Additively Built Separator Disc Spacers for Hygienic Centrifuges

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Solution Overview

Problem

Existing separating discs for centrifuges face challenges in maintaining hygiene due to gaps between spacers and the disc, require complex welding processes, and are limited by the need for multiple forming tools for varying spacer geometries, which can lead to material constraints and potential deformation.

Innovation Solution

A separating disc with a truncated cone base body produced through a forming process, featuring spacers designed using additive manufacturing (3D printing) that can be freely configured in geometry and material, allowing for gap-free connection and varied geometry, potentially using different materials for the disc and spacers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If spot welding is used to fasten spacers on the separating plate, then the joining process is simple, but gaps are created between the separating plate and the spacer compromising hygiene

Engineering Contradiction:

Improvejoining process simplicityVSAvoidgaps between plate and spacer

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The spacer and separating plate are merged into a single integrated component produced by additive manufacturing. The spacer is built directly onto the separating plate in one continuous manufacturing process, eliminating the gap creation issue of spot welding while maintaining process simplicity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention uses the same material for both the separating plate and spacer, creating a homogeneous composite structure. This eliminates material incompatibility issues and ensures uniform properties throughout the integrated component, while the additive manufacturing process creates a gap-free joint.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If circumferential laser welding is used to avoid gaps, then hygiene is improved, but the process becomes complex and heat input causes deformation

Engineering Contradiction:

Improvegaps between plate and spacerVSAvoidwelding process complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The invention extracts the joining operation from the manufacturing process entirely. Instead of adding a complex welding step to connect separate components, the design is modified so the spacer and plate are produced as one integrated piece, removing the need for joining operations and their associated complexity and heat input.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical joining process (welding) is replaced with an additive manufacturing process that builds the spacer directly onto the plate. This substitution eliminates the need for complex welding equipment and procedures while achieving gap-free connections without heat-induced deformation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If a forming process is used to produce the separating plate, then the base geometry is created efficiently, but multiple forming tools are needed for varying spacer geometries

Engineering Contradiction:

Improvebase body production efficiencyVSAvoidspacer geometry variability

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The invention introduces dynamic reconfigurability to the manufacturing process. The additive manufacturing module can be programmed with different digital models to produce various spacer geometries on the same base body, allowing the system to adapt to different design requirements without physical tool changes.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The additive manufacturing module serves multiple functions: it can produce spacers of any geometry, attach them to the base body, and be reprogrammed for different designs. This single universal tool replaces the need for multiple specialized forming tools, maintaining productivity while enabling geometric variability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Ease of manufacture

If the same material is used for the separating plate and spacers, then manufacturing is simplified, but design flexibility and material optimization are limited

Engineering Contradiction:

Improvematerial consistencyVSAvoidmaterial selection freedom

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The invention enables different materials to be used for different parts of the same component. The spacer can be made from a different material than the base body, allowing optimization of material properties for specific functional requirements while maintaining the benefits of additive manufacturing for complex geometries.

Inventive Principle:

Principle #3Local quality

Data Source

PatentEP4058199B1Separator disc, separator disc package, centrifuge comprising the separator disc package, and method for producing the separator disc

Publication Date: 2023.08.23 GEA MECHANICAL EQUIP GMBH

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AI summary

The invention relates to a separator disc (8) for a centrifuge (2), in particular for a separator. The separator disc (8) is designed to be arranged in a separator disc stack (7) in the interior (6) of a drum (1) of the centrifuge (2) in order to separate a material mixture, wherein the separator disc (8) has a truncated cone shell-like main part (81) which is produced from a blank in a forming method and comprises an inner surface, an outer surface (83), and at least one functional element applied thereon. The invention is characterized in that the at least one functional element is produced using an additive manufacturing method.