Systems and methods for confined coaxial powder extrusion

Patent metadata

Field	Value
Publication number	US-2024278492-A1
Application number	US-202318385791-A
Country	US
Kind code	A1
Filing date	Oct 31, 2023
Priority date	Feb 16, 2023
Publication date	Aug 22, 2024
Grant date	—

Abstract

The present disclosure relates to a system for additively manufacturing a structure for transporting carbon dioxide. The system makes use of a nozzle component having a housing. The housing has a first nozzle for receiving a powder capable of capturing carbon dioxide, and channeling the powder through the nozzle component. The housing also has a second nozzle configured to receive a polymer component and to channel the polymer through the housing without intermixing of the polymer and the powder. A print head is in communication with the housing and configured to receive both the powder and the polymer, and to co-extrude the powder and the polymer so that the polymer forms a shell that encases the powder as the powder and polymer are co-extruded.

First claim

1 . A system for additively manufacturing a structure for transporting carbon dioxide, the system comprising:
a nozzle component including:
a housing having:
a first nozzle formed on the housing for receiving a powder capable of capturing carbon dioxide, and channeling the powder through the nozzle component;
a second nozzle formed on the housing and configured to receive a polymer component and channeling the polymer through the housing without intermixing of the polymer and the powder; and
a print head in communication with the housing and configured to receive both the powder and the polymer, and to co-extrude the powder and the polymer so that the polymer forms a shell that encases the powder.

2 . The system of claim 1 , wherein the housing includes an internal depending tubular portion extending coaxially through the housing and through the print head.

3 . The system of claim 1 , wherein the print head includes an annular path for channeling the polymer out therefrom.

4 . The system of claim 1 , further comprising a vibration unit configured to provide a vibration energy to the print head.

5 . The system of claim 4 , further comprising an excitation signal generator configured to provide an excitation signal to the vibration unit.

6 . The system of claim 5 , further comprising a computer configured to control the excitation signal generator.

7 . The system of claim 1 , further comprising a nozzle motion control subsystem configured to control motion of the nozzle component along X and Y axes.

8 . The system of claim 7 , further comprising a computer in communication with the nozzle motion control subsystem and configured to provide electronic toolpath commands to the nozzle motion control subsystem for controlling motion of the nozzle component.

9 . The system of claim 1 , further comprising the polymer, and wherein the polymer.

10 . The system of claim 9 , wherein the polymer comprises a carbonate-based composite sorbent capable of capturing carbon dioxide.

11 . The system of claim 9 , wherein the polymer comprises a thermally curable polymer.

12 . The system of claim 1 , further comprising the powder.

13 . The system of claim 12 , wherein the powder comprises bicarbonate-based powder.

14 . The system of claim 12 , wherein the powder comprises stainless steel powder.

15 . The system of claim 12 , wherein the powder comprises at least one of:
a metal organic frameworks (MOF) powder core; a metal-organic frameworks (MOFs); a zeolite; or an activated carbon.

16 . A system for additively manufacturing a structure for transporting carbon dioxide, the system comprising:
a nozzle component including:
a housing having:
a first nozzle formed on the housing for receiving a powder capable of capturing carbon dioxide;
an internal depending tubular portion in communication with the first nozzle for channeling the powder through the nozzle component, the internal depending tubular portion being aligned coaxially with a longitudinal axis extending through the housing;
a second nozzle formed on the housing non-parallel to the first nozzle and configured to receive a polymer component;
an annular flow path formed around an exterior of the internal depending tubular portion for channeling the polymer through the housing without intermixing of the polymer and the powder; and
a print head in communication with the housing and configured to receive both the powder and the polymer, and to co-extrude the powder and the polymer so that the polymer forms a shell that encases the powder as the powder and the polymer are extruded from the print head.

17 . The system of claim 16 , further comprising a vibration unit for generating a vibration signal which is applied to the print head to assist in extruding the powder through the print head.

18 . The system of claim 17 , further comprising an excitation signal generator in communication with the vibration unit and configured to generate an excitation signal which is applied to the vibration unit to control the vibration unit.

19 . The system of claim 16 , further comprising:
a computer; and a nozzle motion control subsystem in communication with the computer for receiving toolpath commands, and generating signals for controlling movement of the nozzle component along at least one of X, Y and Z axes.

20 . A method for additively manufacturing a structure for transporting carbon dioxide, the method comprising:
channeling a powder as a first stream through a first port into a first flow path in a housing of a nozzle component, the powder able to capture carbon dioxide; simultaneously channeling a polymer component as a second stream through a second port of the housing and through an annular second flow path in the housing which surrounds the first flow path; and receiving the first stream of the powder and the second stream of the polymer component in a print head and co-extruding the first and second streams such that the polymer component encases the powder as the first and second streams are depositing on a printing stage.

Assignees

• L Livermore Nat Security Llc

Inventors

• Cerón Hernández Maira R
• Eshelman Hannah V
• Knipe Jennifer Marie
• Overland Alexandra E L
• Troksa Michael J
• Deotte Joshua R
• Nguyen Du T

Classifications

• B29C64/118

  using filamentary material being melted, e.g. fused deposition modelling [FDM] · CPC title

• B29C64/209 Primary

  Heads; Nozzles · CPC title

• B22F10/18

  by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF] · CPC title

• B22F12/53

  Nozzles · CPC title

• B33Y40/00

  Auxiliary operations or equipment, e.g. for material handling · CPC title