Dosing Chute Vibration for Homogeneous Powder Coating
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Solution Overview
Problem
Existing methods for applying free-flowing materials, such as powders, to substrates in layer-by-layer three-dimensional object creation often result in inhomogeneous coatings due to varying material compressions and distribution issues, leading to quality fluctuations and waste during refilling.
Innovation Solution
A device with a continuously filled dosing chute from an integrated storage container maintains a constant fill level, allowing for uniform application by integrating a vibration device for even distribution and eliminating the need for complete emptying of the storage container, reducing waste and storage volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the storage container is completely emptied during refilling to avoid inhomogeneities, then coating homogeneity is improved, but material waste increases and productivity decreases
Solution Approach 1:
The patent applies preliminary action by pre-distributing the powder in the storage container using a distribution screw before refilling occurs. This ensures that when new powder is added, it mixes uniformly with the existing powder, preventing density differences and inhomogeneities in the coating. The distribution screw creates a uniform powder bed in advance, eliminating the need to empty the container while maintaining coating quality.
Solution Approach 2:
The patent replaces the mechanical system of complete container emptying with a distribution screw mechanism that actively mixes and redistributes powder in place. This substitution allows continuous operation without waste while maintaining uniform powder density, resolving the contradiction between coating homogeneity and material waste.
2Manufacturing precision
If mechanical distribution by distribution screw or vibrators is used to distribute powder in the storage container, then coating homogeneity is improved, but device complexity increases
Solution Approach 1:
The patent segments the distribution function into a separate distribution screw mechanism that operates independently within the storage container. This segmentation allows the distribution function to be added without significantly complicating the overall system, as the distribution screw is a simple, dedicated component that can be integrated into the existing storage container structure.
3Loss of substance
If the storage container is made very wide and relatively narrow in depth to reduce material storage volume, then loss of substance is reduced, but powder distribution becomes more difficult and coating homogeneity worsens
Solution Approach 1:
The patent employs mechanical vibration through a vibrator mechanism that agitates the powder in the storage container. This vibration helps to redistribute powder evenly, preventing segregation and ensuring uniform flow characteristics. The vibration compensates for the geometric challenges of wide, shallow containers, maintaining coating homogeneity while allowing for reduced material storage volume.
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
This approach ensures a homogeneous coating with reduced waste and improved surface quality by maintaining consistent material distribution and pressure during application, minimizing local density differences and allowing for efficient refilling without generating additional waste.
Implementation Method 1
a vibration device (40) is provided which is arranged below the storage container (24) and which is used to vibrate both the storage container (24) and the dosing chute (30)
Implementation Method 2
the flowable material is filled from a stationary material supply (10) into a moveable application device (20)... from which the filled material is discharged downwards in continuous layers
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The invention relates to a method and a device for applying a flowable material, especially a particulate material, in individual superimposed layers across a support (50), the flowable material being first filled from a stationary feed station (10) into a storage container (24) of an application device. In the application device (30), which travels back and forth across the support, the flowable material is distributed inside the storage container across the entire length of the device and is then metered through a slot into a metering funnel in such a manner that the filling level in the metering funnel remains constant during application of the flowable material from the metering funnel onto the support.