Polymer Microsphere Atomization for Spherical AM Powder Production

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current additive manufacturing methods for producing powders are slow, inefficient, and costly, often resulting in powders with varying sizes and densities that lack sphericity, and are specific to the desired composition, making them unsuitable for refined print processes.

Innovation Solution

A system comprising a melt chamber, vertical extruder, atomizer, and fall chamber with controlled zones is used to produce polymer microspheres by atomizing a polymer melt and controlling temperature and pressure, allowing for the production of high-quality spherical powders and microfibers with customizable properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional powder forming methods are used, then production cost and time are reduced, but manufacturing precision and sphericity of particles deteriorate

Engineering Contradiction:

Improveparticle sphericityVSAvoidproduction speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The invention changes the physical state parameters of the material by melting polymer at controlled temperatures and then rapidly cooling it through atomization. This parameter transformation from solid to molten to solidified droplets enables spherical particle formation with consistent size distribution, resolving the contradiction between precision and productivity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The process utilizes phase transitions of polymer material - heating to melt phase, then rapid cooling to solidify into spherical particles. This phase transition approach allows continuous production of high-precision spherical powders at high speed, simultaneously improving both manufacturing precision and productivity.

Inventive Principle:

Principle #36Phase transitions

2Manufacturing precision

If conventional powder forming methods are used, then process simplicity is maintained, but manufacturing precision and particle consistency deteriorate

Engineering Contradiction:

Improveparticle size consistencyVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The process segments the particle formation into distinct stages: melting, atomization, and cooling. Each stage is controlled independently to ensure particle size consistency. The segmentation of the process enables precise control over particle properties while maintaining a relatively simple overall system architecture.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention replaces conventional mechanical particle formation methods with a thermal-field-based atomization process. By using controlled thermal energy and fluid dynamics instead of mechanical forces, the system achieves superior particle consistency with a simpler process flow, reducing device complexity while improving manufacturing precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If material-specific methods are used, then composition accuracy is improved, but adaptability to different materials deteriorates

Engineering Contradiction:

Improvematerial compatibilityVSAvoidcomposition control

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The atomization process is universally applicable to various polymer materials. The same basic process - melting and atomizing - works for different polymer compositions, enabling the system to handle multiple materials while maintaining composition control. This universal approach resolves the contradiction between adaptability and precision.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 method enables the rapid production of high-quality spherical powders and microfibers with controlled properties, suitable for various additive manufacturing processes, allowing for parts with variable densities and improved elastomeric properties, and enables the use of these materials in existing AM technologies.

Implementation Method 1

an atomizer that atomizes the polymer melt from the vertical extruder and that distributes the atomized polymer melt

Methodology Applied

Scientific EffectAtomization:

Implementation Method 2

a fall chamber comprising a plurality of zones into which the atomized polymer melt is distributed; and a collector to receive the print material particles formed of the atomized polymer melt after falling through the plurality of zones

Methodology Applied

Scientific EffectPhase change (solidification): Phase Change

Data Source

PatentUS11860618B2Apparatus, system and method of forming polymer microspheres for use in additive manufacturing

Publication Date: 2024.01.02 JABIL INC

AI summary

The embodiments are and include at least an apparatus, system and method for forming print material particles for additive manufacturing (AM) printing. The apparatus, system and method include at least a melt chamber comprising a polymer melt; a vertical extruder that fluidically receives the polymer melt; an atomizer that atomizes the polymer melt from the vertical extruder and that distributes the atomized polymer melt; a fall chamber comprising a plurality of zones into which the atomized polymer melt is distributed; and a collector to receive the print material particles formed of the atomized polymer melt after falling through the plurality of zones.