US 11383405

An analysis of US Patent 11,383,405 is provided below.

Title: Methods for producing ceramic molded body and ceramic structure

Assignee: NGK Insulators Ltd

Inventors:

• Keita Ito
• Yuichi Tajima
• Yoshimasa Kondo

Filing Date: December 29, 2020

Issue Date: July 12, 2022

Abstract:
The patent describes a method for producing a ceramic molded body. The process involves using an extrusion molding machine with a temperature control portion to shape a ceramic molding material. The extruded body is then cut to a predetermined length, and its dimensions are measured. A key aspect of the invention is the pre-established relationship between the temperature of the control portion and the dimensions of the cut ceramic body. This relationship is used to calculate and set an appropriate temperature for the temperature control portion based on the real-time measurements of the cut body, thereby controlling the dimensions of the final product.

Plain-Language Overview of Independent Claims:

• Claim 1: This claim outlines a method for manufacturing a ceramic molded body with improved dimensional accuracy. The process involves three main steps: (1) extruding a ceramic material through a molding machine that has a temperature-controlled section; (2) cutting the extruded ceramic into pieces of a specific length; and (3) measuring the dimensions of the cut piece before it is dried. The core of the method is a feedback loop: a pre-determined relationship between the temperature of the machine's control section and the size of the final cut piece is used. By measuring a freshly cut piece, the manufacturer can calculate the ideal temperature needed to ensure dimensional accuracy and adjust the machine accordingly for subsequent production.

• Claim 6: This claim extends the method described in Claim 1 to produce a finished ceramic structure. It specifies that the ceramic molded body, created using the process in Claim 1, undergoes two additional steps: a drying step and a firing (or baking) step to create the final, hardened ceramic structure.

Litigation Search:

A search of the U.S. Court of Appeals for the Federal Circuit (CAFC) dockets for 2026 was conducted, and no cases specifically citing US patent 11,383,405 were found. It should be noted that this search is not exhaustive of all possible litigation venues.

As of May 12, 2026, a thorough search of patent litigation databases, including PACER, the U.S. Court of Appeals for the Federal Circuit (CAFC) dockets, and the Unified Patents portal, reveals no known litigation involving US patent 11,383,405.

While the assignee, NGK Insulators Ltd., has been involved in other legal matters, including antitrust cases and patent disputes related to different technologies, there is no public record of US patent 11,383,405 being asserted or challenged in court.

Proceedings Overview

As of 2026-05-12, there are no AIA trial proceedings (IPR, PGR, or CBM) on file at the PTAB for US patent 11,383,405. This gives a defendant a clear field for potential invalidity challenges, as the patent's claims remain untested in post-grant proceedings.

Strategic Summary

The absence of any PTAB challenges against US patent 11,383,405 means that all of its issued claims—including independent claims 1 and 6—are currently sustained and untested in an AIA trial context. The patent was issued on 2022-07-12, so the nine-month window to file a Post-Grant Review (PGR), which allows for a broader range of invalidity challenges, has closed. However, the patent remains eligible for Inter Partes Review (IPR) challenges based on prior art patents and printed publications.

From an estoppel perspective, the landscape is entirely open. Because no petitioner has filed a challenge, 35 U.S.C. § 315(e)(2) estoppel does not apply. A potential defendant is free to raise any invalidity ground based on patents or printed publications that they can identify in a future IPR petition. There are no patterns to analyze regarding petitioners or the patent owner's defensive strategies at the PTAB for this specific patent.

Recommended Next Steps

For a defendant facing an assertion of US patent 11,383,405, the primary takeaway is that the patent's validity has not been vetted through the rigorous PTAB trial process. This lack of a challenge history is not uncommon for a patent that is less than four years old.

The recommended next step is to conduct a thorough prior art search to assess the strength of potential invalidity arguments under 35 U.S.C. §§ 102 and 103. If strong prior art is found, filing an Inter Partes Review at the PTAB would be a viable strategic option to challenge the patent's validity in a forum known for its technical expertise and faster timelines compared to district court litigation. All claims of US patent 11,383,405 are currently open to such a challenge.

Inventors

• Keita Ito
• Yuichi Tajima
• Yoshimasa Kondo

All three inventors assigned their interest to NGK Insulators, Ltd. in the initial assignment record (Reel 054765/0097), indicating they were employees or contractors of the company at the time of invention. There are no indications of unusual departure patterns following the filing.

Original assignee

The original assignee is NGK Insulators Ltd., a publicly-traded Japanese company founded in 1919. NGK is a major global manufacturer of ceramic products, including insulators, honeycomb structures for automotive catalysts and filters (embodying the patent's claims), and other industrial components. The company is an active operating entity and ships products worldwide.

Assignment timeline

A search of the USPTO Patent Assignment Search database for US patent 11,383,405 reveals a single recorded assignment.

• 2020-11-04 (executed) / recorded 2020-12-29 — Reel 054765/0097
  • Conveyance: Assignment of Assignor's Interest
  • Assignor: Keita Ito; Yuichi Tajima; Yoshimasa Kondo
  • Assignee: NGK Insulators, Ltd.
  • Correspondent: Wenderoth, Lind & Ponack, L.L.P., 1025 Connecticut Avenue, N.W., Suite 500, Washington, DC 20036
  • Context: This is the initial assignment from the named inventors to their employer, securing corporate ownership of the invention.

No further assignments have been recorded for this patent as of 2026-05-12. The ownership remains with the original assignee.

Timeline diagram

timeline
    title Ownership of US 11383405
    2020 : Filed by NGK Insulators
         : Assigned by inventors to NGK Insulators
    2022 : Issued

NPE / troll-pattern signals

1. Shell-entity transfer: Not present. The patent remains with the original assignee, NGK Insulators Ltd., a known operating company.
2. Known asserter in the chain: Not present. NGK Insulators Ltd. is a manufacturing company, not a known patent asserter.
3. Repeat correspondent across the chain: Not present. There is only one assignment record.
4. Cascading transfers: Not present. There have been no transfers since the initial assignment.
5. Pre-litigation transfer: Not present. There have been no transfers and no known litigation involving this patent.
6. Bankruptcy fire-sale: Not present. The assignee is a financially stable, operating company.
7. Privateering: Not present. There is no evidence that NGK has transferred this patent to a third party for assertion.
8. Defensive aggregator (anti-NPE): Not present. The patent is held by its original operating-company assignee.

Verdict

• Insufficient data

The patent has never been transferred since its initial pre-issuance assignment from the inventors to the operating company, NGK Insulators Ltd. (per Reel 054765/0097). With no post-issuance assignment record, there is no evidence to analyze for NPE activity.

Verification Link: USPTO Assignment Search for Pat. 11,383,405

Analysis of Prior Art for U.S. Patent 11,383,405

An evaluation of the prior art cited during the prosecution of U.S. Patent 11,383,405 reveals several key references that the USPTO examiner considered. These documents are crucial for understanding the landscape of existing technology at the time of the invention and for assessing the patent's novelty and non-obviousness. The following analysis details the most relevant prior art and its potential impact on the claims of the '405 patent.

Key Prior Art and Potential Anticipation

The core of U.S. Patent 11,383,405 lies in its method for controlling the dimensional accuracy of a ceramic molded body by creating a feedback loop. This loop involves measuring the dimensions of the body after it has been cut but before it is dried, and then using a pre-established relationship between those dimensions and the temperature of a control portion of the extrusion machine to adjust the temperature for subsequent production (Claim 1).

Here are the most significant prior art references and their relevance to the claims:

1. JP2017536549A (Corning Incorporated)

• Full Citation: Japanese Patent Application Publication No. 2017-536549 A
• Publication Date: December 7, 2017
• Brief Description: This patent document, cited in the '405 patent itself, discloses a method for controlling extrusion molding by acquiring a shape signal from the outer surface of the ceramic molded body in real-time and comparing it to a reference signal to adjust process parameters.
• Potential Anticipation: This reference is highly relevant as it describes a feedback control system for ceramic extrusion. However, a key distinction from the '405 patent is that JP2017536549A measures the body's shape immediately after extrusion and does not explicitly teach measuring the dimension after cutting to account for any deformation caused by the cutting process. Therefore, while it discloses a similar feedback concept, it likely does not fully anticipate Claim 1 of the '405 patent, which specifies measurement of the cut ceramic molded body.

2. JP6436928B2 (NGK Insulators Ltd.)

• Full Citation: Japanese Patent No. 6436928 B2
• Publication Date: December 12, 2018
• Brief Description: Also cited within the '405 patent, this reference describes a method of measuring the dimension of a ceramic molded body after it has been dried and then adjusting the amount of liquid added to the ceramic material based on this measurement.
• Potential Anticipation: This patent teaches a feedback loop for dimensional control in ceramic manufacturing. However, it differs significantly from the '405 patent in two critical aspects: the measurement is performed after drying, and the adjusted parameter is the liquid content, not the temperature of a control portion. The '405 patent argues that waiting until after the drying step introduces a long delay, making the process less efficient and potentially wasteful. The focus on pre-drying measurement and temperature control distinguishes the '405 patent's claims from this reference.

3. US 2012/0133065 A1 (Caffrey et al.)

• Full Citation: U.S. Patent Application Publication No. 2012/0133065 A1
• Publication Date: May 31, 2012
• Brief Description: This application describes a real-time, closed-loop shape control system for extruded ceramic honeycomb structures. It involves measuring the shape of the extrudate and adjusting process parameters to maintain dimensional accuracy.
• Potential Anticipation: Similar to JP2017536549A, this reference discloses a feedback control system. It teaches monitoring the dimensions of the extruded body and making adjustments. The critical question for anticipation would be whether it discloses measuring the body after a cutting step and specifically adjusting the temperature of a control portion based on a pre-determined relationship. Without these specific elements, it would not fully anticipate Claim 1.

4. US 2011/0278753 A1 (Breuer)

• Full Citation: U.S. Patent Application Publication No. 2011/0278753 A1
• Publication Date: November 17, 2011
• Brief Description: This document details laser scanning systems and methods for measuring extruded ceramic logs. The focus is on obtaining accurate dimensional measurements of the extruded, but not yet fired, ceramic bodies.
• Potential Anticipation: This reference is relevant to the "dimension measuring step" of Claim 1. It provides a detailed method for measuring the dimensions of the unfired ceramic body. However, it does not appear to describe the complete feedback loop claimed in the '405 patent, specifically the pre-established relationship between the measured dimension and a temperature control portion of the extruder, and the subsequent adjustment of that temperature. Therefore, it anticipates a component of the claimed invention but not the entire method.

Summary of Findings

The prior art cited against US patent 11,383,405 establishes that the general concept of using feedback loops to control the dimensions of extruded ceramic bodies was known. However, the inventive step of the '405 patent appears to be the specific combination of elements in its method:

• Timing of Measurement: Measuring the dimension after the cutting step but before the drying step to account for deformation from cutting while still allowing for rapid process adjustments.
• Controlled Parameter: Specifically adjusting the temperature of a control portion of the extrusion machine.
• Control Logic: Utilizing a previously obtained relationship between the temperature and the dimension of the cut body to calculate the necessary adjustment.

While individual elements of this process can be found in the prior art, no single reference appears to disclose the complete combination as claimed in independent claim 1. This unique combination of steps allows for a more responsive and accurate method of dimensional control, addressing the shortcomings of prior art methods that either measure too early (before cutting-induced deformities) or too late (after the lengthy drying process). Consequently, the claims of US patent 11,383,405 were likely found to be novel and non-obvious over this collection of prior art.

An analysis of the obviousness of US patent 11,383,405 under 35 U.S.C. § 103 is provided below, based on the prior art cited in the patent's file.

Person Having Ordinary Skill in the Art (PHOSITA)

A person having ordinary skill in the art (PHOSITA) for this patent would be an engineer or materials scientist with a bachelor's degree or higher in ceramic, chemical, or mechanical engineering, and several years of experience in the field of ceramic manufacturing, specifically with extrusion processes for products like automotive catalysts or particulate filters. This individual would be familiar with process control systems, methods for dimensional measurement, and the effects of process parameters (like temperature and material composition) on the final ceramic product.

Obviousness Analysis of Independent Claim 1

Claim 1 recites a method with the following key elements:

• (a) Extrusion molding a ceramic material using a machine with a temperature control portion.
• (b) Cutting the extruded body to a predetermined length.
• (c) Measuring a dimension of the cut ceramic molded body before drying.
• (d) Using a pre-obtained relationship between the temperature and the dimension of the cut body to calculate and control the temperature in a feedback loop.

A strong case for obviousness can be made by combining the teachings of US 2012/0133065 A1 (hereafter "Caffrey") and US 2014/0151915 A1 (hereafter "Sariego").

Combination of Prior Art

1. Caffrey (US 2012/0133065 A1): This reference discloses the core concept of the feedback loop. It teaches a "real-time, closed-loop shape control of extruded ceramic honeycomb structures." Caffrey describes a system that measures a physical characteristic (i.e., a dimension) of the extrudate and adjusts an "extrusion process parameter" in response to maintain the desired shape. This directly teaches the broad concept of element (d): using a measurement to control a process parameter in a feedback loop to ensure dimensional accuracy.

2. Sariego (US 2014/0151915 A1): This reference explicitly teaches the use of temperature control in extrusion systems. Sariego discloses controlling the temperature of the extrusion die and/or the ceramic material itself to influence the final properties of the extrudate. This directly teaches element (a) of the claim: using an extrusion machine equipped with a temperature control portion.

Motivation to Combine

A PHOSITA would have been motivated to combine the teachings of Caffrey and Sariego for a predictable and improved result. Caffrey provides a general framework for a real-time feedback control system but leaves the specific "extrusion process parameter" open. Sariego identifies temperature as a specific, effective, and well-understood process parameter for controlling the outcome of ceramic extrusion. A PHOSITA, tasked with implementing or improving the dimensional control system taught by Caffrey, would naturally look to known controllable parameters. The use of temperature, as taught by Sariego, would be an obvious choice to implement as the control variable within Caffrey's feedback system. The motivation is straightforward: to use a known control method (temperature adjustment) to achieve the goal of Caffrey's system (improved dimensional accuracy).

Addressing the "After Cutting, Before Drying" Measurement Point

The inventive gist of US 11,383,405 hinges on measuring the ceramic body after it is cut but before it is dried (element c). The patent argues that cutting introduces stress and deformation, so measuring before cutting (as in other prior art) is insufficient, and measuring after drying (as in JP 6436928 B) introduces significant process delays.

However, this specific timing of the measurement would have been an obvious optimization to a PHOSITA.

• The problem identified in the '405 patent—that cutting can deform the extrudate—would be a known phenomenon to a PHOSITA.
• If a PHOSITA implemented the combined Caffrey/Sariego system and found that dimensional errors persisted, a routine step in process optimization would be to analyze the source of the error.
• Upon discovering that the cutting step itself was a significant source of dimensional variation, it would be an obvious and logical modification to move the measurement point of Caffrey's control loop to a position immediately after the cutting step. This allows the feedback loop to account for deformation induced by cutting, thereby providing a more accurate control input.

This is not an inventive leap but rather a predictable step in engineering troubleshooting and process improvement. A PHOSITA understands that for the most effective control, the measurement should capture the state of the object after any step that introduces significant variation. Given the known options of measuring before cutting, after cutting, or after drying, selecting the post-cutting/pre-drying point to gain timely feedback that accounts for cutting deformation would be an obvious choice to try.

Therefore, the combination of Caffrey and Sariego renders the limitations of Claim 1 obvious to a person of ordinary skill in the art.

Obviousness Analysis of Independent Claim 6

Claim 6 recites a method for producing a final ceramic structure by taking the ceramic molded body produced by the method of Claim 1 and adding:

• (e) A drying step.
• (f) A firing step.

The addition of these steps to the process of Claim 1 is obvious. Drying a "green" ceramic body and subsequently firing it in a furnace are fundamental, universally known, and essential steps in nearly all ceramic manufacturing processes. The '405 patent itself acknowledges this in its background section, stating the conventional process is to "obtain a ceramic molded body, and then cutting the ceramic molded body to have a predetermined length, drying and firing it."

There is no unique or synergistic interaction claimed between the feedback control method of Claim 1 and the subsequent, conventional steps of drying and firing. As these are standard, concluding steps in the art, adding them to the otherwise obvious method of Claim 1 does not confer patentability.

Term, Continuations, and Family for US 11,383,405

Patent Term and Expiration

• Patent Term Adjustment (PTA): US patent 11,383,405 has a calculated Patent Term Adjustment (PTA) of 0 days. The USPTO did not identify any prosecution delays that would warrant an extension of the patent's term under 35 U.S.C. § 154(b).
• Patent Term Extension (PTE): There is no indication of any Patent Term Extension (PTE) under 35 U.S.C. § 156, which typically applies to products that undergo a lengthy regulatory review process (e.g., pharmaceuticals).
• Filing Date: The application was filed on December 29, 2020.
• Projected Expiration Date: The patent's term is calculated as 20 years from its filing date. With zero days of PTA or other extensions, the projected expiration date is December 29, 2040.

Continuity and Related Applications

A review of the USPTO's continuity data indicates that US application 17/136,390 (which issued as US patent 11,383,405) is a continuation of the international PCT application PCT/JP2020/012764, filed on March 23, 2020. This PCT application serves as the priority document for the US patent and its international family members.

There are no divisional, continuation, or continuation-in-part applications that claim priority to US patent 11,383,405 itself.

International Patent Family

US patent 11,383,405 is part of a family of patents and applications that all claim priority to the same PCT application, PCT/JP2020/012764. The known members of this international patent family include:

• World Intellectual Property Organization (WIPO): WO2021191978A1
• Japan: JP6790313B1
• China: CN113710443A
• Germany: DE112020000052B4

This indicates that the assignee, NGK Insulators Ltd., sought protection for this invention in key global markets including the US, Japan, China, and Europe (via the German patent).

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

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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
  

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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;
  

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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;
  

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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
      }
  

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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;
  

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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.