the vehicle. In other embodiments, extreme-scale
additive manufacturing can also be achieved over large swaths of
terrain.
[0134] Based on the foregoing, it can be appreciated that a number
of embodiments, preferred and alternative, are disclosed herein. It
should be appreciated that variations of the above-disclosed and
other features and functions, or alternatives thereof, may be
desirably combined into many other different systems or
applications. In an embodiment, a fabrication method comprises
defining a desired pattern for imparting on a target area, mapping
the target area, defining at least one discrete voxel in the target
area, according to the desired pattern to be imparted on the target
area, assigning an irradiation value to each of the at least one
discrete voxels, and delivering a dose of irradiation to each of
the at least one discrete voxels according to the assigned
irradiation value.
[0135] In an embodiment, the method further comprises delivering
the dose of irradiation with an accelerator. In an embodiment the
method comprises adjusting a duty factor of the accelerator
according to the assigned irradiation value for each of the at
least one discrete voxels.
[0136] In an embodiment delivering the dose of irradiation further
comprises at least one of: directing an electron beam accelerator
mounted to a vehicle through the target area, and sweeping an
electron beam over the target area. The method further comprises
directing the vehicle in a predefined path, wherein the predefined
path is selected according to the desired pattern for imparting on
the target area. In an embodiment the method further comprises
determining a position of the vehicle in the target area with at
least one sensor. In an embodiment the method further comprises
depositing a cross-linking material in the target area.
[0137] In an embodiment the accelerator comprises an electron beam
accelerator mounted to a vehicle
[0138] In an embodiment the target area is at least one of:
two-dimensional, and three-dimensional.
[0139] In another embodiment the method further comprises
iteratively creating a plurality of layers, the plurality of layers
forming a three-dimensional structure.
[0140] In an embodiment a fabrication system comprises a mobile
accelerator system, and a control system configured for: defining a
desired pattern for imparting on a target area, mapping the target
area defining at least one discrete voxel in the target area,
according to the desired pattern to be imparted on the target area,
and assigning an irradiation value to each of the at least one
discrete voxels; wherein the mobile accelerator system delivers a
dose of irradiation to each of the at least one discrete voxels
according to the assigned irradiation value.
[0141] In an embodiment the mobile accelerator system further
comprises a mobile unit, an accelerator, and a beam bending
assembly, the beam bending assembly adjusting a terminal position
of a beam provided by the accelerator.
[0142] In an embodiment the beam bending assembly comprises at
least one beam bending magnet. In an embodiment the beam bending
assembly comprises a beam bending snout. In an embodiment the beam
bending assembly is configured to direct an electron beam from the
accelerator through the target area.
[0143] In an embodiment the system further comprises a vehicle for
moving the mobile accelerator system in a predefined path, the
predefined path selected according to the desired pattern for
imparting on the target area. The system can further comprise at
least one position sensor configured for determining a position of
the mobile accelerator assembly in the target area.
[0144] In another embodiment a fabrication method comprises
designing a structure, defining at least one discrete voxel in the
structure, assigning an irradiation value to each of the at least
one discrete voxels, covering a build surface with material, and
delivering a dose of irradiation to each of the at least one
discrete voxels according to the assigned irradiation value.
[0145] In an embodiment the method further comprises preparing the
build surface for fabrication. In an embodiment the method further
comprises iteratively creating a plurality of layers associated
with the structure.
[0146] It should be understood that various presently unforeseen or
unanticipated alternatives, modifications, variations or
improvements therein may be subsequently made by those skilled in
the art which are also intended to be encompassed by the following
claims.
* * * * *