Substrate Inversion for Excess Polymer Removal in CBAM
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Solution Overview
Problem
Current additive manufacturing processes are inefficient and time-consuming in removing excess polymer, relying on mechanical vacuum systems that are unnecessary and slow.
Innovation Solution
A substrate layer frame inversion mechanism that flips the substrate 180 degrees, allowing excess powder to drop into a waste reclaim container for later reuse, optionally using a mechanical vibrator to loosen remaining powder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a mechanical vacuum system is used to remove excess polymer, then the removal process can be performed, but the process is time-consuming and inefficient
Solution Approach 1:
The substrate layer frame is inverted 180 degrees to reverse the removal mechanism. Instead of actively suctioning excess polymer with a vacuum system, the inversion causes excess polymer to passively drop into the reclaim container under gravity, dramatically speeding up the removal process
Solution Approach 2:
The system uses its own weight and gravity to perform the removal function. By inverting the substrate layer frame, the excess polymer automatically drops into the reclaim container without requiring external vacuum power, making the system self-sufficient for this operation
2Ease of manufacture
If a mechanical vacuum system is used to remove excess polymer, then removal can be achieved, but the system complexity increases
Solution Approach 1:
The invention extracts the essential removal function from the complex vacuum system and achieves it through a simple mechanical inversion of the substrate layer frame, eliminating the need for vacuum pumps and complex suction mechanisms
Solution Approach 2:
The mechanical vacuum system is replaced with a simple mechanical inversion mechanism. Instead of using a complex vacuum-based mechanical system, the patent uses a straightforward 180-degree rotation of the substrate layer frame to achieve excess polymer removal
3Productivity
If material is removed quickly without vibration, then the process is faster, but remaining powder is not completely removed
Solution Approach 1:
A mechanical vibrator is applied to the substrate layer frame during or after inversion to vibrate and loosen remaining powder particles. This vibration ensures that even tightly adhered excess polymer is completely removed, maintaining high reliability of material removal
Solution Approach 2:
The mechanical vibration is applied periodically during the inversion process or immediately afterward. This periodic vibrational action effectively loosens and removes remaining powder without requiring continuous vibration, maintaining both speed and completeness of removal
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
This method significantly speeds up the excess polymer removal process, enabling more efficient reuse of materials and reducing the time required for the additive manufacturing process.
Implementation Method 1
The excess powder will simply drop into a waste reclaim container for later reuse
Implementation Method 2
An optional mechanical vibrator may be used to completely loosen any remaining powder
Data Source
AI summary
Apparatus and methods are disclosed for reclaiming unused powder in a composite-based additive manufacturing process. According to aspects of the embodiments, there is provided process and apparatus that use a substrate layer frame inversion mechanism that can flip the substrate over 180 degrees. The excess powder will simply drop into a waste reclaim container for later reuse. An optional mechanical vibrator may be used to completely loosen any remaining powder.