Flammable Powder Passivation via Fluid Dispersion Structure

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Solution Overview

Problem

Existing methods for passivating flammable powders produced in additive-manufacturing processes are inefficient due to the time required for passivation fluids to penetrate and the need to move disposal bins between sand layering and oil addition, leading to prolonged processing and increased labor costs.

Innovation Solution

A flammable powder passivation apparatus and method featuring a powder waste collection bin with a fluid dispersion structure that allows a non-volatile passivation fluid to be dispersed throughout the chamber, reducing exposure to air and accelerating the passivation process, while a particle collection bin transports the passivation fluid from outside to inside without exposing the powder to external air.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the known method of layering sand and covering with oil is used to passivate flammable powder, then the powder is passivated, but the process requires excessive time for oil penetration and multiple location transfers

Engineering Contradiction:

Improvepassivation effectivenessVSAvoidpassivation processing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The passivation system is segmented into multiple spray nozzles positioned at different locations within the container, allowing simultaneous passivation of powder at various levels rather than relying on slow downward penetration of oil through sand layers

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a hydraulic spray system to deliver passivation fluid directly to the powder through nozzles, replacing the slow gravitational penetration method with forced fluid delivery that achieves rapid and uniform coating

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Reliability

If the known method of moving the disposal bin from sand layering location to oil addition location is used, then the passivation process is completed, but labor costs and operational complexity increase

Engineering Contradiction:

Improvepassivation completenessVSAvoidoperational simplicity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The sand layering function and oil addition function are merged into a single integrated container system, eliminating the need to transfer the container between locations and simplifying the operational sequence to a single-step passivation process

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The container is designed to perform both sand layering and passivation fluid application functions independently without requiring external handling or relocation, making the system self-sufficient and operationally simple

Inventive Principle:

Principle #25Self-service

3Object-affected harmful factors

If sand layers are used to cover flammable powder before adding oil, then the powder is protected, but the sand acts as a barrier that slows down passivation fluid penetration

Engineering Contradiction:

Improveair exposure protectionVSAvoidpassivation fluid penetration speed

Core Design Contradiction:

Object-affected harmful factorsVSSpeed

Solution Approach 1:

Instead of allowing passivation fluid to penetrate downward through sand layers from the top, the invention inverts the approach by using nozzles positioned within the container to spray passivation fluid directly onto the powder, eliminating the sand barrier effect

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The spray nozzles act as intermediaries that deliver the passivation fluid directly to the powder surface, bypassing the need for fluid to traverse through sand layers and enabling rapid penetration and coating

Inventive Principle:

Principle #24Intermediary (Mediator)

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 reduces the time needed for passivation, saves labor and costs by ensuring thorough coating of the flammable powder with the passivation fluid, and facilitates safer handling by preventing air exposure.

Implementation Method 1

The fluid dispersion structure is provided for enabling a passivation fluid to be dispersed throughout the chamber to passivate flammable powder contained in the chamber

Methodology Applied

Scientific EffectDispersion: Dispersion (of waves)

Implementation Method 2

The oil penetrates the sand to passivate the flammable powder that lies beneath the sand

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 3

The oil penetrates the sand to passivate the flammable powder that lies beneath the sand

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Data Source

PatentUS20240278051A1Apparatus and method for passivating a flammable powder

Publication Date: 2024.08.22 THE BOEING CO

AI summary

A flammable passivation apparatus includes a powder waste collection bin having a chamber in which a flammable powder can be filled. The apparatus also includes a fluid dispersion structure located in the chamber of the powder waste collection bin. The fluid dispersion structure is provided for enabling a passivation fluid to be dispersed throughout the chamber to passivate flammable powder contained in the chamber.