Passivation Device for Additive Manufacturing Filter Residues

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Solution Overview

Problem

Additive manufacturing processes, particularly those involving metal-containing materials like titanium or aluminum, face risks of uncontrolled filter blazes and dust explosions due to the reaction of metal particles with oxidative materials at high temperatures, especially when oxygen reaches filter elements during filter changes.

Innovation Solution

A passivation device is introduced to address this by using a reaction unit with an oxidant inlet, coupling unit, discharge unit, and energy supply to control the oxidation of filter residues, preventing uncontrolled reactions and explosions. This device isolates the oxidation process from the environment, utilizing preheated oxidants like oxygen and controlling the energy supply to prevent adhesion or fusion of condensate particles, ensuring a controlled and safe oxidation process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If filter residues are removed from the process gas circuit during filter changes, then operational safety is improved, but oxygen may reach the filter element causing uncontrolled reactions

Engineering Contradiction:

Improveoperational safetyVSAvoiduncontrolled filter blazes

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The passivation device performs preliminary oxidation of filter residues before they are removed from the filter element. By introducing oxidant and supplying energy to the reaction unit, the hazardous metal particles are converted to stable oxides in advance, eliminating the risk of uncontrolled reactions during subsequent filter maintenance operations

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The device converts the harmful reactive metal particles into beneficial stable oxide layers through controlled oxidation. The same oxidant that could potentially cause dangerous reactions is instead used in a controlled manner to passivate the particles, transforming a hazard into a safety mechanism

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Productivity

If filter cleaning intervals are extended, then productivity is improved, but hazardous condensate particles accumulate on filter elements

Engineering Contradiction:

Improvefilter cleaning intervalsVSAvoidhazardous condensate particles

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The accumulated hazardous condensate particles are converted into stable, non-hazardous oxide material through controlled oxidation in the passivation device. This allows extended filter cleaning intervals since the particles can be safely passivated in place rather than requiring frequent removal

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The chemical state of the filter residues is changed from reactive metal particles to stable oxides by controlling the oxidation parameters (oxidant concentration, temperature, reaction time). This parameter change eliminates the hazard while allowing longer operational intervals between filter maintenance

Inventive Principle:

Principle #35Parameter changes

3Object-affected harmful factors

If inerting substances are added to separate dust components, then dust explosion risk is reduced, but the dust container must be emptied more often

Engineering Contradiction:

Improvedust explosion riskVSAvoiddust container emptying frequency

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

Instead of using inerting substances to suppress explosions, the device directly converts the hazardous dust particles into stable oxides through controlled oxidation. This eliminates the explosion risk without adding volume-increasing inert materials that would require more frequent emptying

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The hazardous property of the dust particles is extracted through oxidation, converting reactive metal particles into stable oxide material. This removes the explosion risk inherent in the original dust without requiring additional inerting additives

Inventive Principle:

Principle #2Taking out (Extraction)

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 passivation device effectively prevents dust explosions by safely oxidizing hazardous condensate particles outside the process gas circuit, extending filter cleaning and replacement intervals, and ensuring the process gas flow remains uninterrupted, thus enhancing operational safety and efficiency in additive manufacturing.

Implementation Method 1

an energy supply unit suitable for effecting a reaction between the filter residues and the oxidant in the reaction unit

Methodology Applied

Scientific EffectOxidation: Oxidation

Data Source

PatentUS20230142672A1Passivation of filter residues

Publication Date: 2023.05.11 EOS GMBH ELECTRO OPTICAL SYST

AI summary

A passivation device for passivating filter residues of a filter device arranged in a process gas circuit of an additive manufacturing apparatus includes a reaction unit having an inlet suitable for supplying an oxidant, a coupling unit adapted to be coupled to the filter device for introducing filter residues into the reaction unit, a discharge unit suitable for discharging passivated filter residues from the reaction unit, and an energy supply unit suitable for effecting a reaction between the filter residues and the oxidant in the reaction unit.