CN105813824A - 具有可移动侧壁的工作箱 - Google Patents

具有可移动侧壁的工作箱 Download PDF

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CN105813824A
CN105813824A CN201480065717.2A CN201480065717A CN105813824A CN 105813824 A CN105813824 A CN 105813824A CN 201480065717 A CN201480065717 A CN 201480065717A CN 105813824 A CN105813824 A CN 105813824A
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sidewall
container
structure container
aforementioned
platform
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I·埃德雷尔
D·冈瑟
B·海梅尔
A·D·哈特曼
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Voxeljet Technology GmbH
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Voxeljet Technology GmbH
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Priority to CN202210522187.6A priority Critical patent/CN114953442A/zh
Priority to CN202210522216.9A priority patent/CN114953443A/zh
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
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    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
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    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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Abstract

本发明涉及一种用于生产三维模型的装置。

Description

具有可移动侧壁的工作箱
技术领域
本发明涉及一种装置及其在用于生产三维模型的方法中的使用。
背景技术
欧洲专利说明书EP0431924B1中描述了一种用于从计算机数据生产三维物体的方法。在该方法中，将颗粒材料以薄层涂覆到平台上，并且使用打印头将粘合剂材料选择性地打印到颗粒材料上。其上打印了粘合剂的颗粒区域在粘合剂的影响下，并且如果必要的话，在额外硬化剂的影响下，粘在一起并固化。继而将平台降低一个层厚度的距离，进入到构造缸中，并且向该平台提供新的颗粒材料层，该新的颗粒材料层也如上所述地进行打印。重复这些步骤，直至达到一定的期望物体高度。从而，由经打印和固化的区域生产出三维物体。
在完成之后，由固化的颗粒材料生产的该物体嵌入在松散的颗粒材料中，并于随后从中移除。这例如使用提取器来完成。之后所期望的物体留下，例如通过手工刷净的方式从其移除粉末沉积物。
在所有的成层技术中，基于粉末状材料和供应液体粘合剂的3D打印是最快的方法。
该方法可以用于处理不同的颗粒材料，包括天然生物原材料、聚合物、金属、陶瓷和沙等(不是穷尽列表)。
在这种类型的方法中使用的机器通常包含工作箱，该工作箱可以插入到3D打印机器中或者从3D打印机器中移除，以用于增加机器运行时间的目的。可以将工作箱从机器中移除，以用于释放未固化材料的成分的目的，即，拆封它们。继而可以将另一工作箱立即插入到机器中，并且打印可以立刻继续，从而避免了不必要的、非生产性的机器停机时间。这种类型的工作箱具有构造平台，颗粒材料被涂覆到该构造平台上。该构造平台通常在高度方面是可调节的，并且在3D打印期间被降低，直到打印过程完成。通过移动和定位该构造平台来调节所期望的层厚度。
构造平台的精确定位对于尺寸精确部件的生产是极其重要和关键的。不仅构造平台在驱动啮合点处的定位十分重要，而且构造平台的所有点的一致定位也会影响构造精确度。构造平台的可能的变形对部件的精密和精确生产带来了问题。
然而，精密而平稳的定位在大型机器中存在巨大的困难。大尺寸导致高弯曲扭矩，这使得构造平台变形。然而，如果相应地强化构造平台，则转而必须精密地定位重物。这些问题的各个方面降低了可实现的装置精确度，或者妨碍了可接受的边际成本。
不同的影响造成了力和由此产生的弯曲扭矩。首先，在构造过程期间增长的粉末给料充当了增大的平面负荷。其次，增长的给料压迫构造容器的壁。此处产生反作用力，该反作用力转而作用在构造平台上。密封件也会产生力，该密封件相对于固定的侧壁而密封移动的构造平台。
专利说明书中描述了对增长的平面负荷的解决方法。例如，DE102010013733A1公开了一种装置，其中构造容器被设计为不动的工作台。用于生成新的粉末层并且用于选择性固化的装置在装置的构造方向上是可移位的。构造平台的设计可以很容易地适应于刚度需求。然而，由于其设计为无壁，因此该装置在可以使用材料的范围方面受到限制。
密封力可能受到结构措施的影响。一个选项是由此使用配备有毡密封件的构造容器，以用于减小密封摩擦的目的。还可以使用可膨胀密封件而使接触力最小化。
在根据现有技术的构造容器或工作箱中，给料对侧壁的横向摩擦作用是尚未解决的问题。根据现有技术，由此产生的力的效应通过结构措施而得到减轻。使用这样的构造容器：其驱动点被选择用于使偏斜最小化的目的。在这种情况下，可以通过材料的重量和摩擦效应将平面负荷纳入考虑，并且可以通过密封件将线性负荷纳入考虑。尽管有这样的优化，但仍可能创建出比实际支撑重力所必需的更庞大的设计。
用于减少力效应的另一结构措施是缩短装置内的力通量。例如，在DE10047614C2中实现了通过构造容器壁的通道。通过带或者帘将该通道相对于颗粒材料的通流密封。针对重的给料，为装置提供对应的大型设计。使用帘的解决方法仅适用于对壁施加非常小的压力的轻质颗粒材料。
特别是在移动构造平台时，横向地产生摩擦，这造成颗粒涂覆材料内的应力。由于这些应力，颗粒涂覆材料中可能发生移动，并且基于CAD数据而打印的预定部件点可能因而移位。部件中存在的空间点继而最终偏离CAD数据，并且所打印的部件不再与数据记录1:1地对应。因此所打印的部件是不精确的。这样的不精确性在很大程度上是基于摩擦问题。
然而，该问题尚未在文献和现有技术中辨别为一个问题和不精确地生产的部件的原因。因此，该问题尚未得到满意程度的解决，并且文献和现有技术中也没有任何针对该问题的解决方法。
因此，本发明的目的是提供一种解决上述问题的装置，并且特别地，提供一种工作箱，借助于该工具箱能够以高再现精确度生产高质量部件，并且其特别地使得具有减少的摩擦问题的工作箱或者避免或至少帮助减少现有技术的缺点的解决方法可供使用。
发明内容
本发明涉及一种构造容器或工作箱，其使得可以生产高质量部件，并且特别地具有减少的摩擦问题。这一目的通过两个，优选地通过三个，有利地通过四个侧向定位的、可移动的侧壁来实现，所述侧壁能够优选地以与根据本发明的工作箱中的构造平台相同的速度移动。
在另一方面，本发明涉及一种3D打印方法，其中可以使用根据本发明的构造容器(工作箱)。
具体实施方式
以下更加详细地解释本发明中的多个术语。
在本发明的意义内，“3D打印方法”涉及现有技术中已知的促进在三维模具中构造部件的所有方法，并且与所描述的方法部件和装置相兼容。特别地，这些方法是基于粉末的方法，例如SLS(选择性激光烧结)。
在本发明的意义内，“选择性粘合剂涂覆”或者“选择性粘合剂体系涂覆”可能在每次颗粒材料涂覆之后发生，或者根据成型主体的需求并且出于优化成型主体生产的目的而不定期地发生，即，在每次颗粒材料涂覆之后非线性地和非平行地发生。因此，“选择性粘合剂涂覆”或者“选择性粘合剂体系涂覆”可以单独地并且在生产成型主体的过程期间设置。
本发明的意义内的“成型主体”或者“部件”是借助于根据本发明的方法和/或根据本发明并具有抗变形能力的装置而生产的所有三维物体。
包含必要部件的任何已知的3D打印装置都可以用作用于实现根据本发明的方法的“装置”。常用的部件包括涂布器、构造区域、用于移动构造区域或其他部件的装置、定量给料装置和加热装置、以及本领域技术人员已知并且因此无需在本文更详细列举的其他部件。
已知用于基于粉末的3D打印的所有材料、特别是沙、陶瓷粉末、金属粉末、塑料、木材颗粒、纤维材料、纤维素和/或乳糖粉末都可以用作“颗粒材料”。颗粒材料优选地是干燥的、自由流动的并且有结合力的坚固粉末。
“构造区域”是这样的几何场所：其中通过重复地涂布颗粒材料在构造过程期间使颗粒材料给料生长。构造区域通常由底座、构造平台、壁和开盖表面、构造平面所划定。
在本发明的意义内，“构造容器”或者特别地“工作箱”实现了构造区域。因此，其具有底座、壁和开放的进入区、构造平面。构造容器总是包括不相对于3D打印装置的框架移动的部件。可拆卸式构造容器使得几乎连续地操作机器成为可能。在第一构造操作中的部件正被拆封时，可以在机器内在第二构造容器中打印新的部件。
“打印和涂布器平面”是当前正在进行中的构造过程的位置的抽象概念。由于定量给料单元和涂布器在具有接近一个高度上的共享部件的定位单元上在装置中结构性地移动，因此本说明书中将“打印和涂布器平面”视作位于新涂覆的层的上边缘。
“构造平台”相对于打印和涂布器平面移动。该相对移动在构造过程期间以层厚度进行间断移动。其限定了层厚度。
“容器壁”或者“壁”或者“侧壁”是指对颗粒材料的屏障。颗粒材料不能从壁的一侧行进到另一侧。本发明意义内的壁可以具有柔性或者刚性的设计。“刚性”标准的偏斜对于给定材料体系中的工件公差是微小的。
本发明意义内的“摩擦学配对”是其摩擦系数显著低于相接触的两个相同材料或者颗粒材料与壁材料之间的接触的摩擦系数的材料接触。
“密封件”是指防止颗粒材料穿过彼此相对移动的壁之间或者壁与构造平台之间的接触点的两个结构元件。
下文更加详细地描述本发明及其优选的具体实施方式。
本发明涉及一种构造容器，特别地是一种工作箱，用于通过逐层生产三维模型的装置，其包括：构造平台上的构造区域，该构造平台在构造容器内可调节高度，并且优选地可从构造容器移除；至少两个侧壁，该至少两个侧壁以这样的方式设计，使得在构造平台的移位期间，所构建的层与侧壁之间的动摩擦被减小或者基本上得到避免，所述构造平台与所述至少两个侧壁以相同的速度移动。
在一个方面，本发明直接减小了构造容器中的颗粒材料与侧壁之间的力。不同的结构措施可以有助于这一目的。相对移动的避免也不会导致除了粉末的重力之外的任何力效应，并且因此可以避免不期望的粉饼沉积。
因此，可以有利地实现对于所涂覆并沉积的层的稳定性具有负面影响的力很少发生或者不发生，并且可以由此提高所打印的部件的再现精确度。
在本发明的一个优选的具体实施方式中，构造容器的特征在于如上所述地设计3个或4个侧壁。构造容器的侧壁优选地在构造方向上可移动。可移动的侧壁进一步有利地相对于构造容器中的两个固定侧壁可移动。
侧壁以有利地服务于本发明的目的的方式进行设计。侧壁优选地被设计成相对于给料压力是刚性的。可以优选地使用本领域技术人员已知的所有加强件和肋板。
在一个优选的具体实施方式中，构造容器的特征在于,侧壁相对于给料压力不是刚性的，并且经由额外侧壁而支撑。优选地至少1个、优选2个、3个或4个侧壁被设计成在一个方向上是柔性的。进一步优选的是，至少1个、优选2个、3个或4个侧壁是分段的和/或金属壁，并且被设计成在一个方向上是柔性的。
在另一优选的具体实施方式中，构造容器的特征在于，具有金属/塑料摩擦学配对，以用于减少摩擦效应。构造容器优选地包括至少一个滚柱支承，以用于减少摩擦效应。构造容器进一步优选地包括支撑带作为侧壁，该支撑带在所有方向上是柔性的。
构造容器可以进一步优选地包括由具有减摩层的多种材料制成的带。环形带优选地用作侧壁。该带特别优选是有限带，并且通过弹簧的方式或者通过重力张紧。有限带优选地卷绕在构造容器的上部区域中。
在其他优选的具体实施方式中，本发明特别地涉及一种用于生产部件(3D成型主体)的装置，其中(a)借助于粉末涂布器(101)，在第一步骤中向构造平台(102)涂覆颗粒层；(b)借助于粘合剂定量给料装置(100)，在第二步骤中选择性地涂覆粘合剂(400)；(c)借助于热源(600)，在另一步骤中使所涂覆的一个或多个层经受热处理；(d)将构造平台(102)降低一个层的厚度，或者将粉末涂布器(101)和可能的额外装置部件抬高一个层的厚度；重复步骤a)到d)，直到部件构造完毕。
根据颗粒材料(300)的性质，所产生的给料构成构造容器和构造平台的负荷。在壁(200)上发生特征压力分布(201)，其类似于流体静压力。在静态情况下不发生构造高度上的压力的线性特征。然而，如果通过机械振动来激发粉末，则发生接近流体静压、即线性的压力特征。
由粉末造成的容器壁上的压力负荷表现为与壁相垂直的力。一旦发生与力的方向相垂直的移动，就会经由摩擦而出现反作用力。
力通量通常在装置的大部分部件上闭合。图3示出了一种可能的装置的截面图。在容器壁(200)与给料(300)之间出现力。由于给料，该力被传导到容器底座(102)中。该过程继续通过驱动点(301)，经由耦合(302)，到达Z轴驱动器，该Z轴驱动器通常被设计为升降主轴(303)。后者通常经由支承(304)被支撑于该装置的主框架上。力通量在构造容器保持螺栓上闭合，其转而经由构造容器壁而安装在装置的框架上。
根据结构设计，由于力通量而发生影响装置精密度的弯曲和伸长。根据本发明，力通量不会显著地在结构上缩短，并且装置不具有负荷优化设计，但是相反，在相对移动期间使摩擦力的效应最小化。
可以通过涂层来使由于壁与颗粒材料之间的直接接触而造成的摩擦最小化。然而，磨蚀性颗粒材料将会在相对移动期间快速地使该涂层失效。即使塑料粉末也具有磨蚀效应。
实现上述用于在构造容器内生产模型的步骤的装置是一种用于避免相对移动的解决方法。在构造过程期间，涂层和打印单元(100、101)行进到构造容器之外。继而可以在上端位置更换构造容器。这种类型的装置具有这样的缺点：涂层单元(101)和定量给料单元(100)部分具有有限的尺寸，并且不只覆盖工作区域。这将会不必要地使装置增大。另外，必须将部件的加速斜坡纳入考虑，这是因为只有在线性移动的情况下才能完美无缺地实现其功能。
根据本发明，还可以将这种在技术上不利的设计精简成相对于给料定位的两个壁。图6示出了这种类型的装置的构造容器设计的一个示例。
为此，形成了U形主体，其包括两个刚性壁(400)和构造平台(102)。该主体在两个刚性的、框架固定的壁(400)之间移动，所述两个壁(400)与U形主体的壁垂直地定位。密封件(401)防止颗粒材料的流出，其安装在主体的端面上。在该装置中，所要形成的新层的平面(701)总是位于框架固定的壁的上边缘。
该装置中的涂布器和定量给料单元可以通过所产生的“轴”移动，并且可被加速。其他功能特征与具有常规构造容器的装置的功能特征相同。
在该设计中，移动的壁上的力不会导致任何摩擦效应。直立的壁上的力产生与常规设计中也会出现的相同的摩擦力。然而，在根据本发明的整体结构的布置中，可以显著减少构造平台上的力和特别有害的弯曲扭矩。
定量给料单元和涂布器的移位区域的限制在这种类型的装置中会引起麻烦。为了避免这种情况，壁必须在理论上在构造平台向下移动期间提供在定量给料和涂布器平面中。
在通过使用具有柔性壁(402)的滚柱(700)的第一解决方法中可以实现这种类型的效果。滚柱由于构造平台(102)的移动而沿着壁滚动。
柔性壁(402)由于给料的压力而变形。为了避免危害构造过程，必须通过结构措施来使变形最小化。根据本发明，由刚性壁(400)来支撑柔性壁(402)。根据本发明，相接触的材料之间的摩擦系数必须小于刚性壁与颗粒材料之间的摩擦系数。
根据本发明的典型材料配对是金属/塑料接触或者配对作为不同金属。例如，由金属制成的柔性壁(402)可以设计成薄金属片带。利用塑料或黄铜条(900)来涂布该设计中的刚性壁(400)。还可以将壁设计成塑料带，其在金属表面滑动。
该带优选地还可以由多种材料制成。例如，与颗粒材料接触的材料可以具有特别耐磨的设计。可以通过特别条带来提供刚性。可以向背面涂覆减摩涂层。
类似地，柔性壁(402)还可以在滚柱(901)上滑动。不渗透粉末的链环适于这一目的。相对于摩擦学配对，摩擦力可以进一步减小。然而，在设计方面，这种类型的滚柱可能仅在用于大型装置中时才是合理的。
上述具有不相对于给料移动的两个壁的装置还可以被设计成具有四个不移动的壁。这种类型的装置将会与上述根据本发明的具有4个刚性直立壁的装置类似地大大减小摩擦力。
以下讨论本发明的其他优选方面以及一个优选具体实施方式的示例和优点。
根据本发明的优选工作箱的示例
图12和图13示出了根据本发明的特别有利的构造容器。
该容器被设计用于约2000升的构造体积。当使用诸如沙或铬矿砂的铸造成型材料作为颗粒材料时，给料重量可以高达4500kg。在构造过程期间，必须利用构造平台提供300μm作为公共层高度。为了工艺安全的构造，定位不确定性应当小于+/-30μm。
为了减少静态变形并且使反冲效应最小化，层施加的顺序如下。从上一个选择性固化的层的位置开始，首先将构造平台降低远大于目标层厚度的量。继而才将构造平台放置于期望的位置上。该位置比已经施加并固化的上一层低一个层厚度。
在定位期间，诸如机器框架或构造平台等不同部件由于作用力而变形。继而，如果构造平台没有装载足够的粉末给料，则该构造平台可能被卡在构造容器中，并且只有在解决了所有的反冲并且部件的变形反作用力克服了摩擦力之后才能进行定位移动。在降低期间必须至少提供该距离。
继而，构造平台必须向上移动到预定位置中。此处的行进距离也应当至少要求装置到达实现稳定条件的程度。
为了安全地消除这样的定位不确定性，在构造过程期间不断增长的重力相比于给料摩擦所造成的力来说问题更小。由于给料的沉淀和已知的粘滑效应，这些力不仅随着重力而增长，而且还具有不可预测的性质。因此，定位不确定性由于这些力而显著增大。
根据图12的装置具有2个固定壁(400)。这些壁由实心铝板制成，其在外侧具有凹陷，以用于减轻重量的目的。该构造容器的壁的内部区域具有平滑的铣削表面。
由于很重的重力，构造平台(102)具有大肋条设计。在每种情况下，在短边上发生驱动啮合。长边配备有密封件。该密封件具有两件式设计。为了设置均匀的接触压力并从而形成牢固密封，存在弹簧元件和能够沿着构造容器的壁平滑地滑动的密封件。弹簧元件是绳索，其具有矩形横截面，并且由硅酮泡沫制成。密封件是具有矩形横截面的毡绳索。
在其下端位置，构造平台处于构造容器中。这确保了在释放驱动啮合时，能够从机器中移除构造容器。
短边固定连接到柔性容器壁(402)。
在该构造容器中，柔性壁(402)由铝链环(1202)制成。后者包括20mm宽并由橡胶条互连的板。
短边壁在内部具有刚性壁(400)。后者被设计成由矩形管型材(profile)制成的焊接框架。这些型材支撑构造容器内部的塑料轨(900)。这些轨使摩擦最小化。
该壁支撑位于其上端的反向滚柱(700)。在该滚柱之上引导铝链环(1202)。配重(1300)安装在铝链环(1202)上背对容器内部的壁的一侧。这些配重确保向上行进期间的张紧链。
围绕该外部链环引导驱动啮合。因此，其易于通过3D打印装置而接触。
通过毡绳索再一次实现了铝链环与构造容器的长边上的刚性壁(400)之间的密封作用。在长边的板上存在引导密封绳索的凹陷。
构造容器的上边缘在反向滚柱的区域中配备有型材，其矩形地形成该容器内部。此处发生的摩擦可以忽略不计，这是因为给料压力在该位置仍然是非常低的。
长壁和短壁形成框架，该框架与构造平台一起代表容器。后者由底板结构(1201)加固。在其下侧附加地安装滑轨，以使得容器能够借助于滚柱传送系统而移动。
在短壁上存在用于连接容器和3D装置的装置。在插入容器之后，这些装置可以被锁定。由此，将容器定位和锁定到位。
构造容器衬有额外的金属片(1200)，以用于针对外部污染而进行密封的目的。
附图说明
图1：以截面等距视图示出了基于粉末的3D打印机的部件的示意图；
图2：示出了粉末给料的力的效应的示意图；
图3：示出了根据现有技术的装置中的力通量的示图；
图4：示出了刚性和柔性容器壁的表示；
图5：示出了包括具有相对于给料不移动的4个刚性壁的构造容器的装置；
图6：示出了具有相对于给料不移动的2个刚性壁以及相对于给料移动的2个刚性壁的构造容器的设计；
图7：示出了由于柔性壁而避免了定量给料单元和涂布器的移位区域中的壁的示图；
图8：示出了经由连续连接的壁而释放压缩力的示图；
图9：示出了通过利用摩擦学配对而使力最小化以及通过利用滚柱而使力最小化；
图10：示出了具有相对于给料不移动的2个柔性壁的构造容器；
图11：示出了具有相对于给料不移动的4个柔性壁的构造容器；
图12：示出了具有相对于给料不移动的柔性壁的构造容器的截面表示；
图13：示出了具有相对于给料不移动的柔性壁的构造容器的设计细节。
参考标号列表
100粘合剂定量给料装置
101粉末涂布器
102构造平台
103部件(3D成型部件)
104构造区域边界
107粉末层
200壁
201力分布
300颗粒材料
301驱动点
302耦合
303升降主轴
304支承
400刚性壁
401(毡)密封件
402柔性壁
500定位单元
501导引件
700反向滚柱
701打印和涂布器平面
800自由偏斜
900滑动表面
901滚柱
1200外壳
1201底座
1202铝链环
1300平衡配重

Claims (10)

1.一种用于通过逐层生产三维模型的装置的构造容器，所述构造容器包括：构造平台上的构造区域，所述构造平台在所述构造容器内可调节高度并且优选地可从中移除；至少两个侧壁，所述至少两个侧壁以这样的方式设计，使得在所述构造平台的移位期间，所构建的层与所述侧壁之间的动摩擦被减少或者基本上被避免，所述构造平台和所述至少两个侧壁以相同的速度移位。
2.根据权利要求1所述的构造容器，其特征在于，以这种方式设计3个或4个侧壁。
3.根据权利要求1或2所述的构造容器，其特征在于，所述构造容器的所述侧壁在构造方向上可移动；优选地
其特征在于，可移动的侧壁相对于两个固定侧壁可移位；优选地
其特征在于，所述侧壁相对于给料压力是刚性的。
4.根据前述权利要求中的一项所述的构造容器，其特征在于，所述侧壁相对于给料压力不是刚性的，并且经由额外的侧壁得到支撑。
5.根据前述权利要求中的一项所述的构造容器，其特征在于，至少1个、优选2个、3个或4个侧壁被设计成在一个方向上是柔性的。
6.根据前述权利要求中的一项所述的构造容器，其特征在于，至少1个、优选地2个、3个或4个侧壁是分段的和/或金属壁，并且被设计成在一个方向上是柔性的。
7.根据前述权利要求中的一项所述的构造容器，其特征在于，利用金属/塑料摩擦学配对来减少摩擦效应；优选地
其特征在于，利用至少一个滚柱支承来减少摩擦效应。
8.根据前述权利要求中的一项所述的构造容器，其特征在于，使用在所有方向上都是柔性的被支撑的带作为所述侧壁；优选地
其特征在于，使用由具有减摩层的多种材料制成的带。
9.根据前述权利要求中的一项所述的构造容器，其特征在于，使用环形带作为所述侧壁。
10.根据前述权利要求中的一项所述的构造容器，其特征在于，使用有限带作为所述侧壁，并且通过弹簧或重力的方式张紧所述有限带；优选地
其特征在于，所述有限带卷绕在所述构造容器的上部区域中。
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