Vortex-Assisted 3D Printer Extrusion for Fiber Impregnation
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Solution Overview
Problem
Existing 3D printers face challenges in impregnating thermoplastic matrix fibers due to high processing viscosity, and cutting systems are complex and imprecise, leading to high costs and operational inefficiencies.
Innovation Solution
An extrusion device and cutting device for 3D printers that efficiently impregnate thermoplastic matrix fibers with a twisting mechanism and precise cutting using a piezoelectric actuator, respectively, to produce high-quality 3D articles with minimal residual tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoplastic matrix fibers are used for impregnation, then the mechanical performance and flexibility of composite materials are improved, but the processing viscosity increases making impregnation more difficult
Solution Approach 1:
The patent applies parameter changes by controlling the temperature of the thermoplastic matrix fiber to its melting point or above, transforming it from a solid state with high viscosity to a molten state with reduced viscosity. This enables the molten matrix fiber to effectively impregnate the reinforcing fiber, resolving the impregnation difficulty while maintaining the mechanical performance benefits of thermoplastic composites.
2Ease of operation
If conventional cutting systems are used for impregnated fibers, then cutting operations can be performed, but the systems become constructionally complex and costly to produce and maintain
Solution Approach 1:
The patent replaces complex mechanical cutting systems with a laser-based cutting method. The laser beam directly cuts the impregnated fiber bundle without requiring mechanical contact, eliminating the need for complex mechanical cutting mechanisms and reducing system complexity, production costs, and maintenance requirements while maintaining cutting effectiveness.
3Ease of operation
If conventional cutting systems are used for impregnated fibers, then cutting can be performed, but precision during cutting operations is reduced
Solution Approach 1:
The laser cutting system provides superior precision compared to mechanical cutting systems. The laser beam can be precisely controlled and focused to cut fibers with high accuracy, eliminating the mechanical tolerance issues inherent in conventional cutting systems and achieving better cutting precision for impregnated fiber bundles.
4Ease of manufacture
If thermoplastic matrix fibers are impregnated without melting, then processing is simpler, but the impregnation effectiveness is reduced due to high viscosity
Solution Approach 1:
The patent changes the thermal parameter of the matrix fiber by heating it to its melting point or above, transforming it from a solid with high viscosity to a molten state with low viscosity. This parameter change enables effective impregnation of the reinforcing fiber while maintaining process simplicity, as the molten material naturally flows and penetrates the fiber structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables efficient impregnation of thermoplastic matrix fibers with reduced viscosity challenges and precise cutting, resulting in superior quality 3D articles with minimal energy consumption.
Implementation Method 1
at least one movable cutter operated by at least one piezoelectric actuator
Implementation Method 2
produce a vortex movement of the thermoplastic material inside said impregnation chamber and therefore—by means of said vortex—cause twisting of the reinforcing filaments
Data Source
AI summary
Extrusion device comprising first means for feeding reinforcing filaments; second means for feeding molten thermoplastic material; an impregnation chamber for impregnating the reinforcing filaments with the thermoplastic material so as to provide an impregnated multifilament; a device body which defines: (a) first openings for transit of the reinforcing filaments from the first feeding means to the impregnation chamber; (b) at least one second opening for transit of the thermoplastic material from the second feeding means to the impregnation chamber; a nozzle for dispensing the impregnated multifilament; a twisting member arranged, in terms of fluid flow, upstream of and rotatably with respect to the dispensing nozzle so as to produce the vortex movement of the thermoplastic material inside the impregnation chamber and therefore—by means of said vortex—cause twisting of the reinforcing filaments.