Flow Modification Element for Additive Manufacturing Impurity Removal
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Solution Overview
Problem
Existing additive manufacturing devices face challenges in efficiently removing impurities such as splatter, smoke, vapors, and gases from the process chamber, which can affect the quality and efficiency of the manufacturing process.
Innovation Solution
A flow modification element and device that introduces a gas flow into the process chamber, featuring a gas inlet side, a gas outlet side, and multiple channels defined by gas guide elements. The configuration ensures that the gas flow is directed towards the build area, with varying channel cross-sectional areas to control flow velocities and reduce turbulence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a gas flow is generated to transport impurities out of the process chamber, then impurity removal effectiveness is improved, but gas flow homogeneity and directionality may be insufficient leading to reduced manufacturing quality
Solution Approach 1:
The gas inlet element is segmented into multiple channels (first channels, second channels, third channels) arranged at different positions and orientations. This segmentation allows different gas flow paths to be created, with each channel contributing to overall flow homogeneity and directionality toward the build area, resolving the contradiction between impurity removal effectiveness and manufacturing quality
Solution Approach 2:
Different channels are designed with different total opening cross-sectional areas at their outlets. The first channels have a first total opening cross-sectional area, the second channels have a second total opening cross-sectional area, and the third channels have a third total opening cross-sectional area. This local variation in channel properties creates differentiated gas flow characteristics that collectively improve both impurity removal and flow homogeneity
2Stability of the object's composition
If multiple channels are used to improve gas flow distribution, then flow homogeneity is improved, but device complexity increases
Solution Approach 1:
Multiple channels (first channels, second channels, third channels) with different configurations are merged into a single integrated gas inlet element. This merging approach achieves improved gas flow homogeneity and directionality while avoiding the complexity of multiple separate gas inlet components, as all channels are formed within one unified element
3Productivity
If gas flow velocity is increased to improve impurity removal, then productivity is improved, but turbulence increases reducing flow control precision
Solution Approach 1:
The total opening cross-sectional area parameter is varied across different channels to optimize gas flow characteristics. By adjusting the cross-sectional area of each channel type (first, second, and third channels), the gas flow velocity and turbulence are controlled to achieve effective impurity removal while maintaining flow control precision
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 effectively enhances the removal of impurities from the process chamber by improving the homogenization and directionality of the gas flow, thereby maintaining high manufacturing quality and efficiency.
Implementation Method 1
a gas flow is usually generated in the process chamber that transports impurities out of the process chamber
Implementation Method 2
a total opening cross-sectional area associated with the number of first channels on the gas outlet side differs from a total opening cross-sectional area associated with the number of second channels on the gas outlet side
Implementation Method 3
improving the homogenization and directionality of the gas flow
Data Source
AI summary
Disclosed is a flow modification element including a gas guide element extending from a gas inlet side to a gas outlet side and a plurality of channels. The channels are spaced apart such that the number of second channels is arranged closer to the build area in a direction perpendicular to the build area than the number of first channels. A total opening cross-sectional area of the number of first channels on the gas outlet side differs from a total opening cross-sectional area of the number of second channels on the gas outlet side, and the total opening cross-sectional areas of the number of first channels and of the number of second channels on the gas inlet sides are substantially equal. Or, at least a partial gas flow introduced into the process chamber from the number of first channels is directed towards a plane of the build area.