Derivative works — US Patent 11383405

Defensive Disclosure Document

Reference Patent: US 11,383,405
Purpose: To establish prior art for derivative inventions and incremental improvements related to the methods disclosed in US 11,383,405. This document describes novel variations, applications, and integrations.
Publication Date: 2026-05-12

Section 1: Material & Component Substitution Derivatives

Derivative 1.1: Thermoplastic Polymer Extrusion with Peltier-Based Thermal Control

Enabling Description: This method adapts the core feedback loop for extruding high-precision thermoplastic polymer components, such as PEEK (polyether ether ketone) for medical implants or Ultem (polyetherimide) for aerospace applications. The ceramic molding material is replaced with a thermoplastic pellet feedstock. The "temperature control portion" (24) is replaced with an array of solid-state thermoelectric Peltier modules arranged circumferentially just prior to the die (21). These modules allow for rapid, bi-directional (heating and cooling) temperature control with millidegree precision. A non-contact, structured-light 3D scanner serves as the dimension measuring device, capturing the full cross-sectional geometry of the cut extrudate. The control algorithm uses the measured profile to adjust the voltage and polarity applied to the Peltier modules, actively adding or removing heat to maintain the target dimension by controlling die swell and thermal shrinkage.

Diagram:

flowchart TD
    A[Thermoplastic Pellets In] --> B{Extruder Screw};
    B --> C[Melt Zone];
    C --> D[Peltier Module Array];
    D --> E(Extrusion Die);
    E --> F[Continuous Extrudate];
    F --> G{Cutter};
    G --> H[Cut Polymer Part];
    H --> I(3D Structured Light Scanner);
    I -- Measured Dimensions --> J{Control System};
    J -- Pre-established Algorithm --> K[Peltier Power Controller];
    K -- Voltage/Polarity Adjustment --> D;
    J -- Data Log --> L[Process Database];

Derivative 1.2: Metal-Matrix Composite Extrusion with Inductive Heating and Ultrasonic Measurement

Enabling Description: This variation applies to the extrusion of metal-matrix composites (MMCs), such as aluminum reinforced with silicon carbide particles. The "temperature control portion" is an induction heating coil positioned around the die throat. This allows for rapid, non-contact heating of the electrically conductive MMC material. Temperature control is critical to manage the viscosity of the metal matrix without degrading the reinforcing particles. The dimension measurement is performed in-situ on the hot, just-cut extrudate using a pair of opposed ultrasonic transducers. These transducers measure the time-of-flight of ultrasonic pulses to calculate the diameter of the hot MMC profile. This data feeds back to a Proportional-Integral-Derivative (PID) controller that modulates the power supplied to the induction coil, ensuring dimensional stability before the part cools and undergoes significant thermal contraction.

Diagram:

sequenceDiagram
    participant Extruder
    participant InductionCoil
    participant Cutter
    participant UltrasonicSensor
    participant PIDController

    Extruder->>InductionCoil: Pushes MMC Material
    InductionCoil->>Extruder: Heats Material at Die
    Extruder->>Cutter: Extrudes Profile
    Cutter->>UltrasonicSensor: Presents Cut Part
    UltrasonicSensor->>PIDController: Send Diameter Measurement
    PIDController->>PIDController: Calculate Error from Setpoint
    PIDController->>InductionCoil: Adjust Power Output

Derivative 1.3: Hydrogel Extrusion for Bioprinting with Infrared Thermal Control

Enabling Description: The method is adapted for fabricating scaffolds in tissue engineering using a temperature-sensitive hydrogel (e.g., pluronic F-127). The temperature control portion is a set of focused infrared (IR) lamps aimed at the extrusion nozzle. The IR lamps provide precise, non-contact heating to control the hydrogel's sol-gel transition, which dictates its extrudability and final shape. The "cutting" step is performed by a high-speed fluid jet to avoid mechanical deformation. The "dimension measuring" is done via a machine vision system with backlighting that captures the silhouette of the cut hydrogel segment. The measured width of the silhouette is used in the feedback loop to modulate the intensity of the IR lamps, ensuring the creation of dimensionally consistent scaffolds for cellular infiltration.

Diagram:

graph LR
    subgraph Extrusion System
        A[Hydrogel Syringe] --> B(Extrusion Nozzle)
    end
    subgraph Thermal Control
        C[IR Lamps] -- Heat --> B
    end
    subgraph Cutting & Measurement
        B -- Extrudes Strand --> D[Fluid Jet Cutter]
        D --> E{Cut Hydrogel Scaffold}
        E --> F[Machine Vision Camera]
    end
    subgraph Feedback Loop
        F -- Measured Width --> G[Controller]
        G -- Intensity Signal --> C
    end

Section 2: Operational Parameter Expansion Derivatives

Derivative 2.1: Nanoscale Fiber Extrusion with Micro-Kelvin Control

Enabling Description: The invention is scaled down for the production of continuous polymeric nanofibers (50-500 nm diameter) via electrospinning. The "extrusion molding machine" is an electrospinning apparatus where a polymer solution is drawn from a charged needle by an electric field. The "temperature control portion" is a micro-Peltier element integrated directly into the spinning needle, capable of controlling its temperature with micro-Kelvin resolution. Temperature subtly alters the solution's viscosity and surface tension, which directly impacts the final fiber diameter. The "cutting" is virtual, defined by the length of fiber collected on a rotating mandrel over a specific time. The "dimension measuring step" is performed by an integrated Atomic Force Microscope (AFM) that periodically scans a segment of the deposited fiber. The measured fiber diameter feeds back to the controller to make minute adjustments to the needle's temperature, ensuring extreme uniformity for applications in filtration membranes or nanoelectronics.

Diagram:

stateDiagram-v2
    [*] --> Spinning
    Spinning --> Measuring: Collection Interval Ends
    Measuring --> Spinning: Adjust Temperature
    state Spinning {
        direction LR
        [*] --> E_Field_On
        E_Field_On --> Fiber_Drawn
        state "Control Loop" as CL {
            Needle_Temp: Maintained by Micro-Peltier
        }
    }
    state Measuring {
        direction LR
        [*] --> AFM_Scan
        AFM_Scan --> Calculate_Diameter
        Calculate_Diameter --> Update_Algorithm
        Update_Algorithm --> [*]
    }

Derivative 2.2: Hypersonic Manufacturing of Refractory Metal Rods

Enabling Description: The process is adapted for manufacturing rods from refractory metals like tungsten or molybdenum at extremely high speeds. The material is fed as a powder into a plasma torch which acts as the heating and extrusion mechanism, expelling a molten stream. The stream is shaped by a magnetic field (a non-contact "die"). The "temperature control portion" is the power modulation of the plasma torch itself. The extruded rod cools and solidifies in-flight. "Cutting" is performed by a high-power laser. "Dimension measurement" uses a laser-based optical micrometer that measures the rod's diameter as it flies past. The measured diameter is fed back to the plasma torch controller, which adjusts the plasma enthalpy to control the initial molten stream diameter, compensating for thermal variations and ensuring consistent final dimensions at production rates orders of magnitude higher than conventional extrusion.

Diagram:

graph TD
    A[Metal Powder Feed] --> B{Plasma Torch};
    B -- Molten Stream --> C(Magnetic Shaping Field);
    C --> D[Solidifying Rod];
    D --> E{Laser Cutter};
    E --> F[Cut Rod Segment];
    F --> G(Optical Micrometer);
    G -- Diameter Data --> H{Plasma Power Control};
    H -- Feedback --> B;

Section 3: Cross-Domain Application Derivatives

Derivative 3.1: Aerospace - Automated Fiber Placement (AFP) Tape Manufacturing

Enabling Description: The method is applied to the production of carbon fiber-reinforced thermoplastic tapes used in Automated Fiber Placement (AFP) for creating aircraft fuselages. A thermoplastic matrix material (e.g., PEEK) is extruded around continuous carbon fiber tows. The "temperature control portion" is a multi-zone infrared heater at the extrusion die. It controls the polymer's impregnation viscosity. After extrusion, the continuous tape is cut to lengths for spooling. A laser line scanner measures the tape's width and thickness post-cutting. This dimensional data is critical, as variations affect the final part's strength and weight. The measured dimensions are fed back to the multi-zone heater controller to adjust the temperature profile, ensuring consistent tape geometry, which is paramount for void-free AFP layups.

Diagram:

flowchart LR
    A[Carbon Tows] & B[PEEK Pellets] --> C{Co-Extrusion Die};
    D[Multi-Zone IR Heater] -- Heat --> C;
    C --> E[Continuous AFP Tape];
    E --> F(Cutter);
    F --> G[Cut Tape];
    G --> H{Laser Line Scanner};
    H -- Width/Thickness Data --> I(Heater Controller);
    I -- Adjust Temp Zones --> D;

Derivative 3.2: AgTech - Precision Nutrient Paste Extrusion for Vertical Farming

Enabling Description: In vertical farming, a nutrient-rich paste is extruded as a growth medium. The method ensures each plant receives a consistent volume of nutrients. The "ceramic material" is a hydrogel paste containing a mix of fertilizers and minerals. The "temperature control portion" is a heated jacket around the extrusion nozzle, which controls the paste's viscosity. After extrusion onto a tray, a blade "cuts" the deposit. A machine vision system (a top-down camera) measures the diameter of the deposited paste "puck." This dimension correlates directly to the volume. The measurement is used to adjust the nozzle temperature, ensuring each deposit has the precise, intended nutrient volume, optimizing growth and minimizing waste.

Diagram:

sequenceDiagram
    participant Extruder
    participant HeatedJacket
    participant VisionSystem
    participant Controller

    loop For each plant pod
        Extruder->>HeatedJacket: Push nutrient paste
        HeatedJacket->>Extruder: Control paste viscosity
        Extruder->>VisionSystem: Deposit and cut paste
        VisionSystem->>Controller: Measure diameter of deposit
        Controller->>HeatedJacket: Adjust temperature for next deposit
    end

Derivative 3.3: Consumer Electronics - Manufacturing of Thermally Conductive Gap Pads

Enabling Description: The invention is used to produce thermally conductive silicone gap pads for cooling CPUs and GPUs in electronics. A silicone base filled with thermally conductive ceramic particles (e.g., alumina, boron nitride) is extruded into a continuous sheet. The "temperature control portion" is a heated die, which influences the final cross-linking and dimensional properties of the silicone. The sheet is cut into pads of a specific length. A laser displacement sensor measures the thickness of each cut pad. Pad thickness is a critical parameter for ensuring proper thermal contact without stressing the circuit board. The measured thickness is used in a feedback loop to adjust the die temperature, controlling die swell and ensuring all pads meet the strict thickness tolerances required for high-performance electronics.

Diagram:

graph TD
    A[Silicone & Ceramic Mix] --> B{Extruder};
    C[Heated Die] -- Controls Cross-linking --> B;
    B --> D[Continuous Sheet];
    D --> E{Guillotine Cutter};
    E --> F[Cut Gap Pad];
    F --> G(Laser Displacement Sensor);
    G -- Thickness Data --> H{Main Controller};
    H -- Temp Setpoint --> C;

Section 4: Integration with Emerging Tech Derivatives

Derivative 4.1: AI-Driven Predictive Control with a Digital Twin

Enabling Description: The pre-established relationship between temperature and dimension is replaced by a recurrent neural network (RNN) model. This AI model is part of a "digital twin" of the extrusion line. It receives real-time data from a network of IoT sensors measuring not only the final cut dimension but also barrel pressure, screw torque, ambient humidity, and the temperature from the control portion. The RNN model predicts the dimension of the next part to be cut based on the current state vector. It then calculates the temperature adjustment needed to preemptively counteract any predicted drift. This moves the system from a reactive feedback loop to a proactive, predictive control paradigm, reducing scrap to near-zero.

Diagram:

flowchart TD
    subgraph Physical Extruder
        A[IoT Sensors: Pressure, Torque, etc.] --> B{Extrusion Process};
        C(Dimension Sensor) -- Measures --> B;
    end
    subgraph Digital Twin
        D[AI/RNN Model];
        A -- Real-time Data --> D;
        C -- Real-time Data --> D;
    end
    D -- Predicted Dimension --> E{Control Logic};
    E -- Optimal Temp Setpoint --> F[Temp Controller];
    F -- Heats/Cools --> B;
    D -- State Update --> G[System State Database];

Derivative 4.2: Blockchain-Verified Supply Chain for Medical Implants

Enabling Description: The method is used to manufacture patient-specific ceramic bone implants. After each implant is extruded, cut, and measured, a data packet is created containing the final dimensions, the full temperature log during its creation, the raw material batch ID (from an RFID tag), and the machine operator's ID. This data packet is cryptographically hashed, and the hash is recorded as a transaction on a private blockchain. The physical part is laser-etched with a QR code corresponding to the blockchain transaction ID. This creates an immutable, auditable, and verifiable record for each individual part, ensuring full traceability from raw material to patient, which is critical for FDA compliance and patient safety.

Diagram:

erDiagram
    IMPLANT ||--o{ MEASUREMENT : has
    IMPLANT {
        string ImplantID
        string QRCode
    }
    MEASUREMENT {
        string ImplantID PK
        float dimension_X
        float dimension_Y
        string timestamp
    }
    IMPLANT ||--|| BATCH : uses
    BATCH {
        string BatchID
        string material_spec
    }
    IMPLANT ||--o{ BLOCKCHAIN_TX : is_recorded_in
    BLOCKCHAIN_TX {
        string TransactionID
        string data_hash
        string block_number
    }

Section 5: The "Inverse" or Failure Mode Derivatives

Derivative 5.1: Fail-Safe Extrusion with Intentional Oversizing

Enabling Description: The system is designed for manufacturing critical components where an undersized part is a catastrophic failure, but an oversized part can be reworked. The control system incorporates a "health check" on the dimension measurement sensor. If the sensor's reading becomes unstable, goes offline, or provides a value outside a statistical norm (indicating sensor failure), the control logic immediately overrides the feedback algorithm. It forces the temperature control portion to a pre-defined "fail-safe" temperature. This temperature is known from historical data to produce parts that are consistently 2-5% oversized. An alarm is triggered, and production continues, creating slightly larger, salvageable parts instead of shutting down the line or producing potentially undersized scrap.

Diagram:

stateDiagram-v2
    state "Nominal Operation" as Nominal {
        [*] --> Measuring
        Measuring --> Calculating: Dimension OK
        Calculating --> Adjusting
        Adjusting --> Measuring
    }
    Nominal --> FailSafe: Sensor Fault Detected
    state "Fail-Safe Mode" as FailSafe {
        [*] --> Set_Oversize_Temp
        Set_Oversize_Temp --> Trigger_Alarm
        Trigger_Alarm --> Manual_Reset
    }
    FailSafe --> Nominal: Manual Reset

Derivative 5.2: Low-Power Mode with Screw Speed as a Thermal Proxy

Enabling Description: A simplified, low-cost version of the invention for applications with wider dimensional tolerances (e.g., producing ceramic bricks). The dedicated temperature control portion (like a heater or cooler) is eliminated to save cost and energy. Instead, thermal control is achieved passively. The shear forces from the extruder screw (11) are the primary source of heat. The feedback loop measures the dimension of the cut brick and, instead of adjusting a heater, it modulates the rotational speed of the extruder screw. Increasing speed increases shear and thus temperature, while decreasing speed reduces it. This creates a coarse but effective feedback loop where screw speed is used as a proxy for direct temperature control, minimizing capital and operational costs.

Diagram:

flowchart TD
    A[Clay Material In] --> B{Extruder Screw};
    B -- Shear Heating --> C(Die);
    C --> D[Continuous Brick Column];
    D --> E{Cutter};
    E --> F[Cut Brick];
    F --> G(Laser Sensor);
    G -- Width Measurement --> H{Controller};
    H -- Adjust RPM --> I[Screw Drive Motor];
    I -- Rotates --> B;

Section 6: Combination Prior Art Scenarios

Combination 6.1: Integration with OPC UA for Plug-and-Produce Modularity: The extrusion machine, including the temperature controller, screw drive, and dimension measurement station, is designed as a self-contained module exposing its services and data via the OPC UA (Open Platform Communications Unified Architecture) standard. A supervisory control system can discover and integrate this module without custom drivers. The dimension measurement is published as an OPC UA variable, and the temperature setpoint is a writable variable. This enables the creation of flexible production lines where an OPC UA-compliant extruder can be swapped or reconfigured on-the-fly, and its feedback control loop managed by a standardized factory orchestration layer.
Combination 6.2: MQTT Protocol for Lightweight Retrofit and Cloud Analytics: An older, existing extrusion line is retrofitted with the claimed invention's feedback loop. A laser micrometer and a thermocouple are added. These sensors do not connect to the legacy PLC. Instead, they are connected to a small gateway device that publishes their readings to an MQTT (Message Queuing Telemetry Transport) broker under topics like line1/dimension and line1/temperature. A separate micro-controller for the heater subscribes to a line1/heater/setpoint topic. A control application, running on-premise or in the cloud, subscribes to the sensor topics, performs the control calculation, and publishes the new setpoint. This decouples the components and allows for easy data aggregation for cloud-based process analytics.
Combination 6.3: ROS (Robot Operating System) for Integrated Robotic Handling: The entire process is orchestrated using ROS. The extruder is a ROS node (/extruder_node) that can be commanded to start/stop. A robotic arm (/robot_arm_node) performs the "cutting step" by moving a cutting tool through the extrudate path. The same robot then moves the cut part to a fixed measurement station, which is another ROS node (/dimension_scanner_node). The scanner publishes the dimension data to a ROS topic (/part_dimensions). A central control node (/process_controller_node) subscribes to this topic, calculates the required temperature adjustment based on the pre-established relationship, and publishes the new setpoint to the /extruder_node, which then controls its temperature portion. This creates a highly automated and flexible workcell.