Multi-nozzle Extruder Spool Valve for Additive Manufacturing

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Solution Overview

Problem

Multi-nozzle extruders face issues with varying effective pitch at non-standard movement angles, nozzle closure causing unwanted material ejection, and leakage due to difficult sealing of pin passageways, which affect precision and efficiency in forming complex objects.

Innovation Solution

A new multi-nozzle extruder design featuring a spool valve and actuator system that allows bidirectional movement and rotation, enabling precise control over nozzle opening and closing while maintaining the ability to form acute angles and wide swaths, with improved sealing to prevent material loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If pin-based valve mechanism is used to close nozzles, then nozzle closure is achieved, but unwanted material ejection occurs due to material displacement

Engineering Contradiction:

Improvenozzle closure reliabilityVSAvoidunwanted material ejection

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The disturbing element (pin mechanism causing material displacement) is extracted and replaced with a spool valve system that controls material flow without direct contact with the material path, eliminating the harmful side effect of unwanted material ejection while maintaining nozzle closure functionality

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The spool valve acts as an intermediary mechanism between the actuator and the nozzles, providing precise control over material flow through the nozzles without directly displacing material, thus preventing unwanted material ejection while achieving reliable nozzle closure

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If pin passageways are sealed to prevent leakage, then sealing is improved, but device complexity increases due to difficult sealing requirements

Engineering Contradiction:

Improvesealing reliabilityVSAvoidsealing structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The complex mechanical sealing system for pin passageways is replaced with a spool valve mechanism that inherently controls material flow through precision machining surfaces, eliminating the need for complex sealing structures while maintaining leakage prevention

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The sealing approach is changed from mechanical seals in pin passageways to precision-machined surfaces in the spool valve assembly, where tight tolerances and smooth surfaces provide sealing without additional complex sealing components

Inventive Principle:

Principle #35Parameter changes

3Productivity

If multiple nozzles are used to increase productivity, then manufacturing speed improves, but effective pitch varies at non-standard movement angles

Engineering Contradiction:

Improvemanufacturing speedVSAvoideffective pitch consistency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system dynamically adjusts which nozzles are active based on the movement angle and direction, allowing the effective pitch to vary adaptively with the movement parameters while maintaining precision through selective nozzle activation rather than fixed pitch constraints

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS12017409B2Multi-nozzle extruder and method for operating a multi-nozzle extruder during additive manufacturing

Publication Date: 2024.06.25 GENESEE VALLEY INNOVATIONS LLC

AI summary

An additive manufacturing system has a controller configured to operate a spool valve to open and close nozzles in a multi-nozzle extruder while the extruder moves in an X-Y plane and rotates about an axis perpendicular to the XY plane to form swaths in the X-Y plane. The controller operates one actuator to rotate the multi-nozzle extruder so a longitudinal axis of a nozzle array in the extruder remains perpendicular to a movement path for the extruder and to operate another actuator to move a cylindrical member of the spool valve.