AM Waste Condensation and Curing to Cut Filter Replacement
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Solution Overview
Problem
Existing additive manufacturing (AM) processes generate significant waste, including liquid and airborne contaminants that require frequent carbon filter replacement, leading to increased operational costs and environmental contamination risks.
Innovation Solution
A waste management system for AM devices that includes a cold trap filter to condense vapors into a liquid state, reducing the need for frequent carbon filter replacement by combining airborne waste with collected liquid waste and treating it to neutralize photoactive components, allowing safe disposal as common trash.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If carbon filtering is used to trap airborne components in AM devices, then air quality outside the enclosure is improved, but the frequency of filter replacement increases and operational costs increase
Solution Approach 1:
The patent applies preliminary action by condensing airborne photopolymerizable components into liquid form before they can contaminate the external environment. The condensation system captures volatile components during the printing process, converting them to liquid state for collection and curing, thereby preventing the need for frequent carbon filter replacement and reducing operational interruptions
Solution Approach 2:
The patent changes the physical state parameter of airborne contaminants from gas/vapor phase to liquid phase through condensation. By lowering the temperature of airborne photopolymerizable components, the system transforms them into collectable liquid waste that can be cured and disposed of, eliminating the need for carbon filter media and reducing replacement frequency
2Object-affected harmful factors
If carbon filters are replaced frequently to maintain air quality, then air contamination is reduced, but operational costs and device downtime increase
Solution Approach 1:
The patent utilizes phase transition by condensing airborne photopolymerizable components from vapor phase to liquid phase. This phase change enables the collection and curing of volatile components in liquid form, preventing environmental contamination without requiring frequent carbon filter replacement, thereby maintaining continuous operation and productivity
Solution Approach 2:
The patent converts the harmful airborne volatile components into a beneficial collectable liquid waste stream. By condensing and curing the photopolymerizable vapors, the system transforms environmental contaminants into solidified waste that can be easily disposed of, eliminating the need for carbon filters and maintaining operational continuity
3Productivity
If photopolymerizable material is deposited at elevated temperatures, then deposition efficiency is improved, but release of active volatile components increases
Solution Approach 1:
The patent introduces an intermediary condensation system between the elevated temperature deposition process and the external environment. The condensation apparatus acts as a mediator that captures and cools volatile photopolymerizable components released during high-temperature deposition, converting them to liquid form for collection and curing, thereby enabling efficient deposition while controlling emissions
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
Reduces the frequency of carbon filter replacement, decreases operational costs, and minimizes environmental contamination by effectively managing both liquid and airborne waste through condensation and curing processes.
Implementation Method 1
an air cleaning device installed within an enclosure of the AM device and configured to condense vapors formed within an enclosure of the AM device during operation of the AM device
Implementation Method 2
When cured, the solid material formed includes only a low content of photoactive components, and therefore may be discarded as common trash
Data Source
AI summary
A waste management system for an AM device includes a waste container, an air cleaning device installed within an enclosure of the AM device, a first conduit and at least one second conduit. The air cleaning device condense vapors formed within an enclosure of the AM device during operation of the AM device. The first conduit directs the condensed vapors in a liquid state from the air cleaning device to the waste container and the at least one second conduit directs waste accumulated during operation of the AM device to the waste container. The waste container stores waste accumulated by the AM device during operation of the AM device.