Printhead Direct Heating Plate for High-Viscosity Material Discharge
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Solution Overview
Problem
Current 3D printing technologies face challenges with high material costs, inefficient heating, and difficulty in handling high-viscosity deposition materials, leading to slow production of large-sized objects due to indirect heating and the need for expensive, bulky nozzles that can clog or require frequent replacement.
Innovation Solution
A printhead design featuring a flow path formed by heating plates that directly heat the deposition material, allowing for continuous discharge of high-viscosity materials and enabling the use of low-cost, plate-based components, with discharge openings arranged in rows for efficient layering and rapid production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If indirect heating through heater block is used, then heating stability is improved, but thermal efficiency deteriorates and heating time increases
Solution Approach 1:
The invention extracts the heating function from the separate heater block and integrates it directly into the nozzle structure. The heating element is now embedded within the nozzle itself, allowing direct heating of the deposition material at the point of discharge, thereby improving thermal efficiency while maintaining heating stability through controlled temperature regulation.
Solution Approach 2:
The invention introduces a thermal conductor as an intermediary between the heating element and the deposition material. This thermal conductor efficiently transfers heat from the heating element directly to the deposition material, minimizing heat loss and improving thermal efficiency while maintaining stable heating conditions.
2Reliability
If cylindrical nozzles with screw connections are used, then sealing and connection reliability are improved, but manufacturing cost increases and device size enlarges
Solution Approach 1:
The invention adopts a flat plate nozzle design that simplifies the complex cylindrical nozzle structure. By copying the essential function of material discharge from the cylindrical nozzle but implementing it through a flat plate with discharge openings, the manufacturing process becomes simpler and more cost-effective while maintaining reliable material discharge capability.
Solution Approach 2:
The invention extracts the nozzle function from its traditional cylindrical form with screw connections and reimagines it as a flat plate structure. This extraction of the essential discharge function from the complex cylindrical geometry eliminates the need for screw connections and through-holes, reducing manufacturing complexity and cost.
3Productivity
If deposition material discharge amount is increased for large-sized objects, then productivity is improved, but material viscosity control becomes difficult and clogging occurs
Solution Approach 1:
The invention creates different local conditions within the nozzle structure to handle high-viscosity materials effectively. The flow path is designed with specific local characteristics including appropriate width, depth, and curvature radius that facilitate smooth material flow. The heating element is positioned to provide localized heating exactly where needed, maintaining optimal temperature and viscosity for discharge control even at higher production speeds.
Solution Approach 2:
The invention optimizes the physical parameters of the flow path including width, depth, and curvature radius to improve material flow characteristics. By carefully controlling these parameters, the system can discharge larger amounts of high-viscosity material without clogging, thereby improving productivity while maintaining reliable discharge control.
4Ease of operation
If heating temperature is increased to discharge high-viscosity materials, then discharge ability is improved, but material degradation and carbonization occur
Solution Approach 1:
The invention provides localized heating through the heating element positioned within the nozzle, creating optimal temperature conditions only where needed for discharge. This localized approach allows the system to maintain lower overall temperatures that prevent material degradation and carbonization while still achieving sufficient heat at the discharge point to enable smooth flow of high-viscosity materials.
Solution Approach 2:
The invention optimizes the heating temperature parameter to find the optimal balance between discharge ability and material integrity. By carefully controlling the temperature parameter within the heating element, the system achieves sufficient heat to discharge high-viscosity materials without exceeding the threshold that would cause degradation or carbonization.
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 design enhances thermal efficiency, reduces material costs, and allows for the rapid production of large-sized objects by directly heating the deposition material and enabling continuous, controlled discharge, even for high-viscosity materials, while also simplifying the manufacturing process.
Implementation Method 1
a first heating plate 2 constituting a first side wall portion 121, which is a part of a side wall forming flow paths 12... and heating the deposition material in the flow paths 12
Implementation Method 2
enhances thermal efficiency... by directly heating the deposition material
Implementation Method 3
One example of materials for forming such fabricated object includes materials which are formed into a melted state by increasing its temperature such as thermoplastic resins
Data Source
Figure 1A~1B
Figure 1C~2
Figure 3~4A
AI summary
There is provided a printhead dispensing deposition material which can discharge even a deposition material with a high viscosity in a prescribed place in a predetermined amount, with a flow path structure body which can be easily produced with considerably low-cost materials such as plates. The printhead dispensing deposition material comprises a first heating plate constituting a first side wall portion, which is a part of a side wall forming a flow path for flowing the deposition material, and heating the deposition material in the flow path; a closing plate constituting a second side wall portion which is a part of the side wall other than the first side wall portion; a discharge opening communicating with the flow path and formed on one tip of the flow path; and a material supply opening communicating with the flow path and formed on another tip of the flow path.