Additive Manufacturing Compression Roller Cooling
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Solution Overview
Problem
Existing 3D printing systems face challenges in maintaining a freewheeling compression roller with minimal rotational friction and effective cooling, particularly when processing high-temperature polymers like polyphenylene sulfide, which can lead to polymer adhesion and print defects.
Innovation Solution
A system utilizing a cooled liquid coolant routed through a rotary union and a tubular compression roller with low friction bearings, allowing the roller to rotate freely while being cooled below the polymer's melting temperature, thereby preventing adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the compression roller is cooled to prevent polymer adhesion, then polymer adhesion is prevented, but rotational friction increases
Solution Approach 1:
A coolant fluid serves as an intermediary substance, flowing through channels in the roller to transfer heat away from the compression roller surface. This mediator enables cooling without direct thermal contact that would cause adhesion, while the roller surface remains free to rotate with minimal friction.
Solution Approach 2:
The patent employs a hydraulic cooling system where coolant fluid is pumped through internal channels of the compression roller. This hydraulic approach efficiently removes heat from the roller to prevent polymer adhesion while maintaining the roller's mechanical properties for low-friction rotation.
2Force
If the compression roller is made to rotate freely to reduce friction, then rotational friction is minimized, but cooling effectiveness decreases
Solution Approach 1:
The compression roller is segmented into functional zones with internal coolant channels distributed throughout its structure. This segmentation allows cooling to occur at multiple points simultaneously, maintaining effective temperature control while the external surface rotates freely with minimal friction.
Solution Approach 2:
The cooling function is moved from the external surface to the internal structure of the roller through embedded coolant channels. This dimensional transition allows the external surface to rotate freely for low friction while the internal channels provide continuous cooling.
3Strength
If a solid compression roller is used to maintain structural integrity, then structural strength is maintained, but cooling efficiency is reduced
Solution Approach 1:
The compression roller incorporates thin-walled internal channels formed within its structure. These thin film-like channels provide extensive surface area for heat transfer while maintaining the overall structural integrity and strength of the roller through optimized wall thickness and channel distribution.
Solution Approach 2:
The roller structure incorporates a network of internal channels that create a porous-like flow path for the coolant. This channelled structure increases the surface area available for heat transfer while maintaining the structural strength needed for compression operations.
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
This solution ensures the compression roller operates with minimal friction and maintains a temperature below the polymer's melting point, preventing adhesion and ensuring defect-free printing of high-temperature polymers.
Implementation Method 1
a coolant circuit operable to cool the compression roller
Implementation Method 2
The compression roller may include a coolant circuit and low friction bearings
Data Source
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AI summary
An additive manufacturing system (1) may include a nozzle (51) having an inlet for receiving a flowable material (53) and an outlet for depositing the flowable material. The system also may include an applicator head (43) surrounding at least a portion of the nozzle. Additionally, a roller (59) may be mounted on the applicator head and rotatable about an axle (73). A coolant circuit may extend through at least a portion of the applicator head and through a lumen of the axle.