Ceramic Slurry Extruder with Dispersion Blade and Vibration

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Solution Overview

Problem

Heterogeneous ceramic slurries with higher density particles or fibers are difficult to extrude in additive manufacturing due to settling issues, leading to inconsistent deposition and nozzle clogging, which previous methods like increased pressure fail to address effectively.

Innovation Solution

An extruder design featuring a receptacle with a dispersion blade and nozzle configuration that maintains even mixing and flow, using a combination of pressurization and mechanical vibration to prevent settling and clogging, with the nozzle positioned to avoid accumulation of settled material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If higher pressure is applied to force slurry through the nozzle, then extrusion capability is improved, but deposition consistency deteriorates due to sputtering and inconsistent material flow

Engineering Contradiction:

Improveextrusion capabilityVSAvoiddeposition consistency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent changes the physical parameters of the slurry by incorporating vibration at specific frequencies (typically 20-2000 Hz) to modify the flow characteristics and prevent particle settling, allowing consistent extrusion at lower pressures while maintaining deposition quality

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies mechanical vibration to the slurry either through the nozzle or within the reservoir to keep particles suspended and evenly distributed, preventing clogging and ensuring consistent material flow through the nozzle without requiring high pressure

Inventive Principle:

Principle #18Mechanical vibration

2Quantity of substance

If higher density material is used in the slurry, then ceramic particle concentration is improved, but settling rate increases leading to nozzle clogging

Engineering Contradiction:

Improveceramic particle concentrationVSAvoidnozzle clogging resistance

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent uses mechanical vibration applied to the slurry reservoir or nozzle to counteract gravitational settling of high-density ceramic particles, keeping them suspended and evenly distributed throughout the liquid medium, thus preventing nozzle clogging even at high particle concentrations

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

The patent counteracts the gravitational force causing particle settling by applying vibrational forces that create upward motion components, effectively balancing the settling tendency and maintaining particle suspension without requiring additional mechanical agitation devices

Inventive Principle:

Principle #8Anti-weight (Counterweight)

3Manufacturing precision

If nozzle diameter is reduced to achieve finer features, then feature resolution is improved, but particle clogging increases when diameter is comparable to particle size

Engineering Contradiction:

Improvefeature resolutionVSAvoidextrusion consistency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent applies vibration directly to the nozzle or the slurry within the nozzle to prevent particle accumulation and clogging, enabling consistent extrusion through small diameter nozzles that would otherwise be prone to blockage from ceramic particles of comparable size

Inventive Principle:

Principle #18Mechanical vibration

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

Ensures consistent and uniform extrusion of ceramic slurry, reducing material inconsistencies and preventing nozzle blockages, thereby improving the quality and reliability of additive manufacturing processes.

Implementation Method 1

a dispersion blade positioned within the receptacle

Methodology Applied

Scientific EffectMechanical mixing: Stirring

Implementation Method 2

the nozzle defines a first opening positioned within an interior of the receptacle, defines a second opening positioned outside of the receptacle and defines a channel which extends from the first opening through the nozzle to the second opening

Methodology Applied

Scientific EffectFluid flow through channel:

Data Source

PatentUS12115697B2Apparatus for extruding ceramic slurry

Publication Date: 2024.10.15 THE BOEING CO

AI summary

An extruder includes a receptacle for containing material to be extruded. The extruder further includes a dispersion blade positioned within the receptacle and a nozzle secured to the receptacle. The nozzle defines a first opening positioned within an interior of the receptacle, defines a second opening positioned outside of the receptacle and defines a channel which extends from the first opening through the nozzle to the second opening defining a flow path which extends from the first opening, through the channel and to the second opening. The nozzle extends through a wall of the receptacle and into the interior of the receptacle such that the first opening is positioned spaced apart from the wall.