Sealed Build Chamber Tool Exchange Using Expandable Channel Seals
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Solution Overview
Problem
Existing additive manufacturing systems face challenges in maintaining a controlled environment during tool exchange, as tools need to be lifted out of the sealed chamber, disrupting the controlled environment.
Innovation Solution
An additive manufacturing system with a sealing assembly and tool bays that allows tools to be exchanged while maintaining the controlled environment by using a gantry to move tools above the build chamber, accompanied by expandable channel seals that seal the chamber as tools are removed and replaced.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If tools are lifted out of the sealed chamber for exchange, then tool exchange can be performed, but the controlled environment is disrupted and heat or gases may escape
Solution Approach 1:
The tool exchange function is extracted from the sealed chamber environment. Tools are removed from tool bays that are positioned outside the sealed chamber, eliminating the need to breach the seal for tool exchange while maintaining the controlled environment inside the chamber
Solution Approach 2:
Tool bays serve as an intermediary structure positioned between the sealed chamber and the external environment. Tools are stored in these bays and can be exchanged without entering the sealed chamber, acting as a buffer zone that maintains the seal integrity while enabling tool exchange operations
2Reliability
If a sealed build chamber is used to maintain controlled environment, then heat and gases are contained, but tool exchange becomes difficult without disrupting the seal
Solution Approach 1:
The system is segmented into distinct zones: a sealed build chamber for maintaining controlled environment, and separate tool bays for tool storage and exchange. This segmentation allows the sealed chamber to maintain its integrity while tool operations occur in the unsealed tool bay area
Solution Approach 2:
Tool bays are positioned in a different spatial dimension (outside and adjacent to the sealed chamber) rather than inside it. The gantry system moves tools horizontally above the chamber and uses vertical guide rails for tool bay access, separating the tool exchange dimension from the sealed chamber dimension
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 system maintains a sealed build chamber during tool exchange, preventing heat or gas escape, ensuring consistent operational conditions.
Implementation Method 1
Each first channel seal expands or contracts based on a relative movement between the associated tool and the associated slider
Implementation Method 2
The two guide rails are movable along a second direction perpendicular to the first direction, so as to enable alignment of the guide rails with one of the tool bays at a time
Implementation Method 3
The tool mount is arranged to detachably couple the selected tool to the gantry
Data Source
AI summary
Provided herein is an additive manufacturing system having a build chamber, a plurality of tools and a plurality of tool bays where each tool bay is arranged to store one tool. A gantry is arranged to select one tool and removes the selected tool from a tool bay. A tool mount is slidably arranged on the gantry and to detachably couple the selected tool to the gantry. Two guide rails extend in a first direction and are arranged to receive the selected tool. The guide rails are movable along a second direction perpendicular to the first direction, so as to enable alignment of the guide rails with one of the tool bays at a time. Channel seals expand or contract based on a relative movement between the tools and the sliders.