Multi-Outlet Nozzle for Rib-Like Interior Extrusion
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Solution Overview
Problem
Existing technologies face challenges in constructing strong structures with minimal material usage, varying extruded widths, and regulating material amounts during the extrusion process.
Innovation Solution
A nozzle system with multiple outlets and a controller that allows for controllable extrusion of unhardened materials, including cementitious, insulation, and polymeric materials, with a third outlet capable of traversing between the first and second extrudates to create spaced or filled patterns, and a vibration-generating device to regulate material flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single outlet nozzle is used for extrusion, then the device complexity is low, but the manufacturing precision and ability to create varied patterns is limited
Solution Approach 1:
The nozzle is divided into multiple independent outlets (first outlet, second outlet, third outlet) that can extrude material separately. Each outlet can be controlled independently to create different extrudates with specific patterns, enabling precise control over material distribution and structural formation while maintaining relatively simple individual outlet structures
Solution Approach 2:
The multi-outlet nozzle serves multiple functions: it can extrude different materials (cementitious, insulation, polymeric, foam) through different outlets, create various patterns (spaced, filled, rib-like interiors) by controlling which outlets are active, and regulate material amounts from each outlet. This universal design allows a single nozzle assembly to perform what would otherwise require multiple different nozzle configurations
2Strength
If material is extruded continuously to fill spaces, then the structural strength is improved, but the material usage efficiency decreases
Solution Approach 1:
The nozzle system applies material with local quality by selectively extruding from different outlets at different locations and times. The first and second outlets create outer shell extrudates, while the third outlet creates interior extrudates only where needed to form rib-like structures. This localized material application provides structural strength exactly where required while leaving voids or insulation material in non-structural areas, optimizing material usage efficiency
Solution Approach 2:
Instead of continuously filling all spaces with structural material, the system uses partial action by extruding from the third outlet only intermittently to create rib-like interior structures. The controller regulates material flow to provide just enough material for structural reinforcement without excessive filling, thereby improving material usage efficiency while maintaining necessary structural strength
3Productivity
If the extrusion speed is increased to improve productivity, then the production rate increases, but the manufacturing precision of material distribution decreases
Solution Approach 1:
The nozzle system incorporates dynamic control where the controller can adjust the extrusion rate, positioning, and activation of different outlets in real-time. This dynamic regulation allows the system to maintain precise material distribution control even at higher extrusion speeds by adaptively adjusting flow rates and outlet activation sequences, thereby preserving manufacturing precision while improving productivity
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 construction of strong, efficient structures with precise control over material distribution and flow, allowing for varied patterns and reduced material usage.
Implementation Method 1
a vibration-generating device to regulate material flow
Data Source
AI summary
A nozzle for extruding a surface may include a first outlet configured to controllably extrude a first extrudate of unhardened material, a second outlet configured to controllably extrude a second extrudate of unhardened material that is separated from the first extrudate, a third outlet configured to extrude a third extrudate of unhardened material between the first and the second extrudates, and a controller. The third outlet may have a width that is substantially less than the distance between the first and second extrudates. The controller may be configured to cause the third extrudate to repeatedly traverse between the first and second extrudates and/or to cause the third extrudate to leave a plurality of substantial and separated spaces between the first and second extrudates.