Gear Pump Extrusion System for Viscous Material Flow
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Solution Overview
Problem
Extrusion printing systems face challenges in handling high-viscosity build materials, leading to inconsistent flow, increased energy consumption, and equipment wear due to high pressure requirements, as well as inefficiencies in controlling material viscosity throughout the extrusion process.
Innovation Solution
The system employs a series of consecutively arranged gear pump units, each with a first and second gear element featuring lobes that cooperate to facilitate a pumping action, along with a feed channel to induce movement and apply shear forces to the build material, reducing its viscosity and improving flow consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional high-pressure feed systems are used to push paste material through the extrusion nozzle, then the material can be delivered to the nozzle, but equipment wear increases and energy consumption rises
Solution Approach 1:
The patent replaces the traditional high-pressure mechanical feed system with a gear pump-based dosing system. The gear pump uses rotational mechanical action to positively displace and meter the paste material, eliminating the need for high-pressure pushing mechanisms while reducing energy consumption and equipment wear.
Solution Approach 2:
The patent changes the pressure parameter from high-pressure continuous delivery to low-pressure intermittent dosing. By using the gear pump to create controlled pressure pulses only during the dosing phase, the system achieves material delivery without sustained high pressure, thereby reducing energy loss and wear.
2Productivity
If traditional high-pressure feed systems are used to push paste material, then material can be delivered to the nozzle, but equipment wear increases
Solution Approach 1:
The patent replaces the traditional high-pressure mechanical feed system with a gear pump-based dosing system. The gear pump uses rotational mechanical action to positively displace and meter the paste material, eliminating the need for high-pressure pushing mechanisms while reducing energy consumption and equipment wear.
Solution Approach 2:
The patent employs a dosing mechanism that can be easily replaced or maintained. The gear pump and associated dosing components are designed as modular units that can be serviced independently, extending the overall system longevity even if individual components require periodic replacement.
3Productivity
If traditional feed systems are used, then material can be supplied to the nozzle, but flow consistency deteriorates due to inability to control viscosity
Solution Approach 1:
The patent incorporates a dosing mechanism that meters material based on controlled rotational displacement of the gear pump. This provides feedback-controlled volumetric delivery, ensuring consistent flow rates regardless of variations in material viscosity, thereby improving flow consistency and print precision.
Solution Approach 2:
The patent changes the material delivery from pressure-driven continuous flow to volume-driven intermittent dosing. The gear pump's fixed displacement per rotation ensures that each dose is precisely metered, maintaining flow consistency even when material viscosity varies during the printing process.
4Productivity
If high pressure is maintained continuously to handle viscous material, then material can be pushed through the system, but energy consumption increases
Solution Approach 1:
The patent employs periodic dosing action where the gear pump delivers material in controlled intervals rather than continuous flow. The pump rotates to meter material, creates a dose, and then pauses, repeating this cycle. This periodic action reduces average energy consumption compared to continuous high-pressure maintenance while ensuring consistent material transport.
Solution Approach 2:
The patent replaces the traditional high-pressure mechanical feed system with a gear pump-based dosing system. The gear pump uses rotational mechanical action to positively displace and meter the paste material, eliminating the need for high-pressure pushing mechanisms while reducing energy consumption and equipment wear.
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 configuration enables precise control over the build material's flow rate, reduces energy consumption, extends equipment longevity, and enhances the system's ability to handle a variety of build materials with different viscosities, resulting in higher-quality and more consistent 3D printed structures.
Implementation Method 1
the gear pump units are configured to apply shear forces to the build material in the feed channel so as to introduce movement in the build material. Advantageously, this can result in a reduction of the viscosity of the build material.
Implementation Method 2
each gear pump unit comprises a first gear element having a plurality of first lobes disposed circumferentially around a first central axis, and a second gear element having a plurality of second lobes disposed circumferentially around a second central axis, wherein the first lobes are configured to cooperate with the second lobes to facilitate a pumping action of the build material
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
An extrusion printing system configured to extrude a build material, wherein the system includes: a plurality of gear pump units arranged consecutively, wherein each gear pump unit has an inflow portion for receiving build material and an outflow portion for transferring build material towards at least one nozzle, wherein each gear pump unit comprises a first gear element having a plurality of first lobes disposed circumferentially around a first central axis, and a second gear element having a plurality of second lobes disposed circumferentially around a second central axis, wherein the first lobes are configured to cooperate with the second lobes to facilitate a pumping action of the build material; a feed channel in fluid communication with the inflow portion of each of the plurality of gear pump units, wherein the feed channel is configured to feed build material to each of the plurality of gear pump units; and wherein, during operation, the gear pump units are configured to induce movement to the build material within the feed channel.