Method and device for switching a particulate material flow in the construction of models in layers

• US 9,174,392 B2
• Filed: 06/18/2010
• Issued: 11/03/2015
• Est. Priority Date: 06/22/2009
• Status: Active Grant

• Current Assignee: Voxeljet AG
• Original Assignee: Voxeljet AG
• Inventors: Hartmann, Andreas Dominik
• Primary Examiner(s): Nicolas, Frederick C
• Assistant Examiner(s): LEMBO, MATTHEW A
• Application Number:
  US13/378,487
• Publication Number:
  US 20120097258A1
• Time in Patent Office: 1,964 Days
• Field of Search: 222/200, 222/459, 222/1, 222482-484, 222195-196, 137/14, 427/197, 141/8, 141/21, 141/25, 141/46, 264/112
• US Class Current: 1/1
• CPC Class Codes: B28B 1/001 Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00
• CPC Class Codes: B28B 17/04 Exhausting or laying dust
• CPC Class Codes: B29C 31/02 Dispensing from vessels, e.g. hoppers into a mould cavity B29C31/04; large containers characterised by discharge means B65D88/28, B65D88/54
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B29C 64/321 Feeding
• CPC Class Codes: B29C 64/329 using hoppers
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 40/00 Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: Y10T 137/0396 Involving pressure control
• CPC Class Codes: Y10T 137/8593 Systems

Abstract

The invention relates to a method for switching a particulate material flow in the construction of models in layers, wherein particulate materials are fed to a subsequent method step from a container having an opening in the direction of a workpiece platform. The particles in the container are exposed to a vacuum and to overpressure.

Claims

1. A system for production of three-dimensional models comprising:

a workpiece platform for layer-wiser application of a particulate material;

a coating device for repeated application of layers of the particulate material to the workpiece platform; and

a filling device for filling the coating device with the particulate material, wherein the filling device includes a container having two opposing walls and an opening in the direction of the workpiece platform for feeding to the coating device, the opening not being sealed off from the environment around the filling device, the filling device includes a means for exposing the particulate material to vacuum and excess pressure for controlling the flow of the particulate material from the filling device, wherein the means for exposing the particulate material includes at least one connector to each of the opposing walls for i) providing vacuum from the opposing walls for forming a bridge of the particulate material between the two opposing walls and ii) providing excess pressure for destroying the bridge;

wherein the two opposing walls are flat and tapered inwardly, and the intersection of the opposing walls with the horizontal plane are parallel lines;

a length of the container is a multiple of a width of the container so that the opening of the container is long and narrow for filling the coating device across a length of the coating device.

2. The system according to claim 1, wherein in or on the container, nozzles are provided for supply of gases.

3. The system according to claim 1, wherein the nozzles are independently activated.

4. The system according to claim 3, wherein valves are provided for activation of the nozzles.

5. The system according to claim 4, wherein porous materials, whose pore size is smaller than a smallest diameter of the particulate material, are arranged in the container.

6. The system according to claim 1 wherein porous materials, whose pore size is smaller than a smallest diameter of the particulate material, are arranged in the container.

7. The system according to claim 1, wherein the filling device includes sieve arrays for sealing the opening of the container.

8. The system according to claim 7, wherein a mechanical slide valve is provided for sealing of the opening in the container.

9. The device according to claim 1, wherein the opposing walls have a plurality of openings for applying the vacuum along the length of the opposing walls.

10. A method for construction of models in layers comprising the steps of:

forming a bridge of a particulate material in a container of a filling device by exposing the particulate material to a vacuum from two opposing walls of the container, wherein the opposing walls are flat and tapered inwardly and the intersection of the opposing walls with a horizontal plane are parallel lines;

applying a first layer of the particulate material to a workpiece platform using a coating device;

destroying the bridge by impacting the bridge with an excess pressure;

feeding the particulate material from the filling device to the coating device for filling the coating device with the particulate material, and

applying an additional layer of the particulate material over the first layer using the coating device;

wherein the container of the filling device has an opening in the direction of the workpiece platform, the opening not being sealed off from the environment around the filling device, wherein the feeding of the particulate material from the filling device is controlled by exposing the particulate material in the container to the vacuum for forming the bridge and to the excess pressure for destroying the bridge; and

wherein a length of the container is a multiple of a width of the container so that the opening of the container is long and narrow for filling the coating device across a length of the coating device.

11. The method according to claim 10, wherein the method includes the step of moving the coating device to a final position when a fill level of the particulate material in the coating device is low, where the filling device is arranged above the final position;

wherein the exposing of the particulate material to a vacuum stops a discharge of the particulate material from the opening of the container and the excess pressure leads to the discharge of the particulate material from the opening of the container.

12. The method according to claim 11, wherein the process includes a step of locally solidifying the particulate material with the vacuum.

13. The method according to claim 12, wherein the step of exposing the particulate material to the vacuum or the excess pressure occurs by means of porous materials provided in or on the container, wherein a pore width of the porous materials is smaller than a smallest diameter of the particulate material and that gases are supplied and extracted through the porous materials.

14. The method according to claim 10, wherein the particulate material is solidified locally due to the vacuum.

15. The method according to claim 10, wherein the exposing of the particulate material to the vacuum or the excess pressure occurs by means of porous materials provided in or on the container, wherein a pore width of the porous materials is smaller than a smallest diameter of the particulate material and that gases are supplied and extracted through the porous materials.

16. The method according to claim 10, wherein the filling device includes nozzles for exposing the particulate material to the vacuum or the excess pressure and the process includes individually controlling the nozzles via independent valves.

17. The method according to claim 16, wherein the individual control of the nozzles, in the case of one nozzle freeing up, will prevent a drop in pressure at the other nozzles.

18. The method according to claim 10, wherein the exposing the particulate material to excess pressure includes introducing gases into the particulate material.

19. The method according to claim 10, wherein the process further comprises a step of selectively imprinting a binder on an area of the particulate material of the first layer, and a step of selectively imprinting the binder on an area of the particulate material of the additional layer, wherein the binder bonds to the particulate material, and wherein the layer-wise application of the particulate material and the imprinting of the binder are repeated until a desired height of the object is achieved;

wherein the imprinting of the binder employs a print head.

20. The method of claim 10, wherein the vacuum is applied via openings along the length of the opposing walls.