Alignment system for magnetic particulate material used for additive manufacturing

Patent metadata

Field	Value
Publication number	US-11980939-B2
Application number	US-202117231498-A
Country	US
Kind code	B2
Filing date	Apr 15, 2021
Priority date	Apr 16, 2020
Publication date	May 14, 2024
Grant date	May 14, 2024

Abstract

An electromagnet alignment system for in-situ alignment of a magnetic particulate material is provided. The magnetic particulate material is dispensed through an orifice of a dispensing nozzle used for 3D printing. The system has an electromagnet assembly having a coil. The coil is configured to generate a pulsed magnetic field having a target magnetic flux intensity upon energization of the coil when the magnetic particulate material is being heated and moved through the dispensing nozzle. As a result, the magnetic particulate material is at least partially aligned with respect to a direction by the pulsed magnetic field. The system further includes a power source for implementing the energization of the coil.

First claim

What is claimed is:

1. An electromagnet alignment system for in-situ alignment of at least one magnetic particulate material dispensed through an orifice of a dispensing nozzle used for 3D printing, comprising:
an electromagnet assembly comprising a coil, wherein the coil is configured to generate a pulsed magnetic field having a target magnetic flux intensity upon energization of the coil when the at least one magnetic particulate material is being heated and moved through the dispensing nozzle, such that the at least one magnetic particulate material is at least partially aligned with respect to a direction by the pulsed magnetic field; and
a power source for implementing the energization of the coil,
wherein the electromagnet assembly further comprises a tube having an inner surface proximal to the dispensing nozzle and an outer surface distal to the dispensing nozzle,
wherein the coil is cylindrical and wound around the outer surface of the tube, and
wherein the tube, the coil and the dispensing nozzle are concentric,
wherein the dispensing nozzle comprises: a connecting portion connected to a delivery port of an extruder of a 3D printer used for the 3D printing; a terminal portion comprising the orifice; and an elongated portion extending between the connecting portion and the terminal portion,
a heating layer attached to an outer surface of the elongated portion of the dispensing nozzle for maintaining the temperature of the elongated portion at a predetermined value,
an insulation layer provided between the heating layer and the inner surface of the tube,
wherein the insulation layer is configured to reduce heat-transferring from the heating layer to the tube,
wherein the heating layer and the insulation layer are provided between the outer surface of the elongated portion of the dispensing nozzle and the inner surface of the tube of the electromagnet assembly to provide frictional engagement between the outer surface of the elongated portion and the inner surface of the tube, such that the dispensing nozzle and the electromagnet assembly are coupled to each other through pressure and friction to prevent the dispensing nozzle from moving with respect to the electromagnet assembly.

2. The system according to claim 1 , wherein the target magnetic flux intensity is in a range of 0.2 T-1 T.

3. The system according to claim 2 , wherein the target magnetic flux intensity is in a range of 0.3-0.5 T.

4. The system according to claim 2 , wherein the target magnetic flux intensity is in a range of 0.4-0.6 T.

5. The system according to claim 2 , wherein the target magnetic flux intensity is in a range of 0.5-0.7 T.

6. The system according to claim 2 , wherein the target magnetic flux intensity is in a range of 0.6-0.8 T.

7. The system according to claim 2 , wherein the target magnetic flux intensity is in a range of 0.7-0.9 T.

8. The system according to claim 2 , wherein the target magnetic flux intensity is in a range of 0.8-1.0 T.

9. The system according to claim 2 , wherein the target magnetic flux intensity is based on at least one of: the at least one magnetic particulate material; a temperature of the heating of the at least one magnetic particulate material; and a binding material used in conjunction with the at least one magnetic particulate material.

10. The system according to claim 9 , wherein the binding material comprises a thermoplastic polymer material.

11. The system according to claim 10 , wherein the thermoplastic polymers include at least one of nylon, polyphenylene sulfide, polycarbonate and ABS.

12. The system according to claim 2 , wherein a pulse width of the pulsed magnetic field is in a range of 1 millisecond to 10 seconds, wherein the pulse width is determined based on a flow rate of the least one magnetic particulate material through the orifice of the dispensing nozzle.

13. The system according to claim 12 , wherein the pulse width is in a range 1 second to 5 seconds.

14. The system according to claim 12 , wherein the pulse width is in a range 2 seconds to 6 seconds.

15. The system according to claim 12 , wherein the pulse width is in a range 3 seconds to 7 seconds.

16. The system according to claim 12 , wherein the pulse width is in a range 4 seconds to 8 seconds.

17. The system according to claim 12 , wherein the pulse width is in a range 5 seconds to 9 seconds.

18. The system according to claim 12 , wherein the pulse width is in a range 6 seconds to 10 seconds.

19. The system according to claim 1 , wherein:
the coil has an inner surface radially proximal to the dispensing nozzle and an outer surface radially distal to the dispensing nozzle;
the coil has a first radius defined radially from a longitudinal central axis of the coil to the inner surface of the coil; and

the coil has a second radius defined radially from the longitudinal central axis of the coil to the outer surface of the coil.

20. The system according to claim 19 , wherein:
the first radius is about 25.4 mm; and
the second radius is in a range of about 101.6 mm to about 254 mm.

21. The system according to claim 19 , wherein:
the coil has a top surface and a bottom surface opposite each other in a direction of the longitudinal central axis;
the coil has a length defined between the top surface and the bottom surface in the direction of the longitudinal central axis; and
wherein the length of the coil is in a range of about 177.8 mm to 203.2 mm.

22. The system according to claim 1 , wherein the connecting portion comprises a threaded portion.

23. The system according to claim 1 , wherein the heating layer comprises a heating tape and a controller for controlling the heating temperature of the heating tape.

24. The system according to claim 1 , wherein the dispensing nozzle is made of a non-magnetic stainless steel.

25. The system according to claim 1 , wherein nylon is being used as a binding material with the at least one magnetic particulate material and wherein the predetermined value of the temperature is in a range of 180° C.-250° C.

26. The system according to claim 1 , wherein polyphenylene sulfide (PPS) is being used as a binding material with the at least one magnetic particulate material and wherein the predetermined value of the temperature is in a range of 270° C.-324° C.

27. The system according to claim 1 , wherein the tube is made of a thermo-insulation and non-magnetic material.

28. The system according to claim 1 , further comprising a temperature sensor being configured to provide an instant temperature at the elongated portion of the dispensing nozzle, wherein the heating layer is adjustable based on the instant temperature for maintaining the temperature of the elongated portion at the predetermined value.

29. The system according to claim 1 , further comprising a support associated with the electromagnet assembly, wherein the support comprises a base having an opening, wherein the electromagnet assembly is attached to the base, such that a central passageway defined by the inner surface of the tube is aligned with the opening of the base.

30. The system according to claim 1 , further comprising a cooling device associated with the coil of the electromagnet assembly, wherein the cooling device is configured to maintain the temperature of the coil at a predetermined value.

Assignees

• Ut Battelle Llc

Inventors

• Paranthaman Mariappan Parans
• Post Brian K
• Sales Brian C

Classifications

• B22F12/53 Primary

  Nozzles · CPC title

• B22F1/10

  Metallic powder containing lubricating or binding agents; Metallic powder containing organic material · CPC title

• B22F10/34

  of powder characteristics, e.g. density, oxidation or flowability · CPC title

• B22F10/85

  for controlling or regulating additive manufacturing processes · CPC title

• B22F12/13

  to preheat the material · CPC title