3D Printer Cover with Negative Pressure Fume Control

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Solution Overview

Problem

Three-dimensional modeling apparatuses using powder bed fused bonding methods face issues with fumes generated during laser irradiation, which accumulate and reduce modeling accuracy by affecting the laser's energy density and optical path, potentially leading to operational failures.

Innovation Solution

A three-dimensional modeling apparatus equipped with a cover that includes an energy beam transmitting portion to allow the laser to pass through while locally surrounding the irradiated area and a stream regulating mechanism to manage gas flows, preventing fumes from diffusing and adhering to the laser optical path.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-generated harmful factors

If a cover frame with a window is used to collect fumes, then fume collection is improved, but positive pressure inside the cover frame causes fumes to flow out and dwell on the laser optical path

Engineering Contradiction:

Improvefume collectionVSAvoidlaser optical path cleanliness

Core Design Contradiction:

Object-generated harmful factorsVSReliability

Solution Approach 1:

A gas stream regulator is introduced as an intermediary device between the fume collection system and the cover frame interior. This regulator controls the gas flow to maintain negative pressure inside the cover frame, preventing fumes from escaping toward the laser optical path while still enabling effective fume collection through the side surface openings.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The pressure parameter inside the cover frame is changed from positive pressure (in the prior art) to negative pressure (in this invention). This parameter change fundamentally alters the fume flow direction, ensuring fumes are drawn into the collection system rather than escaping toward the laser path, thereby resolving the contradiction between fume collection and optical path protection.

Inventive Principle:

Principle #35Parameter changes

2Object-generated harmful factors

If gas supply and collection timing are adjusted for fume suppression, then fume dwelling is reduced, but positive pressure causes fumes to diffuse beyond the cover frame

Engineering Contradiction:

Improvefume dwelling suppressionVSAvoidfume diffusion

Core Design Contradiction:

Object-generated harmful factorsVSObject-affected harmful factors

Solution Approach 1:

Instead of using positive pressure to suppress fume dwelling (as in the prior art), this invention uses negative pressure to achieve the same effect. The gas stream regulator inverts the pressure approach, creating a suction effect that draws fumes into the collection system while preventing their diffusion beyond the cover frame boundaries.

Inventive Principle:

Principle #13The other way round (Inversion)

3Area of stationary object

If the cover frame is made smaller than the laser processing area, then laser access is improved, but fume collection effectiveness is reduced

Engineering Contradiction:

Improvecover frame areaVSAvoidfume collection effectiveness

Core Design Contradiction:

Area of stationary objectVSObject-generated harmful factors

Solution Approach 1:

The fume collection system is segmented with multiple openings distributed across the side surface of the cover frame. This segmentation allows the cover to remain compact while maintaining effective fume collection through multiple entry points, resolving the contradiction between small size and collection effectiveness.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution effectively suppresses the diffusion of fumes around the modeling stage, maintaining the laser's energy density and preventing operational interruptions, thus ensuring accurate and continuous three-dimensional modeling.

Implementation Method 1

selectively, radiationally heating material powder laid by a powder spreading roller with an energy beam to solidify the powder

Methodology Applied

Scientific EffectRadiative heating: Absorption (EM radiation)

Implementation Method 2

a stream regulating mechanism that regulates a stream of gas containing the fumes so as to cause the fumes to be apart from the portion of the modeling material irradiated with the energy beam

Methodology Applied

Scientific EffectGas flow regulation: Convection

Implementation Method 3

a cover that includes an energy beam transmitting portion that allows the energy beam to pass, locally surrounds a portion of the modeling material arranged on the modeling stage irradiated with the energy beam, and suppresses diffusion of fumes generated by irradiation of the energy beam

Methodology Applied

Scientific EffectFume containment: Physical Containment

Data Source

PatentUS10549346B2Three-dimensional modeling apparatus, three-dimensional model body manufacturing method, and three-dimensional modeling data

Publication Date: 2020.02.04 CANON KK

AI summary

In a three-dimensional modeling apparatus, diffusion of fumes generated around the modeling stage accompanying irradiation with an energy beam can be efficiently prevented. Three-dimensional modeling is performed by repeating scanning a modeling material arranged on a modeling stage with laser light to form a solidified layer. A cover is provided that locally surrounds an irradiation portion on the modeling material arranged on the modeling stage irradiated with the laser light, and suppresses diffusion of the fumes caused by irradiation with the laser light. In the cover, a stream of gas containing the fumes is regulated so as to cause the fumes to flow toward an upward portion inside the cover apart from the irradiated portion irradiated with the laser light.