Methods related to inductive heating in extruders

• US 10,307,939 B2
• Filed: 01/25/2017
• Issued: 06/04/2019
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: ProtoParadigm LLC
• Original Assignee: ProtoParadigm LLC
• Inventors: Stirling, Ralph L., Chilson, Luke, English, Alex
• Primary Examiner(s): Daniels, Matthew J
• Assistant Examiner(s): Shafi, Leith S
• Application Number:
  US15/415,849
• Publication Number:
  US 20170144334A1
• Time in Patent Office: 860 Days
• Field of Search: 425375, 264308, 264431
• CPC Class Codes: B29C 2035/0816 using eddy currents
• CPC Class Codes: B29C 2948/92209 Temperature
• CPC Class Codes: B29C 2948/92704 Temperature
• CPC Class Codes: B29C 35/0805 using electromagnetic radiation
• CPC Class Codes: B29C 48/802 Heating
• CPC Class Codes: B29C 48/92 Measuring, controlling or regulating
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29K 2101/12 Thermoplastic materials
• CPC Class Codes: B29K 2105/0067 Melt
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: H05B 2206/023 using the curie point of the material in which heating current is being generated to control the heating temperature
• CPC Class Codes: H05B 6/06 Control, e.g. of temperature, of power
• CPC Class Codes: H05B 6/14 Tools, e.g. nozzles, rollers, calenders

Abstract

Methods related to inductive heating in extruders. In some embodiments, a method for heating a feedstock or liquid material can include providing a heating body having inlet and outlet orifices connected via a passage or passages or mixing chamber to define a nozzle, and forming a magnetic loop with a coil of conductive wire wound through the center and around the outside of a core of magnetic but electrically non-conductive or low-conductivity material. The method can further include a high-frequency alternating current applied to the coil, producing a magnetic flux locally heating the nozzle. Some embodiments have passive regulation or limiting of nozzle temperature by selection of a core material with an appropriate Curie temperature.

Claims

1. A method for heating a feedstock of meltable or flowable material, comprising:

a) providing a heating body of electrically conductive material, having inlet and outlet orifices connected via a passage or passages or mixing chamber to define a nozzle;

b) said nozzle sandwiched between the two ends of, or inserted through a hole or gap in, a continuous or segmented core of material having high magnetic permeability but low electrical conductivity, forming a complete magnetic loop, said nozzle not oriented substantially in the same plane as said magnetic loop,

c) one or more coils of electrically conductive wire passing through the center of said loop and around the outside of said loop, and one or more sources of alternating current connected to said coil or coils, inducing said magnetic flux lines and said eddy currents,

d) feeding said feedstock in the form of filament, rod, wire, granules, or liquid stream into said inlet orifice or orifices;

e) said feedstock being heated by contact with said nozzle, and

f) extruding said feedstock from said outlet orifice or orifices.

2. Method of claim 1, maintaining a relatively constant temperature of said heating body by means of a temperature sensor or thermostatic device thermally connected to said heating body, controlling the heating effect by varying voltage amplitude, current amplitude, or frequency of said alternating current source or sources, or by cycling said alternating current source or sources on and off.

3. Method of claim 1, where said magnetic core is formed from material chosen for a specific Curie temperature, such that said heating body is passively limited to or regulated at a specific temperature.

4. Method of claim 1, where said feedstock is heated at two or more different temperatures in two or more heat zones in said heating body, by means of two or more of said magnetic cores sandwiching said heating body.

5. Method of claim 1, where two or more sources of said feedstock are heated, mixed, and extruded, by feeding said feedstock into two or more inlet orifices connected to a mixing chamber and thence to an outlet orifice defining a mixing nozzle.

6. Method of claim 1, where two or more sources of said feedstock are heated, mixed, and extruded, by feeding said feedstock into two or more inlet orifices, connected to a mixing chamber, with individual heating zones for each feedstock inlet, connecting to an outlet orifice defining a mixing nozzle.

7. Method of claim 1, where two or more sources of said feedstock are heated and extruded, without mixing, by feeding said feedstock into two or more inlet orifices connected to two or more outlet orifices by individual passages defining one or more nozzles in one heating body.

8. Method of claim 1, where said heating body has a flange comprising a heat sink attached to or formed in said heating body to selectively cool portions of said heating body.

9. A method for heating a feedstock of meltable or flowable material for additive manufacturing or 3D printing, comprising:

a) providing a heating body of electrically conductive material, having inlet and outlet orifices connected via a passage or passages or mixing chamber to define a nozzle;

b) said nozzle sandwiched between the two ends of, or inserted through a hole or gap in, a continuous or segmented core of material having high magnetic permeability but low electrical conductivity, forming a complete magnetic loop, said nozzle not oriented substantially in the same plane as said magnetic loop,

c) one or more coils of electrically conductive wire passing through the center of said loop and around the outside of said loop, and one or more sources of alternating current connected to said coil or coils, inducing said magnetic flux lines and said eddy currents,

d) feeding said feedstock in the form of filament, rod, wire, granules, or liquid stream into said inlet orifice or orifices;

e) said feedstock being heated by contact with said nozzle, and

f) extruding said feedstock from said outlet orifice or orifices.

10. Method of claim 9, maintaining a relatively constant temperature of said heating body by means of a temperature sensor or thermostatic device thermally connected to said heating body, controlling the heating effect by varying voltage amplitude, current amplitude, or frequency of said alternating current source or sources, or by cycling said alternating current source or sources on and off.

11. Method of claim 9, where said magnetic core is formed from material chosen for a specific Curie temperature, such that said heating body is passively limited to or regulated at a specific temperature.

12. Method of claim 9, where said feedstock is heated at two or more different temperatures in two or more heat zones in said heating body, by means of two or more of said magnetic cores sandwiching said heating body.

13. Method of claim 9, where two or more sources of said feedstock are heated, mixed, and extruded, by feeding said feedstock into two or more inlet orifices connected to a mixing chamber and thence to an outlet orifice defining a mixing nozzle.

14. Method of claim 9, where two or more sources of said feedstock are heated, mixed, and extruded, by feeding said feedstock into two or more inlet orifices, connected to a mixing chamber, with individual heating zones for each feedstock inlet, connecting to an outlet orifice defining a mixing nozzle.

15. Method of claim 9, where two or more sources of said feedstock are heated and extruded, without mixing, by sequentially feeding said feedstocks into two or more inlet orifices connected to one or more outlet orifices by individual passages defining one or more nozzles in one heating body.

16. Method of claim 9, where said heating body has a flange comprising a heat sink attached to or formed in said heating body to selectively cool portions of said heating body.

17. A method for heating a feedstock of meltable or flowable material for adhesive application, comprising:

a) providing a heating body of electrically conductive material, having inlet and outlet orifices connected via a passage or passages or mixing chamber to define a nozzle;

b) said nozzle sandwiched between the two ends of, or inserted through a hole or gap in, a continuous or segmented core of material having high magnetic permeability but low electrical conductivity, forming a complete magnetic loop, said nozzle not oriented substantially in the same plane as said magnetic loop,

c) one or more coils of electrically conductive wire passing through the center of said loop and around the outside of said loop, and one or more sources of alternating current connected to said coil or coils, inducing said magnetic flux lines and said eddy currents,

d) feeding said feedstock in the form of filament, rod, wire, granules, or liquid stream into said inlet orifice or orifices;

e) said feedstock being heated by contact with said nozzle, and

f) extruding said feedstock from said outlet orifice or orifices.

18. Method of claim 17, maintaining a relatively constant temperature of said heating body by means of a temperature sensor or thermostatic device thermally connected to said heating body, controlling the heating effect by varying voltage amplitude, current amplitude, or frequency of said alternating current source or sources, or by cycling said alternating current source or sources on and off.

19. Method of claim 17, where said magnetic core is formed from material chosen for a specific Curie temperature, such that said heating body is passively limited to or regulated at a specific temperature.

20. Method of claim 17, where said heating body has a flange comprising a heat sink attached to or formed in said heating body to selectively cool portions of said heating body.