Rotating Distributor Wheel for Extruder Material Bridging
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Solution Overview
Problem
The use of screw extruders in additive manufacturing is limited by their weight and size, which makes them difficult to move or requires an oversized 3D printing device, due to the need for a long extruder screw and inefficient material feeding mechanisms that can lead to bridging and uneven material distribution.
Innovation Solution
A filling device that includes a hopper and a feed device to actively return and mix processing material with the extruder screw, using mechanical, electrical, pneumatic, or magnetic means, which comminutes the material to prevent bridging and allows for a more compact extruder design by increasing bulk density and reducing air pressure needed for homogenization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a traditional gravity-driven hopper system is used to feed material to the extruder screw, then the device structure is simple, but material bridging occurs and material distribution becomes uneven
Solution Approach 1:
The patent introduces a rotating distributor wheel with radially arranged feed channels that dynamically redirects material flow. Instead of a static gravity-driven system, the rotating wheel actively controls material distribution to the extruder screw, preventing bridging by continuously changing the flow path and maintaining reliable material supply.
2Manufacturing precision
If a long extruder screw is used to ensure adequate material conveyance and homogenization, then material mixing quality improves, but the extruder weight and size increase
Solution Approach 1:
The patent performs preliminary material distribution and pre-mixing actions in the hopper region using the rotating distributor wheel before material enters the extruder screw. This preliminary action reduces the burden on the extruder screw, allowing for a shorter screw length while maintaining adequate homogenization quality, thereby reducing extruder weight and size.
3Reliability
If the hopper cross-section is increased to prevent material bridging, then material flow reliability improves, but the device occupies more space
Solution Approach 1:
Instead of increasing the static hopper cross-section, the patent uses a dynamic rotating distributor wheel with radially arranged feed channels. This dynamic system prevents material bridging by continuously redirecting flow through multiple paths without requiring a larger hopper area, thus maintaining compact device dimensions while ensuring reliable material flow.
4Productivity
If high air pressure is applied to homogenize and convey granular material, then material flow speed increases, but energy consumption increases
Solution Approach 1:
The patent employs a controlled pneumatic system that uses air pressure selectively and efficiently to homogenize and convey granular material through the rotating distributor wheel and feed channels. By directing air pressure only where needed in the material flow path and using the rotating wheel to assist material movement, the system achieves high conveyance speed with reduced overall energy consumption compared to continuous high-pressure air application.
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 solution enables efficient and compact extruder operation by preventing material bridging, improving material distribution, and allowing for high-speed extrusion without compromising component quality, thus overcoming the size and weight limitations of traditional screw extruders.
Implementation Method 1
a material reservoir (3) for the gravity-driven feed of the processing material to the hopper (5)
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The solution proposed relates, in particular, to a charging system (B) for feeding processing material, in particular granular processing material, to at least one extruder screw (2), the system comprising • - a hopper (5), designed to conduct the processing material in a feed direction (Z) to the extruder screw (2), and • - a material reservoir (3) for gravitational feeding of the processing material to the hopper (5). The charging system has a feed system (8), using which processing material that is returned to the hopper (5) in the opposite direction to the feed direction (Z) as a result of the action of the extruder screw (2), can be conveyed again, together with processing material fed from the material reservoir (3), towards the extruder screw (2).