Continuous Powder Mixing Device for Additive Manufacturing

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Solution Overview

Problem

Industrial processes involving powders, such as metal additive manufacturing, face challenges with contamination and oxidation of unused powder due to splashes and fumes, leading to inefficient recycling and mixing, and existing mixing devices require high energy and pose safety risks.

Innovation Solution

A continuous mixing device that uses gravimetric dosing apparatuses and a screw mixer to blend powders efficiently, with inerting gas to prevent oxidation and explosive risks, allowing for precise control and sampling of the mixed powder.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If batch-mixing method with high-power actuators is used, then mixing capability is improved, but energy consumption increases and safety risks increase

Engineering Contradiction:

Improvemixing capabilityVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The mixing system is divided into multiple dosing apparatuses that operate independently and continuously, each handling a portion of the powder flow. This segmentation allows lower-power individual components to achieve effective mixing through coordinated operation rather than requiring a single high-power actuator.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements continuous dosing and mixing operation where powders are fed continuously through dosing apparatuses into a mixing chamber. This continuous operation eliminates the need for high-power intermittent actuators, reducing overall energy consumption while maintaining mixing effectiveness through sustained, low-intensity action.

Inventive Principle:

Principle #20Continuity of useful action

2Productivity

If batch-mixing method with high-power actuators is used, then mixing capability is improved, but safety risks increase

Engineering Contradiction:

Improvemixing capabilityVSAvoidsafety risks

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

By dividing the mixing function across multiple independent dosing apparatuses with lower power requirements, the system reduces the safety hazards associated with high-power actuators in explosive powder environments. Each component operates at lower energy levels, minimizing ignition risks.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces high-power mechanical actuators with a system of continuous dosing apparatuses that use controlled mechanical feeding mechanisms. This substitution eliminates the need for high-energy motors and actuators that pose explosion risks, while maintaining effective powder mixing capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Loss of substance

If recycled powder is used, then material cost is reduced, but contamination increases

Engineering Contradiction:

Improvematerial costVSAvoidcontamination

Core Design Contradiction:

Loss of substanceVSObject-affected harmful factors

Solution Approach 1:

The continuous mixing operation allows for consistent and uniform blending of recycled powder with fresh powder throughout the process. This continuous action ensures thorough mixing that prevents localized contamination and maintains homogeneous composition, making the recycled material fully usable.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The dosing apparatuses act as intermediaries that precisely control the flow rates and proportions of recycled and fresh powders into the mixing chamber. This controlled intermediate feeding mechanism ensures uniform distribution and prevents contamination by regulating the mixing ratio and preventing clumping.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Manufacturing precision

If continuous dosing and mixing is implemented, then mixing quality is improved, but device complexity increases

Engineering Contradiction:

Improvemixing qualityVSAvoiddevice complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The dosing apparatuses are designed with multi-functionality, serving both as powder delivery mechanisms and as mixing initiators. This universal design reduces the need for separate specialized components, simplifying the overall system while maintaining high mixing quality through integrated functionality.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20240375064A1Continuous Mixing Device And Related Method

Publication Date: 2024.11.14 LAIR LIQUIDE SA POUR LETUDE & LEXPLOITATION DES PROCEDES GEORGES CLAUDE

AI summary

A device for continuously mixing a first powder and a second powder, includes a first metering device for continuously metering the first powder, and a second metering device for continuously metering the second powder, a mixer designed to mix the first powder metered by the first metering device and the second powder metered by the second metering device so as to supply a continuous stream of powder mixed according to a determined ratio, and a sampling device designed to sample a fraction of the stream of mixed powder.