Method and apparatus for forming a stable stream of plasticized solid feed material

Abstract

An apparatus for forming a stable stream of plasticized solid feed material, the apparatus comprising an in-cylinder piston ram for compacting a comminuted solid feed material to form a solid billet of plasticized solid feed material in a cylinder and extruding at least a portion of the solid billet from an outlet end of the cylinder, a transfer path in communication with the outlet end of the cylinder, a heater associated with at least a portion of the transfer path to plasticize and heat the plasticized solid feed material to a temperature to form a plasticized solid feed material.

Description

Technical Field

[0001] This invention relates generally to methods and apparatus for processing granular solid materials to form plasticized solid feed materials. It also relates to methods and apparatus for forming plasticized solid feed materials from food products, particularly confectionery products, and the products obtained therefrom. Background Technology

[0002] It is also known to provide 3D printing of food such as confectionery. For example, US2012 / 0251688 provides a 3D printer for 3D printing chocolate, wherein the device includes a reservoir configured to shear and heat chocolate material to provide flowable chocolate, a pump configured to pump flowable chocolate material from the reservoir, and a print head configured to receive the pumped flowable chocolate material and extrude a portion of the pumped flowable chocolate material to form a three-dimensional solid object.

[0003] Similarly, US2017 / 0259482 describes an apparatus and process for 3D printing chocolate, which includes a printer barrel having a barrel body for containing chocolate printing material, an extruder having a nozzle, and a pneumatic system for enabling pressurized air to push the printing material from the printer barrel to the extruder.

[0004] Therefore, known 3D chocolate and confectionery extruders typically utilize a barrel or container for molten and / or tempered chocolate, which is then forced under pressure through an extrusion die head that serves as the printhead. In such equipment, it can be difficult to control the system or the pressure within the equipment, and the use of a barrel or container means that batch processing is usually performed rather than continuous processing.

[0005] Similarly, European Patent No. EP3902405 discloses a 3D printing apparatus comprising at least one printhead, a supply system for continuously supplying at least one type of printing material to the printhead in a flowable state, and at least one pressure regulating device for adjusting the back pressure of the printhead on the printhead. The supply system may include at least one supply path, and in this patent application, it includes at least one screw-type pump (or rotor-type pump).

[0006] Current 3D printing processes use liquid tempered chocolate to fill barrels, which are then cooled and stored to crystallize before use in a 3D printer. This invention eliminates this process step by using a stable, room-temperature solid (crystallized) chocolate stream as direct feed to the 3D printer or to fill the 3D printing barrel.

[0007] Therefore, it is advantageous to provide 3D printing equipment and methods suitable for 3D printing chocolate and other confectionery, wherein a continuous process is possible, which can be modified in situ, and wherein changes in material flow, volume and consistency can be accommodated without halting or adversely affecting the 3D printing process.

[0008] Another advantage is the availability of 3D printing equipment specifically for confectionery and chocolate, where chocolate extrusion can be performed using solid raw materials such as chocolate flakes or powder, and the extrusion can be performed continuously regardless of changes in the volume, flow rate, or consistency of the chocolate material.

[0009] Therefore, the purpose of the embodiments of the present invention is to overcome or mitigate at least one problem of the prior art. Summary of the Invention

[0010] According to a first aspect of the present invention, an apparatus for forming a stable flow of plasticized solid feed material is provided, the apparatus comprising:

[0011] a. A piston-pressing section inside a cylinder, the piston-pressing section inside a cylinder being used to compact and crush solid feed material to form a solid blank of feed material in the cylinder, and to extrude at least a portion of the solid blank from the outlet end of the cylinder;

[0012] b. Transfer path, which is connected to the outlet end of the cylinder;

[0013] c. A heater associated with at least a portion of the transfer path to plasticize the feed material and heat it to a certain temperature to form a plasticized solid feed material.

[0014] According to a second aspect of the present invention, a method for forming a stable flow of plasticized solid feed material is provided, the method comprising the following steps:

[0015] a. Introduce the fragmented solid feed material into the piston stamping section inside the cylinder;

[0016] b. Compact the fragmented feed material to form a solid blank of the feed material in the cylinder;

[0017] c. Extruding at least a portion of the solid blank from the outlet end of the cylinder into a transfer path connected to the outlet end of the cylinder;

[0018] d. The feed material is heated in at least a portion of the transfer path to plasticize it, and the feed material is heated to a certain temperature to form a plasticized solid feed material.

[0019] An apparatus and method are provided for processing granular solid materials to form said plasticized solid feed material. A solid preform is formed in a cylinder, and then the solid preform material is extruded into a conduit heated to a certain temperature to form a direct feed for plasticized solid feed (crystallized) chocolate, for use in a 3D printer or loaded into a barrel used by a 3D printer. Crystallized chocolate is formed by tempering, causing the cocoa butter in the chocolate to present in a stable crystalline form. Properly crystallized chocolate has desired textural characteristics, such as a good "crisp" texture and mouthfeel, a glossy appearance, and melt resistance. Products formed using undercrystallized chocolate have a grayish chocolate shell, dark spots, and melt upon contact. Furthermore, molded chocolates and hollow shapes formed using undercrystallized chocolate will harden very slowly, are difficult to demold, and have a suboptimal appearance.

[0020] While the invention may be described more specifically with reference to the formation of plasticized solid feed materials in 3D printing or molding processes, particularly food materials such as chocolate, plasticized solid feed materials can be used in a wider range of molding processes, such as in extrusion, to deposit “reshaped” chocolate or other feed materials onto a shaped strip or mold, or to co-extrude them with, for example, fillers, depending on the type of material used.

[0021] The feed material may include any material that is in a solid state, preferably in a granular solid state, at ambient temperature (e.g., room temperature), which may be heated to plasticize but still remain in a solid state.

[0022] Each or every feed material may include polymeric materials, elastomeric materials, plastic materials, ductile materials, or food materials. In a preferred embodiment, the feed material is a food material, more preferably a confectionery material. In a particularly preferred embodiment, the confectionery material is chocolate, such as milk chocolate, dark chocolate, white chocolate, or compound chocolate.

[0023] The equipment preferably forms a stable flow of plasticized solid feed material that exits the transfer path. The piston stamping section inside the cylinder first forms a solid compressed blank in the cylinder, and then plasticizes the material while it is being conveyed through the transfer path.

[0024] The definition of plasticized solid feed material is important. It is the form of plasticized solid feed material used in another downstream process (in contrast to "feed material" which is fed into the process to form plasticized solid feed material). The feed material entering the process / equipment will preferably be solid, and may be granular solid. Importantly, the feed material leaving the process / equipment is solid, but softened or plasticized to allow forced flow through the transfer path. Preferably, the plasticized solid feed material will not flow once the driving force applied by the piston stamping section in the cylinder is removed. The plasticized solid material within the piston stamping section in the cylinder is not liquid and preferably does not flow under the influence of gravity. To achieve this state of the plasticized solid feed material, the temperature of the plasticized solid feed material should be maintained below the melting temperature of the feed material. For example, for chocolate feed material (although depending on the composition of the chocolate), this temperature is typically between 23°C and 35°C, preferably about 29°C. Preferably, the temperature of the feed material at the outlet of the transfer path is about 29°C, as this would be preferable for plasticized solid feed materials. Preferably, the temperature of the plasticized solid feed material remains below 30°C throughout the process. The chocolate is preferably not melted at any stage, but rather plasticized, softened, or otherwise heated so that it can be transported throughout the process and used in subsequent processes.

[0025] The device includes an in-cylinder piston pressing section for compacting and crushing feed material to form a solid blank of feed material in the cylinder, and for extruding at least a portion of the solid blank from the outlet end of the cylinder.

[0026] The fragmented feed material can be fed into the piston stamping section inside the cylinder. The fragmented feed material can have a size between 1 mm and 5 mm. During the feeding of the piston stamping section into the cylinder, there is usually a size distribution of fragmented feed material.

[0027] The feed material can be flakes, lumps, "buttons," granules, etc. The feed material can be provided in large sizes and can be broken down or otherwise reduced in size to feed into the piston stamping section inside the cylinder.

[0028] A cylinder filling hopper or similar device can be provided to collect the shredded feed material and guide it into the upper end of the piston stamping section within the cylinder. In one embodiment, the shredded feed material can be gravity-fed into the upper end of the piston stamping section within the cylinder. Agitation can be provided to assist in filling the piston stamping section within the cylinder. The hopper and / or the piston stamping section within the cylinder can be agitated to assist in filling.

[0029] The piston in the piston stamping section inside the cylinder will preferably reciprocate. The piston will preferably move in a substantially vertical direction.

[0030] The piston stamping section inside the cylinder can be located at the lower end of the cylinder filling hopper. The piston of the piston stamping section inside the cylinder can extend through the outlet opening of the cylinder filling hopper. This helps to press the fragmented feed material into the upper end of the piston stamping section inside the cylinder.

[0031] The lower end of the piston will preferably clear the upper end of the outlet opening of the cylinder filling hopper at the top of the piston's upper stroke. This allows more fragmented feed material to enter the upper part of the cylinder, preferably assisted by gravity and / or agitation.

[0032] During the downward stroke of the piston, the fragmented feed material is initially compacted in the upper portion of the cylinder. This initial compaction preferably allows most of the air to escape from around the piston into the cylinder. Further downward movement of the piston within the cylinder is then preferably used to compress the compacted, fragmented feed material to form a solid billet of feed material in the lower portion of the cylinder. The lower end of the cylinder is preferably converging, leading to the cylinder outlet, to assist in the formation of the billet in the lower portion of the cylinder. The billet is preferably a solid mass of compressed material.

[0033] The blank can always remain in the lower part of the cylinder, meaning the piston never reaches the cylinder outlet, thus retaining the "blank" of material within the cylinder. Alternatively, the piston can expel all the blank before returning to its upper stroke to refill. This alternative is less preferred because it may cause air to remain trapped in the cylinder and / or within the blank itself.

[0034] The cylinder is preferably relatively small in diameter to minimize the force required to compress the material into a blank. The preferred inner diameter of the cylinder is between 15 mm and 500 mm. For relatively small-scale implementations, an inner diameter of approximately 20 mm is preferred.

[0035] An air gap can be provided between the outer cylindrical surface of the piston and the inner cylindrical surface of the cylinder. This air gap allows air within the fragmented feed material to escape during compaction and / or compression. The air gap can be approximately 0.1 mm. For example, the inner diameter of the cylinder can be 22.5 mm, and the outer diameter of the piston can be 22.3 mm.

[0036] The piston speed is preferably relatively slow during the lower stroke. The lower stroke speed can be lower than the upper stroke speed. A lower stroke speed between 1 mm / s and 5 mm / s is preferred, with approximately 1.5 mm / s being particularly preferred.

[0037] The piston may have a flattened or shaped tip. A convex tip may be preferred.

[0038] The compaction and / or compression of the fragmented feed material in the cylinder can increase the temperature of the material in the cylinder. As mentioned above, it is important that the material temperature remain relatively low. The temperature of the cylinder can be controlled to control the temperature of the material in the cylinder. Cooling can be provided. Cooling mechanisms can be provided around the cylinder or a portion thereof, particularly around the lower portion where the compression of the fragmented feed material preferably occurs. Compression in the lower portion of the cylinder can at least begin to plasticize the feed material in the billet within the lower portion of the cylinder.

[0039] Cooling can be provided immediately after the cylinder outlet. Cooling can be provided relative to a portion of the transfer path immediately after the cylinder outlet. Preferably, cooling can be provided between the cylinder outlet and the heater. Any cooling method can be used, such as a fan or a cooling jacket. Any cooling can preferably act circumferentially around a portion of the transfer path. In this case, a material temperature of about 15°C and 20°C may be preferred.

[0040] The length of the cylinder can be between 100mm and 500mm. For a benchtop example, the cylinder length can be between 100mm and 150mm, and most preferably about 125mm. The length should be long enough to allow the fragmented feed material to be initially compacted in the upper portion of the cylinder and then compressed into a billet in the lower portion of the cylinder. If the billet is too large in the cylinder, the force required to move it will increase, but it is equally important that the billet is formed in the cylinder and that a portion of the billet is retained in the lower portion of the cylinder to minimize undesirable air in the transfer path for consistent product.

[0041] A cylinder with a height of approximately 125 mm allows for a compaction height of approximately 60 mm to 65 mm and a compression height (bulk height) of approximately 60 mm to 65 mm. When the cylinder size is changed, the ratio of compaction height to compression height can remain similar or the same, approximately 1:1.

[0042] The device also includes a transfer path that communicates with the outlet end of the cylinder. The transfer path can be an elongated conduit. The length of the transfer path is important because it should be long enough to allow heating of the blank (e.g., to allow chocolate feed material to reach a plasticized state), but not too long, as the length of the transfer path will increase friction within it, which in turn will require a greater force from the piston stamping section inside the cylinder to drive the blank through the transfer path.

[0043] The piston stamping section inside the cylinder is also preferably used to drive at least a portion of the blank through the transfer path.

[0044] A slower temperature rise in the billet is preferable to a faster temperature rise. A slower temperature rise in the billet is preferably more controllable. Therefore, the length of the transfer path is preferably optimized to heat the billet to a preferred temperature, and then maintain the temperature of the billet at that temperature for the remaining length of the transfer path.

[0045] The transfer path can be a conduit with a substantially circular cross-section. The conduit will preferably have a suitably small inner diameter to minimize any interfacial layer effects. This allows the billet to be heated as it travels through the conduit and to be fully plasticized over its entire thickness.

[0046] The length and inner diameter of the conduit will be relevant parameters. For example, a conduit with an inner diameter between 2 mm and 10 mm is preferred, and more preferably, an inner diameter of about 4 mm to 5 mm. When the inner diameter is about 4 mm to 5 mm, the length of the conduit will preferably be between 500 mm and 1000 mm, more preferably between 700 mm and 900 mm, and most preferably between 800 mm and 830 mm. This provides sufficient length to heat the billet in the conduit to plasticize it, while allowing the use of a heater that keeps the material at a sufficiently low temperature so as not to melt the billet. Similar proportions can be used when the conduit is larger.

[0047] The transfer path conduit can be rigid rather than flexible, as long as the billet can move through the conduit under the action of force, but it is not a liquid.

[0048] The conduit can be shaped. A meandering or coiled configuration is preferred. This configuration can also induce axial and / or circumferential mixing of the billet within the conduit as it travels through the conduit, rather than piston flow. This can be used to mix the billet as it travels through the conduit, expose all portions of the billet to heat, and promote flow under force without melting.

[0049] The device also includes a heater associated with a portion of the transfer path to plasticize the feed material and heat it to a certain temperature to form a plasticized solid feed material.

[0050] The heater may be provided relative to a large portion of the transfer path length. Preferably, the heater is provided relative to at least half and, more preferably, at least three-quarters of the length of the transfer path.

[0051] Any type of heater can be used. One or more heaters can be provided. Different heaters can be provided in different sections of the transfer path length. Preferably, all sides of the transfer path conduit are heated equally.

[0052] The heater may be or include a sheath heater and / or a bath heater. In one embodiment, a bath heater may be provided over a portion of the length of the transfer path conduit, and a sheath heater over another portion of the length of the transfer path conduit. The bath heater may be provided closer to the outlet end of the piston stamping section within the cylinder, and the sheath heater is provided after the bath heater.

[0053] The temperature of the billet in the transfer path is important because a higher temperature is preferably required to plasticize the billet to allow it to flow under force, but the temperature is preferably low enough to prevent melting. The temperature of the billet in the conduit will generally depend on several parameters, but will preferably be between 23°C and 35°C, more preferably about 30°C, and most preferably between 28°C and 32°C. For example, processing the billet at this temperature will preferably plasticize but not melt chocolate billets.

[0054] This device can be used in conjunction with a 3D printing device that includes at least one printhead.

[0055] The transfer path can provide plasticized solid feed material to at least one supply path for use in a 3D printing apparatus. In some embodiments, there may be at least two, three, four, five, six, seven, eight, nine, or at least ten supply paths. In a preferred embodiment, a single supply path may be provided.

[0056] Each or every printhead may include an additional in-cylinder piston stamping section. The provision of the additional in-cylinder piston stamping section associated with each or every printhead can assist in the consistent ejection of plasticized solid printing material. Each or every printhead may include a nozzle at its distal end. The presence of the nozzle helps control the thickness of the printing material and / or guides the flow of the printing material as it exits the printhead.

[0057] In this implementation, the plasticized solid feed material is continuously supplied to the printhead or each printhead, and can be extruded from the printhead or each printhead at any desired rate by adjusting the feed at the feed end of the device. Therefore, if a separate feed device is provided, the rate of extrusion from each printhead can be controlled individually.

[0058] Each supply path may include a single printhead, or may include at least 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45 or at least 50 printheads and / or no more than 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45 or no more than 50 printheads.

[0059] At least one printhead in the supply path may be disposed in at least one printing module. In some embodiments, the supply path may include at least one, two, three, four, five, six, seven, eight, nine, or at least ten printing modules. Each printing module may include at least one, two, three, four, five, six, seven, eight, nine, or at least ten printheads. In some embodiments, each printing module may include between three and seven printheads, such as five printheads.

[0060] This device can be used to fill fillable or refillable cartridges. The fillable or refillable cartridge can function similarly to a syringe. The fillable or refillable cartridge may include an elongated hollow cylinder, an outlet at one end of the cylinder, and a movable plunger located within the cylinder. This movable plunger is used to move toward the outlet to expel material from the cylinder and to move away from the outlet to allow filling of the cylinder.

[0061] The container can be made of any material, but for containers used to transport food materials, it is preferably made of metal, with food-grade stainless steel or similar materials being preferred. The container can have any suitable volume, but preferably at least 50 ml.

[0062] The discharge port of the barrel may have an attachment structure provided to allow the barrel to be releasably attached to the 3D printer. Threads may be preferred. One or more structures, such as a matrix or similar structures, may be provided to allow the use of tools to engage the discharge port.

[0063] The plunger can be made of any material, but for food materials, it can be metal, with food-grade stainless steel or similar materials being preferred, or food-grade plastic. One or more scraper seals may be provided between the plunger and the barrel. The outer side or portion of the plunger may include one or more abutment portions, such as a base, to allow the printer to apply force to the plunger, forcing it to move, typically toward the discharge port, to expel material.

[0064] When the barrel is being filled, it can be oriented vertically or horizontally. During filling, the top of the barrel can be at the top or bottom. The barrel can be installed from the top during filling. During filling, the barrel can be attached relative to an indexing mechanism to allow loading of multiple barrels to be filled. Rotary or linear indexing mechanisms can be used.

[0065] One method of filling the barrel is to fill it from the top, and as the barrel is filled, the plunger is forced in the opposite direction.

[0066] The additional cylinder piston stamping section can be used to inject material leaving the transfer path conduit into the barrel.

[0067] The barrel can be heated during the filling process to keep the material in a plasticized form during filling. While any type of heater can be used, a jacketed heater may be preferred. In use, the jacketed heater can extend around the barrel body during filling. The jacketed heater can be separate or provided in more than one section to allow these sections to be separated for loading and unloading the barrel. These sections may be hinged relative to each other.

[0068] Preferably, a coupling joint is provided between the outlet of the transfer path and the top of the barrel. A dry-disconnect coupling joint is preferred because it minimizes or prevents material leakage or loss when the barrel is disconnected.

[0069] During filling, back pressure or counter-pressure can be applied to the plunger of the barrel to prevent air from accumulating in the barrel. A back pressure between 1 bar and 5 bar is preferred, and a back pressure of about 2 bar is particularly preferred.

[0070] In one aspect of the invention, a method is provided for filling a cartridge with a plasticized solid feed material, the cartridge comprising an elongated hollow cartridge, a discharge port at one end of the cartridge body, and a hollow movable plunger located within the cartridge body, the hollow movable plunger being configured to move toward the discharge port to discharge material from the cartridge body and to move away from the discharge port to allow filling of the cartridge body. The method includes the following steps:

[0071] The plunger that couples with the cylinder relative to the piston stamping section inside the cylinder;

[0072] Force the plasticized solid feed material through the top to at least partially fill the cylinder; and

[0073] During filling, counterpressure is applied to the plunger of the barrel to prevent air from accumulating in the barrel. Detailed Implementation

[0074] To provide a clearer understanding of the present invention, one or more embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which:

[0075] Figure 1 This is a schematic diagram of an apparatus for feeding material into a 3D printer, which includes a barrel for feeding plasticized solid material.

[0076] Figure 2 This is a schematic diagram of an implementation plan for the equipment.

[0077] Figure 3 This is an isometric view of an embodiment of an apparatus for forming a barrel and filling the barrel with a plasticized solid feed material.

[0078] Figure 4 This is a cross-sectional side view of the barrel in one implementation scheme.

[0079] Figure 5 This is a schematic cross-sectional view of multiple barrels in a partially filled configuration.

[0080] exist Figures 1 to 3 The illustrated embodiment shows an apparatus 10 for forming a stable flow of plasticized solid feed material. The illustrated apparatus 10 includes an in-cylinder piston stamping section 11 for compacting the fragmented feed material to form a solid preform 12 of the feed material in a cylinder 13, and extruding at least a portion of the solid preform 12 from the outlet end of the cylinder 13. An elongated transfer path conduit 14 is provided in communication with the outlet end of the cylinder 13. A hot bath 15 is associated with at least a portion of the transfer path conduit 14 to plasticize the feed material and heat it to a certain temperature to form a feed of plasticized solid feed material.

[0081] Figures 1 to 3 The illustrated apparatus forms a stable stream of plasticized solid confectionery material (chocolate, such as milk chocolate, dark chocolate, white chocolate, or compound chocolate) as feed material, exiting the transfer path conduit 14. The piston stamping section 11 inside the cylinder first forms a solid compressed blank 12 in the cylinder 13, and then plasticizes the material while it is being conveyed through the transfer path conduit 14.

[0082] For the chocolate feed material (although depending on the chocolate's composition), the processing temperature of the preform in the transfer path conduit 14 is preferably about 29°C. It is preferable that the feed material temperature at the outlet of the transfer path conduit 14 is about 29°C, as this would be preferred for the plasticized solid feed material. Preferably, the temperature of the plasticized solid feed material remains below 30°C throughout the process. The chocolate then does not melt at any stage, but is plasticized, softened, or otherwise heated to achieve plasticization.

[0083] The fragmented solid feed material is fed into the piston stamping section 11 inside the cylinder. The fragmented feed material may have a size between 1 mm and 4 mm. During the feeding into the piston stamping section 11 inside the cylinder, there is usually a size distribution of the fragmented feed material.

[0084] The feed material can be flakes, lumps, "buttons," granules, etc. The feed material can be provided in large sizes and can be broken down or otherwise reduced in size to feed into the piston stamping section inside the cylinder.

[0085] like Figure 1As illustrated, a shredder 18 driven by a motor 21 is provided above the collection hopper 19. This shredder shreds the feed material and provides the shredded feed material to a laterally extending guide tray 20, which extends above the cylinder-filled hopper 17. The guide tray is associated with a mechanical agitator 22 to agitate the shredded feed material, causing it to move along the guide tray and over the cylinder-filled hopper 17.

[0086] exist Figure 1 and Figure 3 In the illustrated embodiment, the cylinder filling hopper 17 collects the fragmented feed material and guides it into the upper end of the piston stamping section 11 within the cylinder. In the illustrated embodiment, the fragmented feed material is gravity-fed into the upper end of the piston stamping section 11 within the cylinder. An agitator 23 is associated with the cylinder filling hopper 17 to assist in the filling of the piston stamping section 11 within the cylinder. Figure 3 In the middle, the crusher 18 is fed from the feed hopper 50.

[0087] The piston 16 in the piston stamping section 11 inside the cylinder will reciprocate during use. In the illustrated embodiment, the piston 16 reciprocates in a substantially vertical direction.

[0088] like Figure 1 As shown, cylinder 13 is located at the lower end of cylinder filling hopper 17. The piston 16 of the piston stamping part 11 inside the cylinder extends through the lower outlet opening of cylinder filling hopper 17.

[0089] like Figure 1 As shown, the lower end of piston 16 cleans the upper end of the outlet opening of cylinder filling hopper 17 at the top of the upper stroke of piston 16. This allows the fragmented feed material to enter the upper part of cylinder 13, preferably assisted by gravity and / or agitation.

[0090] like Figure 2 As shown, during the downward stroke of piston 16, the fragmented feed material is initially compacted at the upper portion 23 of cylinder 13. This initial compaction allows most of the air to escape from around piston 16 into cylinder 13. Further downward movement of piston 16 within cylinder 13 is then preferably used to compress the compacted, fragmented feed material to form a solid billet 12 of the feed material at the lower portion 24 of cylinder 13. The lower end of cylinder 13 is preferably converging, leading to the outlet of cylinder 13, to assist in the formation of the billet 12 in the lower portion of cylinder 13. At this stage, the billet 12 is preferably a solid mass of compressed feed material.

[0091] The blank 12 can always be present in the lower part 24 of the cylinder 13, that is, the piston 16 will never be inserted into the cylinder 13 far enough to reach the outlet end of the cylinder 13, so that the "blank" of the material is retained in the cylinder 13.

[0092] The cylinder 13 is preferably relatively small in diameter to minimize the force required to compress the material into the blank 12. As illustrated, the inner diameter of the cylinder is approximately 20 mm.

[0093] An air gap is provided between the outer cylindrical surface of piston 16 and the inner cylindrical surface of cylinder 13. This air gap allows air within the fragmented feed material to escape during compaction and / or compression. The air gap can be approximately 0.1 mm. In the illustrated embodiment, the inner diameter of the cylinder is 22.5 mm, and the outer diameter of the piston is 22.3 mm.

[0094] The piston speed is preferably relatively slow during the lower stroke. The speed during the lower stroke can be lower than the speed during the upper stroke. A lower stroke speed of approximately 1.5 mm / s is particularly preferred.

[0095] The compaction and / or compression of the fragmented feed material in the cylinder can increase the temperature of the material in cylinder 13. As mentioned above, it is important that the temperature of the material is kept relatively low.

[0096] In the illustrated embodiment, cooling 25 is provided immediately following the outlet of cylinder 13. Any cooling method can be used, for example, such as... Figure 1 The fan 25 shown blows air or as shown Figure 3 The cooling jacket 26 is shown. Any cooling can preferably act circumferentially around a portion of the transfer path. In this case, a material temperature of about 15°C to 20°C is preferred.

[0097] The illustrated embodiment has a cylinder 13 with a length of approximately 125 mm. This length is sufficient to allow the fragmented feed material to be initially compacted at the upper portion 23 of the cylinder 13 and then compressed into a billet 12 at the lower portion 24 of the cylinder 13. If the billet 12 were too large in the cylinder 13, the force required to move it would increase; however, it is equally important that the billet 12 is formed in the cylinder 13, and that a portion of the billet 12 is retained at the lower portion 24 of the cylinder 13, to minimize undesirable air in the transfer path duct 14 for consistent product.

[0098] Figure 2 The height of the cylinder 13 shown is approximately 125 mm, allowing for a compaction height of approximately 60 mm to 65 mm and a compression height (bill height) of approximately 60 mm to 65 mm.

[0099] As shown in the figure, the transfer path is an elongated conduit 14. The length of the transfer path conduit 14 is important because it should be long enough to allow heating of the blank 12 (e.g., to allow chocolate feed material to plasticize without tempering / decrystallizing the material), but it cannot be too long because the length of the transfer path conduit 14 will increase the friction within the transfer path conduit 14, which in turn will require a greater force from the piston stamping section 11 inside the cylinder to drive at least a portion of the blank 12 through the transfer path conduit 14.

[0100] The piston stamping section 11 inside the cylinder is used to compress the feed material and also drives the blank 12 through the transfer path conduit 14.

[0101] The billet 12 is heated in the transfer path conduit 14. A slower temperature rise in the billet 12 is preferred over a faster temperature rise. The slower temperature rise in the billet 12 is preferably more controllable. Therefore, the length of the transfer path conduit 14 is preferably optimized to heat the billet 12 to a preferred temperature, and then maintain the temperature of the billet 12 at that temperature for the remaining length of the transfer path conduit 14.

[0102] The transfer path conduit 14 of the illustrated embodiment has a substantially circular cross-section. Conduit 14 will preferably have a suitably small inner diameter to minimize any interfacial layer effects. This allows the billet 12 to be heated and fully plasticized across its entire thickness as it travels through the conduit.

[0103] The length and inner diameter of the conduit 14 will be relevant parameters. The inner diameter of the illustrated conduit 14 is approximately 4mm-5mm. When the inner diameter is approximately 4mm-5mm, the length of the conduit 14 is preferably between 800mm-830mm. This provides sufficient length to heat the billet 12 within the conduit to plasticize it, while allowing the use of a heater that maintains the material at a sufficiently low temperature so as not to melt the billet 12.

[0104] The illustrated transfer pathway conduit 14 is rigid.

[0105] like Figure 2 As shown, the conduit 14 has a meandering or coiled configuration. This can be used to mix the billet 12 as it travels through the conduit 14, expose all portions of the billet 12 to heat, and promote flow under force without melting.

[0106] like Figures 1 to 3 As shown in each of the embodiments in the figures, the heater is provided relative to at least half, and preferably at least three-quarters, of the length of the transfer path. Preferably, all sides of the transfer path conduit 14 are heated equally.

[0107] Figure 1 The heater in the middle is a sheathed heater 25. Figure 2 and Figure 3 A bath heater 15 is provided over a portion of the length of the transfer path conduit 14. Figure 3 In the middle, after the bath heater 15, a sheath heater 28 is provided over another portion of the length of the transfer path conduit 14.

[0108] The temperature of the blank 12 in the transfer path conduit 14 is important because a higher temperature is needed to plasticize the blank 12 to allow it to flow under force, but the temperature should preferably be kept low enough to prevent melting, reheating, or over-softening. The temperature of the blank 12 in the conduit will generally depend on several parameters, but will preferably be between 29°C and 30°C. For example, processing the blank 12 at this temperature will preferably plasticize but not melt the chocolate blank 12.

[0109] like Figure 1 As shown, device 10 can be used in conjunction with a 3D printing device that includes at least one printhead.

[0110] like Figure 1 As illustrated, each is provided with a pair of cartridges 29 relative to the printing platform. Each cartridge is associated with a supply path at its lower end, which connects to a cartridge outlet leading to two print nozzles 30. Each print nozzle 30 has an associated print cylinder 31 to help ensure consistent feeding of printing material from the cartridge to the print nozzle 30.

[0111] A single motor 32 is shown to move the plungers of the two barrels 29. A motor 33 is also provided to drive the two printing cylinders on each platform.

[0112] An actuation valve 34 is provided for the supply path between the filling and filling cartridge outlet and the print nozzle 30. An actuation valve 35 is also provided at the print nozzle 30.

[0113] exist Figure 1 In the process, each nozzle group's printing platform has an XY tray regulator 36, and each nozzle group's printing platform has a Z tray regulator 37.

[0114] This device can also be used to fill fillable or refillable cartridges 29, examples of which are shown in Figure 4 As shown in the diagram, the fillable or refillable cartridge 29 can function similarly to a syringe. Figure 4 The illustrated fillable or refillable cartridge includes an elongated hollow cylinder 38, an outlet 39 at one end of the cylinder 38, and a movable plunger 40 located within the cylinder 38 for moving toward the outlet 39 to discharge material from the cylinder 38 and moving away from the outlet 39 to allow filling of the cylinder 38.

[0115] The cylinder 38 can be made of any material, but for food-grade materials, food-grade stainless steel or similar materials are preferred. The cylinder has a material volume 41 of approximately 300 ml.

[0116] The discharge port 39 of the barrel may have an attachment structure, such as a threaded portion (not shown), which is provided to allow the barrel 29 (releasably) to be attached to the 3D printer (an example of which is shown in...). Figure 1 example in).

[0117] One or more constructions can be provided, such as Figure 4 The substrate 42 shown is designed to allow the use of a tool (not shown) to engage the outlet 39, thereby attaching and detaching it from the loading system and the 3D printer.

[0118] The plunger 40 can be made of any material, but for food-grade materials, food-grade stainless steel or similar materials are preferred. One or more scraper seals 43 may be provided between the plunger 40 and the cylinder 38. The plunger 40 may also include one or more abutment bases 44 to allow printers (such as...) to... Figure 1 The printer shown applies force to the plunger 40 to force the plunger 40 toward the discharge port 39, thereby discharging material from the barrel 29.

[0119] like Figure 4 and Figure 5 As shown, the plunger 40 may be hollow, with an opening at its front end. The barrel 29 can be filled with material through the hollow plunger 40.

[0120] like Figure 3 or Figure 5 As shown, the barrel 26 can be vertically oriented when it is filled. During filling, the top of the barrel 26 can be at the top.

[0121] like Figure 3 As shown, during filling, the cartridge 26 can be suspended from its top. During filling, the cartridge 26 can be attached relative to the indexing mechanism to allow loading of multiple cartridges to be filled. As shown... Figure 3 The rotary indexing turntable shown or as Figure 5 The linear indexing mechanism shown uses a servo motor 47 to drive the turntable through indexing rotation.

[0122] like Figure 3 As shown, the additional cylinder-mounted piston stamping section can be used to inject material leaving the transfer path conduit into the barrel 26. Figure 3 In the middle, the additional cylinder piston stamping part is located inside the sheath heater 28 and reciprocates as indicated by the large arrow.

[0123] like Figure 3As shown, the barrel 26 can be heated during the filling process to keep the material in a plasticized form during filling. Although any type of heater can be used, a jacketed heater 45 may be preferred. Figure 3 As shown, in use, during filling, the jacket heater 45 can extend around the barrel 38 of the barrel 26. The illustrated jacket heater 45 is either split or provided in more than one part to allow these parts to be separated for loading and unloading the barrel 26. These parts can be hinged relative to each other.

[0124] Preferably, a mating dry disconnect coupling 48 is provided between the outlet of the transfer path conduit 14 and the barrel 26 (plunger 40), as this will minimize or prevent leakage or loss of material when the barrel 26 is disconnected.

[0125] During filling, back pressure or counter-pressure 46 can be applied to the plunger 40 of the barrel 26 to prevent air from accumulating in the barrel 26, such as... Figure 2 As shown. In the illustrated embodiment, a back pressure of approximately 2 bar is particularly preferred.

[0126] like Figure 3 As shown, a plunger driver 49 with a force sensor is used to apply back pressure to the plunger during filling.

[0127] The above description is merely an example of one or more embodiments. Many variations may be made without departing from the scope of protection defined by the appended claims.

Claims

1. An apparatus for forming a stable flow of plasticized solid feed material, the apparatus comprising: a. A piston-pressing section inside a cylinder, the piston-pressing section inside a cylinder being used to compact and crush solid feed material to form a solid blank of feed material in the cylinder, and to extrude at least a portion of the solid blank from the outlet end of the cylinder; b. A transfer path, wherein the transfer path is connected to the outlet end of the cylinder; c. A heater associated with at least a portion of the transfer path to plasticize the solid feed material and heat it to a certain temperature to form a feed of plasticized solid feed material.

2. The device according to claim 1, wherein the feed material is a food material.

3. The device according to claim 1 or claim 2, wherein the piston of the piston stamping part in the cylinder reciprocates, and the lower end of the piston cleans the upper end of the outlet opening of the cylinder at the top of the upper stroke of the piston.

4. The device according to claim 1, wherein an air gap is provided between the outer cylindrical surface of the piston and the inner cylindrical surface of the cylinder.

5. The apparatus of claim 1, further comprising a cooling mechanism provided immediately after the outlet of the cylinder relative to a portion of the transfer path immediately after the outlet of the cylinder.

6. The device according to claim 1, wherein the transfer path conduit is flexible.

7. The device according to claim 1, wherein the transfer path conduit has a meandering or coiled configuration.

8. The device of claim 1, wherein the heater is provided at least half the length of the transfer path.

9. The device of claim 1, wherein a first heater is provided over a portion of the length of the transfer path conduit, and a second heater is provided over another portion of the length of the transfer path conduit after the first heater.

10. The apparatus of claim 1, further comprising a filling station having at least one fillable or refillable cartridge relative to the outlet end of the transfer path conduit.

11. The apparatus of claim 10, wherein the fillable or refillable cartridge comprises an elongated hollow cylinder, an outlet at one end of the cylinder, and a movable plunger located within the cylinder, the movable plunger being configured to move toward the outlet to discharge material from the cylinder and to move away from the outlet to allow the cylinder to be filled with the plasticized solid feed material.

12. The device according to claim 10 or claim 11, wherein the plunger is hollow and has an opening at its front end, such that the fillable or refillable cylinder is filled with the plasticized solid feed material through the plunger.

13. The apparatus of claim 10, wherein an additional in-cylinder piston stamping section is used to inject the plasticized solid feed material exiting the transfer path conduit into the fillable or refillable barrel.

14. The apparatus of claim 13, wherein the heater is provided in more than one section to allow the more than one section to be separated for loading and unloading the barrel.

15. The apparatus of claim 10, further comprising a mating dry disconnect coupling provided relative to the fillable or refillable cartridge.

16. A 3D printing apparatus comprising the apparatus for forming a stable flow of plasticized solid printing material according to claim 1 and at least one print head, wherein the plasticized solid printing material is supplied to at least one supply path of the 3D printing apparatus.

17. A method for forming a stable flow of plasticized solid feed material, the method comprising the steps of: a. Introduce the fragmented solid feed material into the piston stamping section inside the cylinder; b. Compact the fragmented solid feed material to form a solid blank of the feed material in the cylinder; c. Extruding at least a portion of the solid blank from the outlet end of the cylinder into a transfer path communicating with the outlet end of the cylinder; d. Heating the feed material in at least a portion of the transfer path to plasticize the feed material, and heating the feed material to a certain temperature to form a feed of plasticized solid feed material.

18. The method of claim 17, wherein the extrusion step forces the plasticized solid feed material through the transfer path.

19. The method of claim 17 or claim 18, wherein the temperature of the plasticized solid feed material is maintained below the melting temperature of the feed material.

20. The method of claim 17, wherein during the lower stroke of the piston, the fragmented solid feed material is initially compacted at the upper portion of the cylinder.

21. The method of claim 20, wherein the piston moves further downward in the cylinder to compress and break down the crushed solid material to form a solid blank of feed material at the lower portion of the cylinder.

22. The method of claim 17, wherein the blank is always present in the lower portion of the cylinder.

23. The method of claim 17, wherein as the billet of the plasticized solid feed material travels through the transfer path conduit, the billet of the plasticized solid feed material undergoes axial and / or circumferential mixing in the transfer path conduit.

24. The method of claim 17, further comprising the step of filling at least one fillable or refillable cartridge, the at least one fillable or refillable cartridge comprising an elongated hollow cylinder, an outlet at one end of the cylinder, and a movable plunger located within the cylinder, the movable plunger being configured to move toward the outlet to discharge material from the cylinder and to move away from the outlet to fill the cylinder with the plasticized solid feed material.

25. The method of claim 24, further comprising the step of applying back pressure to the plunger during filling to prevent air buildup in the barrel.

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