JP2019518866A - 粉末材料で付加製造するための方法および装置 - Google Patents
粉末材料で付加製造するための方法および装置 Download PDFInfo
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- JP2019518866A JP2019518866A JP2018553387A JP2018553387A JP2019518866A JP 2019518866 A JP2019518866 A JP 2019518866A JP 2018553387 A JP2018553387 A JP 2018553387A JP 2018553387 A JP2018553387 A JP 2018553387A JP 2019518866 A JP2019518866 A JP 2019518866A
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- powder
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- B29K2505/02—Aluminium
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Abstract
【選択図】図1
Description
本願は、2016年4月11日出願の米国仮特許出願第62/320655号及び2017年3月20日出願の米国仮特許出願第62/473605号の優先権の利益を、米国特許法第119条(e)項の下で主張するものであり、この仮出願の内容全体を参照によって本書に援用する。
本発明は、その一部の実施形態では、粉末材料の層による三次元(3D)印刷に関し、さらに詳しくは、粉末金属を構築材料とする金属物体の3D印刷に関するが、それに限定されない。
Claims (54)
- 構築面にマスクパターンを印刷するように構成された印刷ステーションであって、マスクパターンが凝固可能な材料により形成されている印刷ステーションと、
粉末材料の層をマスクパターン上に塗布するように構成された粉末送達ステーションと、
粉末材料の層およびマスクパターンを圧縮するためのダイ圧縮ステーションと、
構築トレイを印刷ステーション、粉末送達ステーション、およびダイ圧縮ステーションの各々に繰返し前進させて、全体で三次元グリーンコンパクトを形成する複数の層を構築するように構成されたステージと
を備えた、三次元グリーンコンパクトを構築するためのシステム。 - 三次元グリーンコンパクトは、形成される物体と支持領域とを含む、請求項1に記載のシステム。
- 凝固可能な材料は、相変化インク、感熱インク、フォトポリマー材料、ワックス、またはそれらの任意の組合せから成る群から選択される、請求項1又は2に記載のシステム。
- 相変化インクは、100℃を超える温度で実質的に蒸発するように構成される、請求項1〜3のいずれかに記載のシステム。
- 粉末材料はアルミニウム合金である、請求項1〜4のいずれかに記載のシステム。
- 粉末送達ステーションは粉末吐出ステーションと粉末展着ステーションとを含む、請求項1〜5のいずれかに記載のシステム。
- 粉末送達ステーションは、粉末材料を貯蔵するように構成された粉末ホッパと、粉末材料を吐出するように構成された吐出チップと、吐出チップからの粉末材料を受容するように構成された粉末吐出トレイと、粉末吐出トレイ上の粉末材料を構築トレイに送達するように構成されたアクチュエータとを含む、請求項1〜6のいずれかに記載のシステム。
- 粉末吐出トレイは、粉末材料を受容するように構成された複数のトラフを含む、請求項7に記載のシステム。
- ホッパが粉末吐出トレイの複数のトラフの各々に粉末を吐出するように、粉末吐出トレイを前進させるように構成された第1レールを含む、請求項8に記載のシステム。
- アクチュエータは、複数のトラフを同時にフリップするように構成される、請求項8又は9に記載のシステム。
- アクチュエータは、複数のトラフの各々の底部に位置する長手方向のアパーチャを同時に開口させるように構成される、請求項8又は9に記載のシステム。
- ホッパが粉末吐出トレイのトラフに沿って粉末を吐出するように、粉末吐出トレイを前進させるように構成された第2レールを含む、請求項7〜11のいずれかに記載のシステム。
- ホッパはオーガを含み、それを介して粉末材料を吐出チップ内に制御可能に前進させる、請求項7〜12のいずれかに記載のシステム。
- 粉末送達ステーションはローラを含み、ローラは粉末材料を展着するために回転しながら層を横切って移動するように作動する、請求項7〜13のいずれかに記載のシステム。
- ローラは前転ローラである、請求項14に記載のシステム。
- 粉末送達ステーションは、ローラが層を横切って移動する間に構築トレイの縁部から落下する余分な粉末材料を受容するように構成された複数のガターを含む、請求項14又は15に記載のシステム。
- 複数のガターは、粉末材料の展着中にローラと共に移動するように作動する第1対のガターを含む、請求項16に記載のシステム。
- 第1対のガターはローラの側方端の下に位置する、請求項17に記載のシステム。
- 第1対のガターにおける各ガターは、ローラの直径の少なくとも2倍の長さを有し、ローラの側方端の両側に延在する、請求項18に記載のシステム。
- 前記第1対のガターに蓄積された粉末は、空気吸引を介して粉末材料の展着中に、ガターの内部空間から連続的に除去される、請求項17〜19のいずれかに記載のシステム。
- 複数のガターは、構築トレイを横切るローラの移動方向に対して、構築トレイの前端および後端に配置される第2対のガターを含む、請求項17〜20のいずれかに記載のシステム。
- 第2対のガターは、構築トレイに近づいたり遠ざかるように作動する、請求項21に記載のシステム。
- 第2対のガターはローラの高さに位置し、前記ガターに蓄積された粉末を除去するように、空気吸引が適用される、請求項21又は22に記載のシステム。
- 第1対のガターに適用される空気吸引がスイッチオフされている場合、空気吸引は第2対のガターに適用される、請求項23に記載のシステム。
- 粉末送達ステーションは余分な粉末材料を粉末ホッパに再循環させるように構成される、請求項16〜24のいずれかに記載のシステム。
- 粉末送達ステーションは、複数のガターから回収された粉末材料から空気を除去するように構成された、少なくとも1つのサイクロンセパレータを含む、請求項16〜25のいずれかに記載のシステム。
- 粉末送達ステーションは、直列作動する複数のサイクロンセパレータを含む、請求項26に記載のシステム。
- 少なくとも1つのサイクロンセパレータは、サイクロンセパレータの動作中に出口を封止するように構成されたキャップを含む、請求項26又は27に記載のシステム。
- 粉末送達ステーションは、粉末材料を粉末ホッパに送達する前に粉末材料をデブリから分離するように構成されたメッシュを含む、請求項16〜28のいずれかに記載のシステム。
- ダイ圧縮ステーションは、構築トレイの周囲に導入されるように構成された側壁を含む、請求項1〜26のいずれかに記載のシステム。
- 側壁は、圧縮ステーションに対する層の接触に基づいて構築トレイの周囲に導入されるように構成される、請求項30に記載のシステム。
- 請求項1〜31のいずれかに記載の三次元グリーンコンパクトを構築するためのシステムと、第2圧縮ステーション、加熱ステーション、焼結ステーション、およびそれらの任意の組合せから成る群から選択された後処理ステーションとを含む、三次元物体を形成するためのシステム。
- 凝固可能な材料により構築面にマスクパターンを印刷するステップと、粉末材料をマスクパターン上に展着することによって層を形成するステップと、層を圧縮するステップと、三次元グリーンコンパクトが完成するまで印刷、形成、および圧縮を繰り返すステップとを含む、三次元グリーンコンパクトを構築するための方法。
- 三次元グリーンコンパクトは、形成される物体と、支持領域とを含む、請求項33に記載の方法。
- 粉末材料を展着するステップは、複数の列の粉末材料を構築面上に吐出するステップと、複数の列の粉末材料をローラにより展着するステップとを含む、請求項33又は34に記載の方法。
- 複数の列の粉末材料は、構築トレイ上に吐出する前にオフラインで用意される、請求項35に記載の方法。
- 複数の列の粉末材料は、展着方向に対し直角に配置される、請求項35又は36に記載の方法。
- 展着ステップは、粉末材料上でローラを転動させることを含む、請求項33〜37のいずれかに記載の方法。
- 展着方向は粉末層毎に次々に反転される、請求項33〜38のいずれかに記載の方法。
- 複数の列の粉末の配置は粉末層毎に次々に変化する、請求項33〜39のいずれかに記載の方法。
- 展着中に構築面の縁部から落下する余分な粉末材料を回収するステップと、余分な粉末材料を粉末ホッパに再循環させるステップとをさらに含む、請求項33〜40のいずれかに記載の方法。
- 回収ステップおよび再循環ステップは、オンラインで実行される、請求項41に記載の方法。
- 余分な粉末を少なくとも1つのサイクロンセパレータに吸引するステップと、少なくとも1つのサイクロンセパレータ内で粉末を空気から分離するステップとを含む、請求項41又は42に記載の方法。
- 複数のサイクロンセパレータを直列作動させるステップを含む、請求項43に記載の方法。
- 少なくとも1つのサイクロンセパレータからの粉末材料をメッシュで濾過するステップと、メッシュを介して濾過された粉末材料を粉末ホッパに送達するステップとを含む、請求項43又は44に記載の方法であって、粉末ホッパは、三次元グリーンコンパクトを構築するための粉末材料を提供する、方法。
- 圧縮中に熱を加えるステップを含む、請求項33〜45のいずれかに記載の方法。
- 圧縮はダイ圧縮である、請求項33〜46のいずれかに記載の方法。
- マスクパターンは層毎のグリーンコンパクトの輪郭を含む、請求項33〜47のいずれかに記載の方法。
- 印刷ステップ、形成ステップ、および圧縮ステップは周囲温度で実行される、請求項33〜48のいずれかに記載の方法。
- 最初の層は、粘着性材料で被覆された構築トレイ上に形成される、請求項33〜49のいずれかに記載の方法。
- 請求項33〜50のいずれかに記載の方法に従って三次元グリーンコンパクトを構築するステップであって、前記三次元グリーンコンパクトが物体と凝固可能な材料を含む支持領域とを備える、ステップと、凝固可能な材料を除去し、物体を支持領域から分離し、物体を焼結することによってグリーンコンパクトを後処理するステップとを含む、三次元物体を形成する方法。
- 凝固可能な材料を除去し、物体を支持領域から分離することは、焼結の前に実行される、請求項51に記載の方法。
- 凝固可能な材料を除去することは、焼結中に実行される、請求項51に記載の方法。
- 後処理ステップは、グリーンコンパクトを全体として圧縮することをさらに含む、請求項51に記載の方法。
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