3D Printer Extrusion Apparatus with Gear Pump for Pellet Resin
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Solution Overview
Problem
Conventional three-dimensional printing methods using fused deposition modeling face limitations in producing large objects due to resin volume reduction, nozzle clogging, and difficulty in controlling discharge of thermally melted polymers, which restrict the use of commercially available pellets and lead to resin dripping.
Innovation Solution
A three-dimensional printer with an extrusion apparatus featuring a screw-driven cylinder, gear pump, and pressure control system, where the screw and gear pump are controlled to manage resin discharge, preventing dripping and allowing for the use of various commercially available pellets, enabling the production of large objects without the need for filament materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If gas pressurization is used to extrude fused resin, then resin discharge is achieved, but resin dripping occurs and discharge control becomes difficult
Solution Approach 1:
The patent replaces gas pressurization with a gear pump mechanism to extrude fused resin. The gear pump uses mechanical rotation to precisely control resin discharge, eliminating the dripping problem associated with gas pressurization while enabling accurate discharge amount control.
Solution Approach 2:
The patent changes the extrusion mechanism from gas pressure-based to gear pump rotation-based. By controlling the rotation speed and direction of the gear pump, the system achieves precise control over resin discharge parameters, preventing dripping while maintaining ease of operation.
2Productivity
If filament material is used in conventional 3D printers, then material feeding is achieved, but nozzle clogging occurs and sending speed control is difficult
Solution Approach 1:
The patent changes the material form from filament to pellets and modifies the feeding mechanism accordingly. The gear pump system handles pellet material effectively, preventing clogging while maintaining continuous operation. The system controls pellet feeding speed through gear pump rotation, ensuring reliable and uninterrupted forming.
Solution Approach 2:
The patent replaces the conventional filament feeding mechanism with a gear pump-based pellet feeding system. This mechanical substitution eliminates the clogging issues inherent in filament systems while enabling precise control over material sending speed through rotation control.
3Manufacturing precision
If syringe volume is reduced to produce minute structures, then fine 3D structures can be formed, but large molded objects cannot be produced
Solution Approach 1:
The patent creates a universal extrusion system using a gear pump that can handle both minute and large-scale molded objects. The gear pump mechanism provides precise control for fine structures while its scalable operation enables production of large objects, making the system multi-functional across different size requirements.
Solution Approach 2:
The patent employs dynamic control of the gear pump rotation to adapt to different production requirements. By adjusting rotation speed and duration, the system can produce either minute structures with high precision or large molded objects with extended operation, providing dynamic versatility.
4Object-affected harmful factors
If nitrogen or carbon dioxide is used to suppress oxide generation, then oxidation is prevented, but material preparation complexity increases
Solution Approach 1:
The patent extracts and eliminates the need for inert gas preparation by using a gear pump system that controls resin discharge mechanically. This removes the harmful oxidation effect without requiring complex gas preparation infrastructure, simplifying the overall 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
The system effectively controls resin discharge, preventing nozzle clogging and dripping, allowing for the production of large objects using a wide range of commercially available resin pellets, enhancing the versatility and capability of three-dimensional printing.
Implementation Method 1
heating the cylinder to fuse the resin material in the cylinder
Implementation Method 2
a screw inside the cylinder, a hopper capable of supplying a granular resin material is attached to the extruder, and the rotation of the screw is controlled by a screw motor
Implementation Method 3
a gear pump provided on the tip side of the screw is controlled by a gear pump motor
Implementation Method 4
heating the gear pump and the nozzle while discharging the fused resin
Data Source
Figure 1~2
Figure 3
AI summary
Provided is a 3D printer which can use pellets of various materials and produce a large molded object without requiring an inactive gas. The printer is equipped with: an extrusion apparatus (A), having a nozzle (2) provided on a lower end side of a cylinder (1), a screw (4) arranged in the cylinder and controllably rotated by a screw motor (3), a gear pump (6) provided on a tip side of the screw and controllably rotated by a gear pump motor (5), a heater (7) for heating an inside of the cylinder, and a hopper (8) for supplying a resin material into the cylinder; a table apparatus positioned facing the nozzle of the extrusion apparatus; and a control apparatus for controlling discharge of a resin from the nozzle of the extrusion apparatus, and for controlling a movement of the extrusion apparatus and/or the table apparatus in X-axis, Y-axis, and Z-axis directions with respect to a reference plane. The extrusion apparatus and/or the table apparatus has a structure moved through position control in the X-axis, Y-axis, and Z-axis directions by the control apparatus.