Rotating Injector Attachment for In-Process 3D Wall Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive manufacturing systems face challenges in efficiently filling air pockets within construction elements with insulation materials, leading to misalignment, increased production time, and higher costs due to the need for separate injection systems, which disrupt the continuous construction process and require skilled labor.
Innovation Solution
A device connectable to an additive manufacturing system, featuring a holder, orbital units, and injectors that allow for the concentric rotation and controlled injection of filler materials within construction elements during the manufacturing process, enabling seamless integration and precise filling of air pockets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a separate injection system is used to fill air pockets with insulation materials, then thermal insulation performance is improved, but production time increases and workflow continuity is disrupted
Solution Approach 1:
The patent combines the injection system with the additive manufacturing system by mounting the injection nozzle on the extruder assembly. This allows the injection of insulation materials into air pockets to occur during the additive manufacturing process without requiring a separate, standalone injection system, thereby maintaining thermal insulation performance while avoiding production delays
Solution Approach 2:
The injection process is integrated into the continuous additive manufacturing workflow. The control system coordinates the extruder movement with the injection timing, allowing insulation materials to be injected into air pockets as they are formed during layer deposition, ensuring continuous production without halting the manufacturing process
2Adaptability or versatility
If the additive manufacturing system is moved to fix injection systems, then air pocket filling capability is improved, but alignment precision deteriorates
Solution Approach 1:
The injection system is merged with the extruder assembly of the additive manufacturing system. The injection nozzle is positioned on the extruder and moves with it, ensuring that the injection point maintains precise alignment with the air pockets being formed during layer deposition, eliminating alignment issues that would arise from moving the entire system
Solution Approach 2:
The control system acts as an intermediary that coordinates the movement of the extruder assembly with the injection timing and positioning. It receives data about air pocket locations from the digital model and controls the injection nozzle to target specific air pockets while the extruder moves to different positions, maintaining precision without requiring system displacement
3Temperature
If external injection systems are used for filling air pockets, then insulation functionality is improved, but device complexity increases
Solution Approach 1:
The injection system is integrated into the existing extruder assembly rather than being implemented as a separate external system. The injection nozzle is mounted on the extruder and shares the same mounting structure and movement mechanism, reducing the number of independent components and simplifying the overall system architecture while still providing insulation functionality
Solution Approach 2:
The extruder assembly is designed to perform multiple functions: it both deposits construction materials to form layers and injects insulation materials into air pockets. This multi-functionality eliminates the need for a dedicated external injection system, reducing device complexity while maintaining the required insulation capability
4Adaptability or versatility
If separate injection systems are implemented, then filling capability is improved, but operational difficulty increases
Solution Approach 1:
The system automatically determines air pocket locations from the digital model data and controls the injection process without requiring manual intervention. The control system coordinates the extruder movement and injection timing based on pre-programmed information about air pocket positions, making the operation straightforward while providing comprehensive filling capability
Solution Approach 2:
The control system uses feedback from the digital model about air pocket locations to adjust the injection timing and nozzle positioning. This automated feedback loop ensures accurate filling of air pockets while simplifying operation, as the system self-regulates based on the known geometry of the structure being built
Data Source
AI summary
The present disclosure is directed to a device connectable to an additive manufacturing system. The device includes a holder which is removably connectable to an extruder of the additive manufacturing system. Further, the device includes an orbital unit which is concentrically coupled to the holder and is adapted to rotate relative to the holder. Furthermore, the device includes at least one injector which is movably coupled to the orbital unit. The at least one injector is configured to inject at least one filler material within a construction element. Additionally, the device includes a control unit which is associated with the additive manufacturing system and is operatively coupled with the orbital unit and the at least one injector. The control unit is configured to selectively rotate the orbital unit and actuate at least one injector for injecting the at least one filler material within the construction element during additive manufacturing.