Double-Layer Filament Resin Strand for 3D Printing
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Solution Overview
Problem
The existing molded resin strands used in 3D printers for fused deposition modeling lack mechanical aptitude and quality, often curving or bending during modeling due to inconsistent diameter and shape, and are prone to moisture absorption, which deteriorates their quality.
Innovation Solution
A molded resin strand with a double-layer structure, where the first layer contains an inorganic filler and the second layer does not, providing enhanced mechanical properties and a constant diameter and circular shape through vacuum sizing, ensuring improved accuracy and resistance to moisture absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single-layer molded resin strand is used, then the manufacturing process is simple, but the mechanical aptitude and quality are insufficient, causing the strand to curve or bend during modeling
Solution Approach 1:
The molded resin strand is divided into multiple layers (first layer and second layer) with different compositions. The first layer contains thermoplastic resin and inorganic filler for mechanical strength, while the second layer contains only thermoplastic resin for flexibility and moisture protection. This segmentation allows each layer to perform its specific function, resolving the contradiction between mechanical aptitude and structural simplicity.
Solution Approach 2:
The invention uses composite materials by combining thermoplastic resin with inorganic filler in the first layer to enhance mechanical properties. The multi-layer composite structure (resin-filler-resin) provides both the required mechanical aptitude and prevents curvature during modeling, while maintaining manufacturing feasibility through extrusion processes.
2Reliability
If the molded resin strand is not protected from moisture, then the manufacturing and storage are easier, but the quality deteriorates due to moisture absorption after unsealing
Solution Approach 1:
The second layer acts as a protective shell or film that covers the first layer. This outer layer is composed of thermoplastic resin that provides a barrier against moisture absorption. The shell structure protects the inner first layer from environmental moisture while maintaining the overall strand functionality, resolving the contradiction between quality stability and structural complexity.
3Manufacturing precision
If the diameter and shape of the resin strand are not controlled, then the manufacturing is simpler, but the accuracy of shaping the three-dimensional object deteriorates
Solution Approach 1:
The invention controls the diameter and shape parameters of the molded resin strand through the multi-layer extrusion process. By precisely controlling the extrusion parameters and layer thicknesses, the strand maintains a consistent circular cross-section with controlled diameter. This ensures accurate material delivery during 3D printing while maintaining manufacturing simplicity through process optimization.
4Ease of operation
If a resin strand with high fluidity is used, then the deposition process is smoother, but it is difficult to perform modeling with such material in fused deposition modeling
Solution Approach 1:
The invention applies local quality by having different material compositions in different layers. The second layer contains pure thermoplastic resin that provides smooth deposition and high fluidity during extrusion. The first layer contains thermoplastic resin with inorganic filler that provides structural integrity and modeling reliability. This local differentiation allows the strand to exhibit both smooth deposition characteristics and reliable modeling performance.
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 double-layer structure enhances the mechanical aptitude and quality of 3D printed objects by maintaining a consistent diameter and shape, reducing bending damage, and preventing moisture absorption, resulting in high-accuracy and durable three-dimensional objects.
Implementation Method 1
the first layer contains an inorganic filler with a first predetermined amount... enhancing mechanical properties
Implementation Method 2
the second layer covers the periphery of the first layer... preventing moisture absorption
Implementation Method 3
The filament is melted in a liquefier carried by the extruding head
Implementation Method 4
a molded resin strand used for a 3D printer employing fused deposition modeling... extruding and laminating/depositing a resin strand
Implementation Method 5
providing enhanced mechanical properties and a constant diameter and circular shape through vacuum sizing
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A molded resin strand 10 includes a first layer 21 containing thermoplastic resin, and a second layer 22 covering the first layer 21 and containing thermoplastic resin exhibiting physical properties different from those of the first layer 21. For example, the second layer 22 is melt-extruded with the second layer 22 covering the first layer 21. A three-dimensional object is modeled by lamination deposition by fusion between adjacent second layers. In a molded resin strand manufacturing method, a melt-kneaded resin material is continuously extruded from a ferrule of an extruder. The extruded molded resin strand is vacuum-sucked while passing through a sizing device. Subsequently, the molded resin strand is wound up after cooling solidification. The sizing device is provided with a space having a circular cross section, and a surface of the sizing device facing the space is provided with a plurality of vacuum suction grooves.