Polymer Microsphere Formation by Atomization and Zoned Free Fall
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Solution Overview
Problem
Current additive manufacturing methods for producing polymer powders are inefficient, expensive, and result in materials with varying sizes and densities, lacking sphericity and requiring custom machines and materials for producing parts with variable densities.
Innovation Solution
An apparatus and method involving a melt chamber, vertical extruder, atomizer, and fall chamber to produce high-quality spherical polymer powders and microfibers through a single-step process, allowing for controlled atomization and crystallization of polymer melts into spherical particles with specific properties.
Engineering Contradictions & Design Principles
Engineering 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
Solution Approach 1:
The patent utilizes phase transition of polymer materials from solid to melt state and back to solid particles. The polymer is heated to melting point, extruded as melt, then rapidly cooled to form spherical particles. This phase transition approach enables high-precision spherical particle formation while maintaining high production efficiency through continuous processing.
Solution Approach 2:
The patent replaces conventional mechanical particle formation methods (such as grinding, crushing, or cutting) with a melt-extrusion-solidification system. By substituting mechanical force-based particle formation with thermal processing and fluid dynamics, the system achieves superior sphericity and surface finish while improving production efficiency through continuous operation.
2Manufacturing precision
If custom machines and materials are used for each print material composition, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent designs a universal polymer particle production system that can process different polymer materials and compositions through a single apparatus. The extrusion and solidification system is configured to handle various thermoplastic materials by adjusting processing parameters (temperature, extrusion rate, cooling conditions) rather than requiring custom machines for each material type, thereby reducing device complexity while maintaining manufacturing precision.
Solution Approach 2:
The patent achieves control over different material properties by changing processing parameters (temperature, pressure, extrusion rate, cooling rate) rather than changing the fundamental system configuration. This parameter-based control allows the same apparatus to produce particles with varying densities, sizes, and material compositions, eliminating the need for custom machines for each print material.
3Manufacturing precision
If conventional extrusion methods are used, then device complexity is reduced, but manufacturing precision and particle uniformity deteriorate
Solution Approach 1:
The patent employs a circular die opening in the extrusion system that produces cylindrical melt streams which solidify into spherical particles during free fall. The circular geometry of the die ensures uniform cross-section and consistent cooling rates around the entire particle circumference, resulting in high sphericity and uniform size distribution. This geometric approach enhances manufacturing precision without requiring complex particle shaping mechanisms.
Solution Approach 2:
The patent transitions from two-dimensional extrusion (flat sheet or rod) to three-dimensional spherical particle formation by extruding into free fall. The melt is extruded as a continuous stream and solidifies in three-dimensional space during descent, allowing uniform cooling from all directions and forming perfectly spherical particles with consistent dimensions, thereby improving particle uniformity.
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 rapid production of parts with variable densities using existing additive manufacturing technologies, allowing for enhanced control over elastomeric properties and improved sphericity, reducing production time and costs while minimizing waste.
Implementation Method 1
an atomizer that atomizes the polymer melt from the vertical extruder and that distributes the atomized polymer melt
Implementation Method 2
an atomizer that atomizes the polymer melt
Implementation Method 3
allowing for controlled atomization and crystallization of polymer melts into spherical particles
Implementation Method 4
crystallization of polymer melts into spherical particles
Implementation Method 5
a fall chamber comprising a plurality of zones into which the atomized polymer melt is distributed
Data Source
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.