Non-Circular Nozzle Bore Fluid Ejector for Additive Manufacturing

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Solution Overview

Problem

Additive manufacturing systems face clogging issues due to airborne particulate build material particles entering the nozzle bore of fluid ejectors, which impede fluid supply and affect the quality of three-dimensional objects being created.

Innovation Solution

The use of fluid ejectors with non-circular nozzle bores and multiple nozzle openings, along with a pillar within the inlet to prevent particle ingress, ensures that airborne particles are blocked from entering the nozzle, maintaining fluid flow and preventing clogging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If a circular nozzle bore is used, then fluid flow is maximized, but airborne particles can easily enter and clog the nozzle

Engineering Contradiction:

Improvefluid flow quantityVSAvoidnozzle clogging resistance

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent applies asymmetry by changing the nozzle bore from a circular to a non-circular cross-section. This asymmetric geometry creates a shape that is less susceptible to particle intrusion while preserving adequate fluid flow characteristics for the additive manufacturing process.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The patent changes the geometric parameters of the nozzle bore by specifying a non-circular cross-section with particular dimensional relationships. This parameter change optimizes the balance between fluid flow capacity and resistance to particle clogging.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If the nozzle bore size is reduced to prevent particle entry, then particle intrusion is inhibited, but fluid flow quantity is reduced

Engineering Contradiction:

Improveparticle intrusion resistanceVSAvoidfluid flow quantity

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The non-circular cross-section creates an asymmetric geometry where the dimensions are optimized to be just large enough to maintain fluid flow while being small enough in critical directions to prevent particle entry. This asymmetric shape allows the nozzle to effectively filter particles without significantly reducing fluid flow capacity.

Inventive Principle:

Principle #4Asymmetry

3Reliability

If multiple nozzle openings are used, then fluid supply reliability is improved, but device complexity increases

Engineering Contradiction:

Improvefluid supply consistencyVSAvoidnozzle structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the fluid supply function into multiple separate nozzle openings. Each opening independently contributes to fluid delivery, and if one becomes blocked, the others can maintain operation. This segmentation improves reliability without requiring complex mechanical systems.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines multiple simple nozzle openings into a single integrated nozzle structure. This merging approach achieves improved reliability through redundancy while avoiding the complexity of multiple separate nozzle assemblies, maintaining a unified and manufacturable component design.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11230055B2Additive manufacturing system fluid ejector

Publication Date: 2022.01.25 HEWLETT PACKARD DEVELOPMENT COMPANY LP

AI summary

An additive manufacturing system may include a fluid ejector. The fluid ejector may be movable across a build material distributor at a maximum speed of less than or equal to 40 inches per second. The fluid ejector may include a nozzle having a non-circular bore.