Double Dump Valve Prevents Backflow in Additive Manufacturing Recycler
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Solution Overview
Problem
Current powder recyclers in additive manufacturing discard smaller particles below 50 microns, leading to waste and diminished process performance, and the combination of helical cyclones with original dump valves causes backflow issues preventing powder from recycling.
Innovation Solution
A powder system recycler design incorporating a helical cyclone with a two-valve system that alternately opens and closes to prevent backflow, allowing for the recycling of a wider range of particle sizes down to 3 microns, effectively recycling almost all powder without discarding smaller particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single dump valve is used in the recycler system, then the structure is simple, but backflow occurs preventing powder from falling into the trough
Solution Approach 1:
The single dump valve is segmented into two separate valves (first dump valve and second dump valve) that operate alternately. This segmentation prevents backflow by ensuring one valve is closed when the other opens, while maintaining the function of powder discharge into the trough.
Solution Approach 2:
The two dump valves operate in a periodic alternating manner, with each valve opening and closing in sequence. This periodic action ensures continuous powder flow while preventing backflow, as one valve is always closed to block reverse flow while the other opens for discharge.
2Device complexity
If the cutoff point is set at 50 microns, then the recycler operates simply, but smaller particles are discarded causing waste and diminished process performance
Solution Approach 1:
The cutoff point parameter is changed from 50 microns to 3 microns by modifying the recycler system. This parameter change allows the system to retain and recycle smaller particles that were previously discarded, reducing powder waste and improving process performance.
3Productivity
If the cutoff point is extended to 3 microns, then powder recycling efficiency is improved, but the device complexity increases
Solution Approach 1:
The recycler system is segmented into multiple functional components including a first recycler with a first dump valve and a second recycler with a second dump valve. This segmentation enables the system to handle a wider particle size range (down to 3 microns) while managing complexity through modular architecture.
Solution Approach 2:
The system incorporates dynamic control of multiple valves that open and close in sequence based on operational requirements. This dynamic operation allows the system to maintain high recycling efficiency for particles down to 3 microns while managing system complexity through automated valve control.
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 solution significantly improves the recycling efficiency by extending the cutoff point from 50 microns to 3 microns, minimizing waste and enhancing the performance of the additive manufacturing process by retaining smaller particles, thus improving the adherence of powder to substrate sheets.
Implementation Method 1
a helical cyclone for retaining the smaller particles
Implementation Method 2
a two-valve (gate or flap) system that alternately open and close to release powder into a trough
Data Source
AI summary
A double dump valve apparatus has the doors flap open in opposite horizontal orientations and directions.