Dynamically controlled screw-driven extrusion

• US 10,684,603 B2
• Filed: 01/13/2016
• Issued: 06/16/2020
• Est. Priority Date: 01/13/2015
• Status: Active Grant

• Current Assignee: Bucknell University
• Original Assignee: Bucknell University
• Inventors: Kim, Charles John, Pratt, Samuel Thomas
• Primary Examiner(s): Zhao, Xiao S
• Assistant Examiner(s): Leyson, Joseph S
• Application Number:
  US14/994,540
• Publication Number:
  US 20160200024A1
• Time in Patent Office: 1,616 Days
• CPC Class Codes: B29C 2948/92085 Velocity
• CPC Class Codes: B29C 2948/92104 Flow or feed rate
• CPC Class Codes: B29C 2948/92209 Temperature
• CPC Class Codes: B29C 2948/9258 Velocity
• CPC Class Codes: B29C 2948/926 Flow or feed rate
• CPC Class Codes: B29C 2948/92704 Temperature
• CPC Class Codes: B29C 48/2522 Shaft or screw supports, e.g. bearings
• CPC Class Codes: B29C 48/2526 Direct drives or gear boxes
• CPC Class Codes: B29C 48/255 Flow control means, e.g. valves flow dividers B29C48/695
• CPC Class Codes: B29C 48/288 in solid form, e.g. powder or granules
• CPC Class Codes: B29C 48/397 using a single screw
• CPC Class Codes: B29C 48/53 having a varying channel depth, e.g. varying the diameter of the longitudinal screw trunk
• CPC Class Codes: B29C 48/6801 characterised by the material or their manufacturing process
• CPC Class Codes: B29C 48/6803 Materials, coating or lining therefor
• CPC Class Codes: B29C 48/802 Heating
• CPC Class Codes: B29C 48/83 Heating or cooling the cylinders
• CPC Class Codes: B29C 48/832 Heating
• CPC Class Codes: B29C 48/834 Cooling
• CPC Class Codes: B29C 48/85 Cooling
• CPC Class Codes: B29C 48/92 Measuring, controlling or regulating
• CPC Class Codes: B29C 64/106 : using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/118 : using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/209 : Heads; Nozzles
• CPC Class Codes: B29C 64/241 : for rotary motion
• CPC Class Codes: B29C 64/245 : Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/295 : Heating elements
• CPC Class Codes: B29C 64/329 : using hoppers
• CPC Class Codes: B29C 64/386 : Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29C 64/393 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29K 2021/006 : Thermosetting elastomers
• CPC Class Codes: B33Y 30/00 : Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: G05B 19/188 : characterised by special applications and not provided for in the relevant subclasses, (e.g. making dies, filament winding)

Abstract

A screw-driven extrusion system includes a novel screw-drive extruder. The extruder includes a motor-driven screw. The screw moves solid pellets from a feed hopper into a section that is actively heated. The solid pellets fully liquefy as they pass through the heated section. A control system controls screw, heating, and optionally cooling, operations to selectively control flow of liquefied material from the extruder'"'"'s tip. The dynamically-controlled can continuously adjust its feed speed and temperature to keep up with continuously changing demands of a larger control system involved in monitoring and running a corresponding 3-D printer in an additive manufacturing process. In contrast to wirefeed extrusion systems that rely on the rigidity of the material in “wire”-formed feedstock, this screw-driven extrusion system is well-suited to use of less-rigid thermoplastic elastomers for the manufacture of objects for use in soft robotics, medical and mold-making applications.

Claims

1. A screw-drive extrusion system comprising:

a toolhead, the toolhead comprising;

a screw-drive extruder, the screw-drive extruder comprising

an upper housing portion defining at a proximal end at least one feedstock port for receiving a flow of feedstock material;

a lower housing portion defining at a distal end an extrusion die defining an extrusion opening, said lower housing portion cooperating with said upper housing portion to define an elongated inner bore having a sidewall;

an elongated screw having at least one flight, said screw comprising a shank portion and a drive portion, said drive portion riding within said elongated inner bore, said at least one flight cooperating with said sidewall to advance feedstock material received via said at least one feedstock port toward said extrusion opening;

a bearing assembly joined to said upper housing portion and comprising support bearings for supporting said shank portion of said screw; and

a heater positioned about said lower housing portion intermediate said upper housing portion and said extrusion opening;

a motor, said motor comprising a drive shaft coupled to the elongated screw;

a hopper for receiving feedstock pellets, and

a conduit extending from a lower end of said hopper to the at least one feedstock port of said screw-drive extruder, said conduit being adapted for conveying feedstock pellets from said hopper to said screw-drive extruder;

and

a control system for dynamically controlling operation of the toolhead, said control system comprising;

a motor speed sensor configured to monitor motor drive shaft position over time and send corresponding motor position data signals to a control processor;

a motor driver configured to send a motor control signal to the motor;

a temperature sensor configured to monitor temperature over time and send corresponding temperature data signals to the control processor;

a heater controller configured to send a temperature control signal to the heater;

said control processor comprising a microprocessor, a memory, an input/output data acquisition connector, firmware, and instructions stored in the memory and executable by the microprocessor to provide a motor control loop and a temperature control loop,

said motor control loop comprising instructions stored in said memory and executable by said microprocessor to send a first control signal to said motor driver to cause said motor to operate in accordance with a speed set point;

said temperature control loop comprising instructions stored in said memory and executable by said microprocessor to send a second control signal to said heater controller to cause said heater to operate in accordance with a temperature set point; and

an extrudate flow controller comprising instructions stored in said memory and executable by said microprocessor to determine, repeatedly over time, a current temperature set point and a current speed set point,

the extrudate flow controller further comprising instructions stored in said memory and executable by said microprocessor to receive, from an external control system, a command for filament length and motor speed for a wirefeed extrusion system, and for determining said current temperature set point and said current speed set point as a function of said filament length and motor speed instructions, said current temperature set point and said current speed set point being determined by calculating a desired volumetric flow rate as a function of said filament length and motor speed instructions and by referencing calibration data stored in said memory to determine said set points.

2. The screw-drive extrusion system of claim 1, the screw-drive extruder further comprising:

a thermal insulation flange, said thermal insulation flange being joined to and between said upper and lower housing portions and cooperating therewith to define said inner bore, said thermal insulation flange providing insulation to thermal conductivity between said lower and upper housing portions.

3. The screw-drive extrusion system of claim 1, the screw-drive extruder further comprising:

a motor shaft coupler joined to the shank portion of said screw; and

a motor mounting flange for mounting the motor in a position with its drive shaft coupled to said motor shaft coupler.

4. The screw-drive extrusion system of claim 1, the screw-drive extruder further comprising:

a motor shaft coupler joined to the shank portion of said screw, wherein the motor shaft coupler comprises one of a pulley and a gear.

5. The screw-drive extrusion system of claim 1, wherein a root of the screw has a surface that tapers radially outwardly from a longitudinal axis of the screw.

6. The screw-drive extrusion system of claim 1, wherein a root of the screw has a distal surface portion that is not tapered, but rather has a consistent cross-section.

7. The screw-drive extrusion system of claim 1, wherein the screw has a tip and wherein said tip has a conical configuration.

8. The screw-drive extrusion system of claim 1, wherein said screw is constructed to be slightly but significantly shorter than the bore to provide a small region between a distal tip of the screw and the opening in the extrusion die that is not swept by the screw.

9. The screw-drive extrusion system of claim 1, further comprising a covering of insulative material, said covering being positioned to surround at least a portion of the lower housing portion of the screw drive extruder.

10. The screw-drive extrusion system of claim 1, further comprising a cooling jacket, said cooling jacket being positioned to surround said upper housing portion of the screw drive extruder and to pass a flow of coolant for cooling the upper housing portion.

11. The screw-drive extrusion system of claim 10, wherein said screw defines a central cavity extending longitudinally within said screw, said screw-drive extruder further comprising:

a thermally conductive member disposed within and extending through said cavity to a free end;

a heatsink supported on said free end.

12. The screw-drive extrusion system of claim 11, wherein said thermally conductive member comprises a heat pipe having a thermal conductivity greater than a corresponding thermal conductivity of a material of said screw.

13. The screw-drive extrusion system of claim 11, wherein said heatsink comprises an array of cooling fins extending radially from said thermally conductive member.

14. The screw-drive extrusion system of claim 13, further comprising a cooling fan disposed to direct a flow of air over said heatsink.

15. The screw-drive extrusion system of claim 1, wherein said screw defines a central cavity extending longitudinally within said screw, said screw-drive extruder further comprising:

a thermally conductive member disposed within and extending through said cavity to a free end; and

a heatsink supported on said free end.

16. The screw-drive extrusion system of claim 15, wherein said thermally conductive member comprises a heat pipe having a thermal conductivity greater than a corresponding thermal conductivity of a material of said screw.

17. The screw-drive extrusion system of claim 15, wherein said heatsink comprises an array of cooling fins extending radially from said thermally conductive member.

18. The screw-drive extrusion system of claim 17, further comprising a cooling fan disposed to direct a flow of air over said heatsink.

19. The screw-drive extrusion system of claim 1, further comprising:

a planetary reduction gear coupling said drive shaft of said motor to a motor shaft coupler.

20. An additive manufacturing system comprising:

a build platform; and

a screw-drive extrusion system according to claim 1; and

a main control system for controlling relative movement of the toolhead and the build platform with at least three degrees of freedom, the main control system providing at least one command for supply of extrudate.

21. A screw-drive extrusion system comprising:

a toolhead, the toolhead comprising;

a screw-drive extruder, the screw-drive extruder comprising

an upper housing portion defining at a proximal end at least one feedstock port for receiving a flow of feedstock material;

a lower housing portion defining at a distal end an extrusion die defining an extrusion opening, said lower housing portion cooperating with said upper housing portion to define an elongated inner bore having a sidewall;

an elongated screw having at least one flight, said screw comprising a shank portion and a drive portion, said drive portion riding within said elongated inner bore, said at least one flight cooperating with said sidewall to advance feedstock material received via said at least one feedstock port toward said extrusion opening;

a bearing assembly joined to said upper housing portion and comprising support bearings for supporting said shank portion of said screw; and

a heater positioned about said lower housing portion intermediate said upper housing portion and said extrusion opening;

a motor, said motor comprising a drive shaft;

a hopper for receiving feedstock pellets, and

a conduit extending from a lower end of said hopper to the at least one feedstock port of said screw-drive extruder, said conduit being adapted for conveying feedstock pellets from said hopper to said screw-drive extruder;

and

a control system for dynamically controlling operation of the toolhead, said control system comprising;

a motor speed sensor configured to monitor motor drive shaft position over time and send corresponding motor position data signals to a control processor;

a motor driver configured to send a motor control signal to the motor;

a temperature sensor configured to monitor temperature over time and send corresponding temperature data signals to the control processor;

a heater control switch configured to send a temperature control signal to the heater;

said control processor comprising a microprocessor, a memory, an input/output data acquisition connector, firmware, and instructions stored in the memory and executable by the microprocessor to provide a motor control loop and a temperature control loop,

said motor control loop comprising instructions stored in said memory and executable by said microprocessor to send a first control signal to said motor driver to cause said motor to operate in accordance with a speed set point;

said temperature control loop comprising instructions stored in said memory and executable by said microprocessor to send a second control signal to said heater control switch to cause said heater to operate in accordance with a temperature set point; and

an extrudate flow controller comprising instructions stored in said memory and executable by said microprocessor to determine, repeatedly over time, a current temperature set point and a current speed set point said extrudate flow controller comprising;

calibration curve data stored in said memory; and

instructions for receiving from an external control system a command for filament length and motor speed for a wirefeed extrusion system, and for determining said current temperature set point and said current speed set point as a function of said filament length and motor speed instructions, said current temperature set point and said current speed set point being determined by calculating a desired volumetric flow rate as a function of said filament length and motor speed instructions, and by referencing said calibration curve to determine said set points.