Elastomer 3D Printing with Clocked Nozzle for Fine Structures
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Solution Overview
Problem
Existing methods for producing molded articles from non-thermoplastic elastomer materials face challenges in achieving high precision and fine structures due to high viscosity and the requirement of impractically high pressures for material conveyance.
Innovation Solution
An additive manufacturing method that processes non-thermoplastic elastomer material through a series of steps including supply, processing, accumulation, and cross-linking, utilizing a clocked nozzle to output the material in a sequential bead chain form, allowing for precise layer-by-layer construction with controlled temperature and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If non-thermoplastic elastomer material is processed using conventional injection molding, then the material can be molded, but the high viscosity requires impractically high pressures for material conveyance
Solution Approach 1:
The patent changes the physical parameters of the elastomer material by maintaining it in a non-thermoplastic state with controlled viscosity (100-1,000,000 Pa·s) and applies controlled heating (20-150°C) and pressurization (up to 600 bar) to enable flow through fine nozzles without requiring impractically high pressures. The cross-linking process is also modified to occur after deposition rather than during injection.
Solution Approach 2:
The patent replaces the conventional high-pressure injection molding mechanical system with an additive manufacturing system that uses a clocked nozzle for sequential material deposition. This substitution allows precise material placement with significantly lower pressures by building structures layer-by-layer rather than injecting under high pressure.
2Productivity
If high pressure is applied to convey viscous elastomer material, then material flow is achieved, but the complexity and cost of the system increases
Solution Approach 1:
The patent replaces complex high-pressure conveyance systems with a simpler additive manufacturing system using a clocked nozzle that deposits material sequentially at controlled rates (0.5-30 g/h). This approach achieves material conveyance with significantly reduced system complexity and lower pressures (up to 600 bar) compared to conventional high-pressure injection molding.
3Productivity
If conventional injection molding is used for elastomer, then production is efficient, but fine structures and high precision cannot be achieved
Solution Approach 1:
The patent segments the manufacturing process into discrete layers deposited sequentially by the clocked nozzle. This segmentation enables precise control over material placement for fine structures while maintaining productivity through automated layer-by-layer construction. The cross-linking process is also segmented to occur after each layer or group of layers is deposited.
Solution Approach 2:
The patent employs periodic action through the clocked nozzle that opens and closes at controlled intervals to deposit material in a sequential bead chain pattern. This periodic deposition enables precise control over material placement for fine structures while maintaining continuous production through automated cycling.
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
Enables the production of molded articles with fine structures and high precision using lower pressures than expected, overcoming the limitations of conventional methods by achieving effective material conveyance and cross-linking.
Implementation Method 1
cross-linking the at least one layer or the entire molded article by means of a cross-linking unit, wherein the cross-linking can take place thermally, optically, or chemically
Data Source
AI summary
A method is provided for producing a molded article from a non-thermoplastic material. The method includes: supplying the non-thermoplastic elastomer material to a processing unit; processing the non-thermoplastic elastomer material to generate a material flow of the non-thermoplastic elastomer material; conveying the non-thermoplastic elastomer material into an accumulator unit to generate a nominal pressure of the non-thermoplastic elastomer material in the accumulator unit; conveying the non-thermoplastic elastomer material to a molding unit to selectively output at least one layer of the molded article to be formed; and cross-linking the at least one layer of the molded article or of the entire molded article by means of a cross-linking unit. The non-thermoplastic elastomer material is highly viscous, and has a viscosity in the range of 100 to 1,000,000 Pa·s.