Cold Trap Filtration for Additive Manufacturing Waste Management

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Solution Overview

Problem

Existing additive manufacturing (AM) processes generate waste materials, including liquid and airborne contaminants, which require frequent carbon filter replacement and specialized treatment, increasing operational costs and downtime.

Innovation Solution

A waste management system that includes a cold trap filter to condense vapors into a liquid state, combining with collected waste for neutralization and disposal, reducing the need for frequent carbon filter replacement and enabling common waste treatment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If carbon filtering is used to trap airborne components, then air quality outside the enclosure is improved, but operational costs increase due to frequent filter replacement and specialized waste treatment

Engineering Contradiction:

Improveair qualityVSAvoidoperational costs

Core Design Contradiction:

Object-affected harmful factorsVSLoss of energy

Solution Approach 1:

The patent converts the harmful airborne photopolymerizable components into a beneficial liquid condensate that can be collected and treated with common waste. The cold trap filter condenses the vaporized components back into liquid form, transforming a harmful airborne contaminant into a manageable liquid waste product that requires less expensive disposal methods.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent changes the physical state parameter of the waste material from gaseous/vapor phase to liquid phase through condensation. This phase change enables the waste to be collected in liquid form and treated using common waste treatment processes instead of requiring specialized carbon filter replacement and handling.

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If carbon filters are used to remove airborne contaminants, then harmful factors are reduced, but device complexity increases due to filter replacement procedures

Engineering Contradiction:

Improveairborne contaminantsVSAvoidfilter replacement procedure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent merges the airborne waste collection function with the liquid waste collection system. Both the condensed vapor from the cold trap filter and the liquid waste from the purging station are directed to the same waste container, consolidating multiple waste streams into a single collection and treatment system, thereby simplifying the overall waste management process.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If frequent carbon filter replacement is performed, then air cleaning effectiveness is maintained, but productivity decreases due to operational downtime

Engineering Contradiction:

Improveair cleaning effectivenessVSAvoidoperational downtime

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The cold trap filter converts airborne photopolymerizable vapor into liquid condensate that can be disposed of through common waste treatment. This eliminates the need for frequent carbon filter replacements, maintaining air cleaning effectiveness while avoiding operational downtime associated with filter changes.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Reliability

If specialized waste treatment is used for carbon filters, then waste disposal compliance is ensured, but operational costs increase

Engineering Contradiction:

Improvewaste disposal complianceVSAvoidwaste treatment costs

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent changes the waste material from a specialized airborne contaminant requiring expensive specialized treatment into a common liquid waste product. By condensing the vapor into liquid form and combining it with other liquid waste streams, the waste can be treated using standard, less expensive waste treatment processes while still meeting disposal compliance requirements.

Inventive Principle:

Principle #35Parameter changes

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, lowers operational costs, and facilitates efficient disposal of waste materials as common trash by neutralizing photoactive components.

Implementation Method 1

a cold trap filter configured to extract volatile substances and liquid vapors expelled in the internal space of the AM device during operation and condense the extracted material to a liquid state

Methodology Applied

Scientific EffectCondensation: Condensation

Implementation Method 2

a UV radiation source configured to cure the collected waste in the waste container

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentUS12441062B2System and method for waste management in an additive manufacturing process

Publication Date: 2025.10.14 STRATASYS LTD

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.