Self-Cleaning Extrusion Orifice Plunger Mechanism
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Solution Overview
Problem
Existing extrusion processes for 3D object manufacturing are disrupted by debris accumulation in orifices, requiring manual cleaning and resulting in reduced throughput and the need for qualified personnel, as continuous extrusion is necessary to maintain production efficiency.
Innovation Solution
A self-cleaning extrusion orifice assembly with a plunger and cylindrical body, utilizing pressurized air flow to move the plunger and scrape debris from surfaces, including multiple-start helical grooves to direct air flow and ensure effective cleaning without interrupting the extrusion process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual cleaning of extrusion orifices is performed, then debris removal effectiveness is improved, but production downtime increases and throughput decreases
Solution Approach 1:
The system employs an automatic plunger mechanism that periodically moves to scrape debris from the orifice surfaces without requiring manual intervention. The plunger is actuated by a drive mechanism that advances it along the orifice, and debris is automatically removed through the gap between the plunger and orifice surface, enabling self-cleaning during or between extrusion cycles
Solution Approach 2:
The cleaning operation is performed periodically through controlled movement of the plunger along the orifice. The drive mechanism advances the plunger in periodic cycles, allowing cleaning to occur at regular intervals without continuous interruption of the extrusion process, thus maintaining productivity while ensuring debris removal
2Productivity
If continuous extrusion is maintained to preserve production efficiency, then manufacturing throughput is improved, but debris accumulation in orifices increases
Solution Approach 1:
The plunger mechanism is positioned and ready to perform cleaning action before debris completely blocks the orifice. The periodic advancement of the plunger prevents complete clog formation by removing accumulated debris in advance, maintaining orifice patency and enabling continuous extrusion operation
Solution Approach 2:
The system enables continuous extrusion by implementing cleaning actions that do not interrupt the material flow. The plunger moves through gaps or channels that allow extrusion material to pass while debris is scraped away, maintaining the continuity of the useful extrusion action while eliminating the harmful accumulation effect
3Reliability
If manual cleaning operations are implemented, then debris removal is improved, but the need for qualified personnel increases and operational complexity increases
Solution Approach 1:
The automated plunger system performs cleaning operations without human intervention. The drive mechanism automatically advances the plunger along the orifice, and the system self-regulates the cleaning cycle, eliminating the need for operators to manually clean orifices and reducing the skill level required for operation
Solution Approach 2:
Manual mechanical cleaning operations are replaced with an automated mechanical system. The plunger drive mechanism uses controlled mechanical motion (potentially powered by motors or actuators) to perform the scraping action, replacing manual hand tools and operator labor with an automated mechanical system
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 continuous extrusion with automatic debris removal, increasing manufacturing throughput and eliminating the need for manual cleaning and post-processing, thus improving production efficiency and reducing downtime.
Implementation Method 1
The self-cleaning extrusion orifice assembly is operated by a pressurized air flow that among others moves the plunger to at least one movement position
Implementation Method 2
The pressurized air flow flushes surfaces of some elements of self-cleaning extrusion orifice assembly removing debris that could be deposited on these surfaces
Implementation Method 3
The dimensions of the plunger of the self-cleaning extrusion orifice assembly are selected to have a clearance or a gap with some other parts of the assembly. Additionally, the cylindrical body of the self-cleaning extrusion orifice assembly includes a number of longitudinal air conducting grooves or channels. The size of the gap allows in course of the plunger movement to scrape extrusion process debris from the surfaces on which some debris have been deposited.
Implementation Method 4
The plunger also includes a segment with multiple-start helical grooves. The multiple-start helical grooves configured to rotate pressurized air flow such that at the exit of inner volume of the self-cleaning extrusion orifice assembly the pressurized air flow becomes a conical toroid that flushes and cleans the plunger conical segment
Data Source
AI summary
Described is a self-cleaning extrusion orifice assembly including an enclosure, a cylindrical body inserted into the enclosure and terminated by an extrusion orifice. The self-cleaning extrusion orifice assembly is operated by a pressurized air flow. The pressurized air flow flushes surfaces of some elements of self-cleaning extrusion orifice assembly removing debris that could be deposited on these surfaces. In addition, some elements of self-cleaning extrusion orifice assembly are configured to scrape extrusion process debris from the same surfaces.