Additive Manufacturing Docking Arrangement with Gas Coupler

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Solution Overview

Problem

Current docking arrangements for additive manufacturing processes lack a comprehensive solution for controlled dispensing and secure coupling of hoppers containing powders to additive manufacturing machines, particularly for large-scale processes where manual control is impractical and environmental control is crucial.

Innovation Solution

A docking arrangement that includes a dock configured to receive a container, a gas supply associated with the dock, and a gas coupler to control the pressure and atmosphere within the container, ensuring stable and controlled dispensing of materials while maintaining a secure and environmentally controlled coupling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual control of material dispensing is used, then the operator can directly control the hopper outlet, but the operator cannot reach the hopper in large-scale processes

Engineering Contradiction:

Improveoperator accessibility to hopper outletVSAvoidscale of manufacturing process

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent replaces manual mechanical control of the hopper outlet with an automated valve system controlled by a control unit. The valve (26) can be opened or closed remotely through actuation signals, eliminating the need for operator physical presence at the hopper outlet while maintaining precise control over material dispensing in large-scale processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If gravity-fed dispensing is used, then the system is simple, but automated control of material flow cannot be achieved

Engineering Contradiction:

Improvedispensing control systemVSAvoidautomated material dispensing control

Core Design Contradiction:

Device complexityVSExtent of automation

Solution Approach 1:

The patent introduces a valve (26) actuated by a control unit (40) that receives actuation signals to automatically control material flow from the hopper. This replaces purely gravity-fed dispensing with an automated control system while maintaining relative simplicity through electronic actuation rather than complex mechanical mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If the hopper is open-coupled to the component, then material flow is simple, but environmental control and secure coupling cannot be maintained

Engineering Contradiction:

Improvecoupling mechanismVSAvoidenvironmental control and coupling stability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent incorporates a locking mechanism (100) with locking members (102a, 102b) that automatically engage when the hopper is docked with the additive manufacturing machine. This preliminary securing action ensures environmental control and stable coupling are established before material dispensing begins, preventing deterioration and maintaining process integrity throughout operation.

Inventive Principle:

Principle #10Preliminary action

4Ease of manufacture

If no locking mechanism is used, then the coupling is simple to assemble, but the hopper cannot be securely secured during material dispensing

Engineering Contradiction:

Improvecoupling assembly simplicityVSAvoidcoupling stability during dispensing

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The locking mechanism (100) with locking members (102a, 102b) is designed to automatically engage when the hopper is docked with the additive manufacturing machine. This preliminary securing action ensures stable coupling during material dispensing while maintaining ease of assembly through automatic engagement rather than manual fastening procedures.

Inventive Principle:

Principle #10Preliminary action

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 docking arrangement enables controlled and automated dispensing of materials from hoppers to additive manufacturing machines, ensuring stable operation and preventing material deterioration, while providing a secure and environmentally controlled coupling that maintains process integrity.

Implementation Method 1

the gas supply provides a source of gas to the container for controlling a pressure level within the container, for example, to assist in the flow of material from the container to the component of the additive manufacturing process

Methodology Applied

Scientific EffectPressure control: Pressure Increase

Implementation Method 2

the gas supply may provide a source of gas to the container for controlling the atmosphere within the container and/or at an interface between the container and the component, for example, to prevent deterioration (e.g. corrosion, oxidation or other deterioration) of the material held within the container

Methodology Applied

Scientific EffectAtmosphere control: Oxidation

Data Source

PatentUS12280430B2Docking arrangement for an additive manufacturing process

Publication Date: 2025.04.22 LPW TECHNOLOGY LTD

AI summary

A docking arrangement (10) for coupling an outlet (16) of a container (12) to an inlet (18) for a component of an additive manufacturing process. The docking arrangement (10) includes a dock (11) configured to receive the container (12) and a gas supply (35) associated with the dock (11). A gas coupler (38a, 38b) is provided and is configured, in use, to couple the gas supply (35) with a gas inlet (32) associated with the container (12) when the container (12) is received within the dock (11).