Filter Unit Particle Reception Chamber Additive Manufacturing
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Solution Overview
Problem
Existing additive manufacturing apparatuses face challenges in efficiently removing non-consolidated particulate build material, smoke, and smoke residues during operation, leading to contamination and requiring time-consuming filter cleaning or replacement, which increases downtime.
Innovation Solution
A plant with a filter unit that separates particles into a particle reception chamber instead of accumulating them on filter elements, allowing for separate handling and reduction of downtime by using a common particle guide and reception chamber system, and optionally incorporating a passivation unit to prevent oxidation and facilitate cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filter elements are used to separate particles from process gas, then particle separation efficiency is improved, but particle accumulation on filter elements increases cleaning time and downtime
Solution Approach 1:
The patent extracts the particle accumulation problem from the filter element by introducing a separate collection chamber. Particles are separated from the gas stream by the filter element but are immediately conveyed away into a collection chamber, preventing accumulation on the filter element itself and enabling continuous operation without cleaning downtime.
Solution Approach 2:
The patent introduces an intermediary particle conveyance system (such as airflow or mechanical conveyors) between the filter element and the collection chamber. This intermediary mechanism efficiently transports particles away from the filter element, preventing accumulation while maintaining the filter element's separation function.
2Productivity
If high power energy beams are used for consolidation, then manufacturing productivity is improved, but particle generation and contamination increases
Solution Approach 1:
The patent converts the harmful particles generated by high power energy beams into a manageable byproduct. Instead of viewing particle generation as purely detrimental, the system captures and collects these particles in a dedicated chamber, transforming the contamination problem into a controlled separation and collection process that enables continued high-power operation.
3Reliability
If filter units are cleaned or replaced frequently, then process gas cleanliness is maintained, but apparatus downtime increases
Solution Approach 1:
The patent enables continuous particle separation by implementing a collection chamber that accumulates particles over time without requiring interruption of the manufacturing process. The filter element remains in continuous service while particles are gradually collected, eliminating the need for frequent cleaning or replacement and maintaining operational continuity.
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 solution reduces downtime and cleaning effort by preventing particle accumulation on filter elements, enabling continuous operation and maintaining clean process gas, while also ensuring safety through passivation of particles.
Implementation Method 1
a filter unit configured to separate particles from the stream of process gas, wherein the filter unit comprises a filter chamber with at least one filter element at least partly arranged in the streaming path of the generated stream of process gas, wherein particles in the stream of process gas are separated from the process gas by the filter element
Implementation Method 2
a particle reception chamber separably connected or connectable to a particle outlet of the filter chamber and configured to receive the particles separated from the process gas
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Apparatus (1) for additively manufacturing of three-dimensional objects by means of successive layerwise selective irradiation and consolidation of layers of a build material which can be consolidated by means of an energy beam, with a stream generating unit (2) configured to generate a stream of a process gas (3) being capable of being charged with particles (4), in particular non-consolidated particulate build material and/or smoke and/or smoke residues, generated during operation of the apparatus (1) and a filter unit (5) configured to separate particles (4) from the stream of process gas (3), wherein the filter unit (5) comprises a filter chamber (6) with at least one filter element (7) at least partly arranged in the streaming path of the generated stream of process gas (3), wherein particles (4) in the stream of process gas (3) are separated from the process gas (3) by the filter element (7), wherein a particle reception chamber (13, 26, 28) is separably connected or connectable to a particle outlet (11) of the filter chamber (6) and configured to receive the particles (4) separated from the process gas (3).