Patent Publication Number: US-2022212401-A1

Title: Interchangeable container with moveable side walls

Description:
CLAIM OF PRIORITY 
     This application is a continuation patent application of U.S. patent application Ser. No. 16/263,716 (filed on Jan. 31, 2019) which is a continuation patent application of U.S. patent application Ser. No. 15/039,267 (filed on May 25, 2016 and granted as U.S. Pat. No. 10,220,568 on Mar. 5, 2019) which is a national phase filing under 35 USC § 371 from PCT Application serial number PCT/DE2014/000609 filed on Dec. 1, 2014, and claims priority therefrom. This application further claims priority from German Patent Application DE 10 2013 018 031.7 filed on Dec. 2, 2013. PCT Application Number PCT/DE2014/000609 and German Patent Application Number 10 2013 018 031.7 are each incorporated herein in their entireties by reference. 
    
    
     DESCRIPTION 
     The invention relates to a device and its use in a method for producing three-dimensional models and systems including the device. 
     A method for producing three-dimensional objects from computer data is described in the European patent specification EP 0 431 924 B1. In this method, a particulate material is applied in a thin layer to a platform, and a binder material is selectively printed onto the particulate material, using a print head. The particle area onto which the binder is printed sticks together and solidifies under the influence of the binder and, if necessary, an additional hardener. The platform is then lowered by a distance of one layer thickness into a build cylinder and provided with a new layer of particulate material, which is also printed as described above. 
     These steps are repeated until a certain, desired height of the object is reached. A three-dimensional object is thereby produced from the printed and solidified areas. 
     After it is completed, this object produced from solidified particulate material is embedded in loose particulate material and is subsequently removed therefrom. This is done, for example, using an extractor. The desired objects remain afterward, from which powder deposits are removed, e.g., by means of manual brushing. 
     Of all the layering techniques, 3D printing based on powdered materials and the supply of liquid binder is the fastest method. 
     This method may be used to process different particulate materials, including natural biological raw materials, polymers, metals, ceramics and sands (not an exhaustive list). 
     The machines used in methods of this type often contain a job box, which can be inserted into and removed from the 3D printing machine for the purpose of increasing the machine runtimes. The job box may be removed from the machine for the purpose of freeing the components of unsolidified material, i.e., to unpack them. Another job box may then be immediately inserted into the machine, and printing may continue right away, avoiding unnecessary, unproductive machine down times. Job boxes of this type have a building platform to which the particulate material is applied. This building platform is generally adjustable in height and is lowered during 3D printing until the printing process is completed. The desired layer thickness is adjusted by moving and positioning the building platform. 
     The precise positioning of the building platform is extremely important and crucial for the production of dimensionally accurate components. Not only is the positioning of the building platform at the drive engagement point important, but a uniform positioning of all points of the building platform also influences the construction accuracy. Possible deformations of the building platform pose a problem to the precise and accurate production of components. 
     A precise and even positioning, however, presents an enormous difficulty in large machines. The large dimensions result in high bending torques, which deform the building platform. If the building platform is reinforced accordingly, however, heavy weights, in turn, must be positioned precisely. The various aspects of these problems reduce the achievable accuracy of the device or prevent an acceptable cost margin. 
     The forces and the resulting bending torques are caused by different influences. First of all, the powder feedstock, which grows during the building process, acts as an increasing planar load. Secondly, the growing feedstock presses against the walls of the build container. Reaction forces result here, which, in turn, act upon the building platform. Forces are also produced by the seal, which seals the moving building platform against the stationary side walls. 
     Approaches to the growing planar load are described in patent specifications. For example, DE 10 2010 013 733 A1 discloses a device, in which the build container is designed as an immobile worktable. The devices for generating a new powder layer and for selective solidification are displaceable in the building direction of the device. The design of the building platform may be easily adapted to the rigidity requirements. Because it is designed without walls, however, the device is limited in the range of materials that may be used. 
     The sealing forces may be influenced by structural measures. One option is thus to use a build container which is equipped with a felt seal for the purpose of reducing seal friction. Inflatable seals may also be used to minimize the contact force. 
     The lateral rubbing action of the feedstock against the side walls is an unresolved problem in build containers or job boxes according to the prior art. According to the prior art, the effects of the forces resulting therefrom are mitigated by structural measures. Build containers are used whose driving points were selected for the purpose of minimizing deflection. In this case, planar loads may be taken into account by the weight of the material and the friction effect, and linear loads may be taken into account by the seal. Despite this optimization, more massive designs are created than would be necessary to actually support the weight force. 
     An also structural measure for reducing the force effects is to shorten the flux of force within the device. A passage through the build container wall is implemented, e.g., in DE 100 47 614 C2. This passage is sealed against through-flow of the particulate material by a belt or a flap. For heavy feedstocks, devices are provided with a correspondingly large design. The approach using the flap is suitable only for light-weight particulate material that applies very little pressure to the wall. 
     When moving the building platform, in particular, a friction is produced laterally, which results in stresses within the particulate application material. Due to these stresses, movements may occur in the particulate application material, and the predetermined component points printed on the basis of the CAD data may be displaced thereby. The spatial points present in the component then ultimately deviate from the CAD data, and the printed component no longer corresponds 1:1 to the data record. The printed component is thus inaccurate. This inaccuracy is based in large part on the friction problem. 
     However, this problem has not been identified in the literature and in the prior art as a problem and a cause of inaccurately produced components. As a result, this problem has not been addressed to a satisfactory degree, nor are there any approaches thereto in the literature and in the prior art. 
     The object of the invention is therefore to provide a device which solves the problems described above and, in particular, provides a job box, with the aid of which high-quality components may be produced with a high reproduction accuracy, and which makes available, in particular job boxes having a reduced friction problem or an approach which avoids or at least helps reduce the disadvantages of the prior art. 
     BRIEF DESCRIPTION OF THE INVENTION 
     The invention relates to a build container or job box, which makes it possible to produce high-quality components and which has, in particular, a reduced friction problem. This object is achieved by two, preferably three, advantageously four laterally situated, movable side walls, which are able to preferably move at the same speed as the building platform in the job box according to the invention. 
     In another aspect, the invention relates to a 3D printing method, in which the build container (job box) according to the invention may be used. 
     DETAILED DESCRIPTION OF THE INVENTION 
     A number of terms in the invention are explained in greater detail below. 
     Within the meaning of the invention, “3D printing methods” relates to all methods known from the prior art which facilitate the construction of components in three-dimensional molds and are compatible with the described method components and devices. In particular, these are powder-based methods, for example SLS (selective laser sintering). 
     Within the meaning of the invention, “selective binder application” or “selective binder system application” may take place after each particulate material application or irregularly, depending on the requirements of the molded body and for the purpose of optimizing the production of the molded body, i.e., non-linearly and not in parallel after each particulate material application. “Selective binder application” or “selective binder system application” may thus be set individually and during the course of producing the molded body. 
     “Molded body” or “component” within the meaning of the invention are all three-dimensional objects that are produced with the aid of the method according to the invention and/or the device according to the invention and which have a nondeformability. 
     Any known 3D printing device that contains the necessary components may be used as the “device” for carrying out the method according to the invention. Common components include a coater, a build space, a means for moving the build space or other components, a dosing device and a heating means and other components which are known to those skilled in the art and therefore do not need to be listed in greater detail here. 
     All materials known for powder-based 3D printing, in particular sands, ceramic powders, metal powders, plastics, wood particles, fibrous materials, celluloses and/or lactose powders, may be used as “particulate materials.” The particulate material is preferably a dry, free-flowing and a cohesive, firm powder. 
     “Build space” is the geometric place in which the particulate material feedstock grows during the build process by repeated coating with particulate material. The build space is generally delimited by a base, the building platform, by walls and an open cover surface, the build plane. 
     A “build container” or, in particular, a “job box” within the meaning of the invention implements a build space. As a result, it has a base, walls and an open access area, the build plane. The build container always includes parts which do not move relative to the frame of the 3D printing device. Removable build containers make it possible to operate the machine more or less continuously. While the parts in a first building operation are being unpacked, new parts may be printed within the machine in a second build container. 
     The “printing and coater plane” is the abstraction of the location of the building process currently in progress. Since the dosing unit and the coater are structurally moved in the device on a positioning unit with shared components at nearly one height, the “printing and coater plane” are viewed in this description as being situated at the upper edge of a newly applied layer. 
     The “building platform” moves relative to the printing and coater plane. This relative movement takes place during the building process in interrupted movements in the layer thickness. It defines the layer thickness. 
     “Container wall” or “wall” or “side wall” designates a barrier to the particulate material. The particulate material is unable to travel from one side of the wall to the other. Walls within the meaning of the invention may have a flexible or rigid design. The deflections for the “rigid” criterion are minor with respect to the workpiece tolerances in a given material system. 
     A “tribological pairing” within the meaning of the invention is a material contact whose coefficient of friction is significantly below that of two equal materials in contact or of the contact between particulate material and a wall material. 
     A “seal” designates two structural elements which prevent a passage of the particulate material through contact points between walls moving relative to each other or between walls and a building platform. 
     The invention, along with its preferred specific embodiments, is described in greater detail below 
     The invention relates to a build container, in particular a job box, for a device for producing three-dimensional models by means of layering, which includes a build space on a building platform, which is adjustable in height within the build container and is preferably removable therefrom, at least two side walls, which are designed in such a way that during the displacement of the building platform, the kinetic friction between the constructed layers and the side walls is reduced or essentially avoided, the building platform and the at least two side walls being moved at the same speed. 
     In one aspect, the invention is the direct reduction of the forces between the particulate material and the side wall in the build container. Different structural measures may be helpful for this purpose. The avoidance of the relative movements also does not cause any effects of force in addition to gravity in the powder and may thus avoid undesirable settling of the powder cake. 
     As a result, it may be advantageously achieved that no or few forces occur which have a negative effect on the stability of the applied and deposited layers, and the reproduction accuracy may thus be increased in the printed components. 
     In one preferred specific embodiment of the invention, the build container is characterized in that 3 or 4 side walls are designed as described above. The side walls of the build container are preferably movable in the building direction. The movable side walls are furthermore advantageously movable relative to two fixed side walls in the build container. 
     The side walls are designed in such a way that they advantageously serve the purpose of the invention. The side walls are preferably designed to be rigid with respect to the feedstock pressure. All reinforcements, cross-braces known to those skilled in the art may preferably be used. 
     In one preferred specific embodiment, the build container is characterized in that the side walls are not rigid with respect to the feedstock pressure and are supported via additional side walls. Preferably at least one, preferably 2, 3 or 4, side wall(s) is/are designed to be flexible in one direction. It is furthermore preferred that at least one, preferably 2, 3 or 4, side wall(s) is/are a segmented and/or metallic wall and is/are designed to be flexible in one direction. 
     In another preferred specific embodiment, the build container is characterized in that it has a metal/plastic tribological pairing for reducing the friction effect. The build container preferably includes at least one roller bearing for reducing the friction effect. The build container furthermore preferably includes a supported belt, which is flexible in all directions, as the side wall. 
     The build container may furthermore preferably include a belt made of multiple materials having an antifriction layer. A continuous belt is preferably used as the side wall. This belt is particularly preferably a finite belt, and it is tensioned by means of springs or by the weight force. The finite belt is preferably wound up in the upper area of the build container. 
     In other preferred specific embodiments, the invention relates, in particular, to a device for producing a component (3D molded body), wherein (a) a particle layer is applied to a building platform ( 102 ) in a first step with the aid of a powder coater ( 101 ); (b) a binder ( 400 ) is selectively applied in a second step with the aid of a binder dosing device ( 100 ); (c) the applied layer or layers is/are subjected to a heat treatment in another step with the aid of a heat source ( 600 ); (d) the building platform ( 102 ) is lowered by the thickness of one layer, or the powder coater ( 101 ) and possibly additional device components is/are raised by the thickness of one layer; steps a) through d) are repeated until the component is built up. 
     According to the nature of particulate material ( 300 ), the resulting feedstock constitutes a load for the build container and the building platform. Characteristic pressure profiles ( 201 ), which are similar to hydrostatic pressures, occur on walls ( 200 ). Linear characteristics of the pressure over the build height do not occur in the static situation. However, if the powder is excited by mechanical vibrations, nearly hydrostatic, i.e., linear, pressure characteristics occur. 
     The pressure loads on the container wall caused by the powder represent forces normal to the wall. Once a movement perpendicular to the direction of force occurs, reaction forces arise via the friction. 
     The flux of force usually closes over extensive parts of the device.  FIG. 3  shows a sectional view of a possible device. The force arises between container walls ( 200 ) and feedstock ( 300 ). Due to the feedstock, the force is conducted into container base ( 102 ). The course continues through driving points ( 301 ), via coupling ( 302 ), to the Z-axis drive, which is usually designed as a lifting spindle ( 303 ). The latter is usually supported on the main frame of the device via a bearing ( 304 ). The flux of force closes over the build container retaining bolt, which, in turn, is mounted on the frame of the device, and via the build container wall. 
     Depending on the structural design, bendings and elongations which influence the precision of the device occur due to the flux of force. According to the invention, the flux of force is not predominantly structurally shortened, and the device does not have a load-optimized design, but instead the effect of the force of the friction is minimized during relative movement. 
     The friction due to the direct contact between the wall and particulate material could be minimized by a coating. Abrasive particulate materials, however, would quickly make this coating ineffective during relative movement. Even plastic powders have an abrasive effect. 
     A device which carries out the aforementioned steps for producing models inside a build container is one approach to avoiding relative movements. During the building process, the coating and printing unit ( 100 ,  101 ) travels out of the build container. The build container may then be replaced in the upper end position. A device of this type has the disadvantage that the coating unit ( 101 ) and dosing unit ( 100 ) parts have finite dimensions and cover not only the work area. This would unnecessarily enlarge the device. In addition, the acceleration ramps of the components must be taken into account, since their function is carried out flawlessly only in the case of linear movement. 
     This technically unfavorable design may also be reduced, according to the invention, to two walls positioned relative to the feedstock.  FIG. 6  shows an example of the build container design of a device of this type. 
     For this purpose, a U-shaped body is formed, which comprises two rigid walls ( 400 ) and build platform ( 102 ). This body is moved between two rigid, frame-fixed walls ( 400 ), which are situated perpendicularly to the walls of the U-shaped body. Seals ( 401 ), which prevent an outflow of particulate material, are mounted on the end faces of the body. In this device, plane ( 701 ) of the new layers to be formed is always at the upper edge of the frame-fixed walls. 
     The coater and the dosing unit in this device may be moved through the resulting “shaft” and may be accelerated. The other function features are the same as those of a device having a conventional build container. 
     In this design, the forces on the moving walls do not result in any friction effect. The forces on the upright walls produce the same frictional forces that also arise in a conventional design. In the arrangement of the overall structure according to the invention, however, the forces and the particularly harmful bending torques on the building platform may be significantly reduced. 
     The limitations in the displacement area of the dosing unit and coater are bothersome in a device of this type. To avoid this, the walls must be conceptually provided in the dosing and coater plane during the downward movement of the building platform. 
     An effect of this type may be achieved during the first approach by using a roller ( 700 ) having a flexible wall ( 402 ). The roller rolls along the wall due to the movement of building platform ( 102 ). 
     A flexible wall ( 402 ) is deformed by the pressure of the feedstock. To avoid jeopardizing the building process, the deformations must be minimized by structural measures. According to the invention, flexible wall ( 402 ) is supported by a rigid wall ( 400 ). According to the invention, the coefficient of friction between the contacting materials must be less than that between the rigid wall and the particulate material. 
     Typical material pairings according to the invention are metal/plastic contacts or pairings as of different metals. For example, flexible wall ( 402 ) made of metal may be designed as a thin sheet-metal band. Rigid wall ( 400 ) in this design is coated with plastic or brass strips. The wall may also be designed as a plastic belt, which is run off a metal surface. 
     The belt may preferably also be made of multiple materials. For example, a contact material to the particulate material may have a particularly resistant design. The rigidity may be provided by a special strap. An antifriction coating may be applied to the back. 
     Likewise, a flexible wall ( 402 ) may also slide on rollers ( 901 ). Powder-impermeable link chains are suitable for this purpose. The frictional forces may be further reduced with respect to tribological pairings. In terms of design, however, rollers of this type may be sensible only when used in large devices. 
     The aforementioned device, having two walls which do not move relative to the feedstock, may also be designed with four immobile walls. A device of this type would greatly reduce the frictional forces similarly to the aforementioned device having 4 rigid, upright walls according to the invention. 
     Other preferred aspects as well as an example of one preferred specific embodiment and advantages of the invention are discussed below. 
     Example of a Preferred Job Box According to the Invention 
       FIGS. 12 and 13  show a build container, which is particularly advantageous according to the invention. 
     The container is designed for a build volume of approximately 2,000 liters. When using foundry molding materials, such as sand or chrome ore, as the particulate materials, the feedstock weight may be up to 4,500 kg. During the building process, 300 μm must be supplied with the building platform as common layer thicknesses. The positioning uncertainty should be less than +/−30 μm for process-secure construction. 
     To reduce static deformations and minimize the effect of backlashes, the sequence of a layer application is as follows. The building platform is first lowered by an amount which is much greater than the targeted layer thickness, starting from the position of the last selectively solidified layer. Only then is the building platform placed in the desired position. This position is one layer thickness lower that the last layer already applied and solidified. 
     During the positioning, different components, such as the machine frame or the building platform, are deformed by the active forces. The building platform may then become stuck in the build container if it is not sufficiently loaded by the powder feedstock, and the positioning movement follows only after all backlashes have been resolved and the deformation reaction forces of the components overcome the frictional forces. This distance at least must be provided during lowering. 
     The building platform must then move upward into the predetermined position. The traveling distance here as well should at least pretension the device to the extent that stable conditions are achieved. 
     To safely account for this positioning uncertainty, the constantly growing weight force during the building process is less problematic than the forces caused by feedstock friction. These forces not only grow along with the weight force, but they have an unpredictable nature, due to the settling of the feedstock and the known stick-slip effect. The positioning uncertainty therefore increases markedly due to these forces. 
     The device according to  FIG. 12  has 2 fixed walls ( 400 ). These walls are made of solid aluminum plates, which have recesses on the outer side for the purpose of reducing the weight. The inner areas of the walls of this build container have smooth, milled surfaces. 
     Building platform ( 102 ) has a greatly ribbed design, due to the heavy weight forces. The building platform typically has a rectangular shape defining long sides ( 1212 ) and short sides ( 1210 ) of the build container. The drive engagement takes place on the short sides in each case. The long sides are equipped with a seal. The seal has a two-part design. To set an even contact pressure and thus to form a secure seal, there is a spring element and a seal, which is able to slide smoothly along the walls of the build container. The spring element is a cord, which has a rectangular cross section and is made of silicone foam. The seal is a felt cord having a rectangular cross section. 
     In its lower end position, the building platform is in the build container. This ensures that the build container is able to be removed from the machine when the drive engagements are released. 
     The short sides are fixedly connected to flexible container wall ( 402 ). 
     In this build container, flexible wall ( 402 ) is made of an aluminum link chain ( 1202 ). The latter comprises plates which are 20 mm wide and which are interconnected by rubber strips. 
     The short side wall has a rigid wall ( 400 ) on the inside. The latter is designed as a welded frame made of rectangular tube profiles. These profiles support plastic rails on the inside of the build container. These rails minimize friction. 
     This wall supports a return roller ( 700 ) on its upper end. Aluminum link chain ( 1202 ) is guided over this roller. Weights ( 1300 ) are mounted on aluminum link chain ( 1202 ) on the side of the wall facing away from the container interior. These weights ensure a taught chain during the upward travel. 
     The drive engagements are guided around this external link chain. As a result, they are easy to contact by the 3D printing device. 
     The sealing action between the aluminum link chain and rigid wall ( 400 ) on the long side of the build container is once again achieved by a felt cord. A recess, which guides the sealing cord, is present on the plate of the long side. 
     The upper edge of the build container is equipped with profiles in the area of the return roller, which rectangularly form the container interior. The friction which occurs here may be disregarded, since the feedstock pressure is still very low in this position. 
     The long and short walls form a frame, which, together with the building platform, represents a container. The latter is reinforced by a floor structure ( 1201 ). Skids are additionally mounted on the underside thereof to enable the container to move with the aid of a roller transport system. 
     Devices for connecting the container and the 3D device are present on the short walls. These devices may be locked after the container is inserted. The container is thus positioned and locked in place. 
     The build container is lined with additional metal sheets ( 1200 ) for the purpose of sealing against external contamination. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1 : shows a schematic representation of the components of a powder-based 3D printer in a sectional isometric view; 
         FIG. 2 : shows a schematic representation of the effect of the force of the powder feedstock; 
         FIG. 3 : shows a diagram of the flux of force in a device according to the prior art; 
         FIG. 4 : shows a representation of a rigid and a flexible container wall; 
         FIG. 5 : shows a device, including a build container which has four rigid walls which are not moved relative to the feedstock; 
         FIG. 6 : shows a design of a build container having two rigid walls which are not moved relative to the feedstock and two rigid walls which are moved relative to the feedstock; 
         FIG. 7 : shows a diagram of the avoidance of walls in the displacement area of the dosing unit and coater due to flexible walls; 
         FIG. 8 : shows a diagram of the discharge of compressive forces via consecutively connected walls. 
         FIG. 9 : shows the minimizing of the forces through the use of a tribological pairing; minimizing of the forces through the use of rollers; 
         FIG. 10 : shows a build container having two flexible walls which are not moved relative to the feedstock; 
         FIG. 11 : shows a build container having four flexible walls which are not moved relative to the feedstock; 
         FIG. 12 : shows a sectional representation of a build container having flexible walls which are not moved relative to the feedstock; 
         FIG. 13 : shows design details of a build container having flexible walls which are not moved relative to the feedstock. 
     
    
    
     LIST OF REFERENCE NUMERALS 
       100  Binder dosing device 
       101  Powder coater 
       102  Building platform 
       103  Component (3D molded part) 
       104  Build space boundary 
       107  Powder layers 
       200  Wall 
       201  Force profile 
       300  Particulate material 
       301  Driving point 
       302  Coupling 
       303  Lifting spindle 
       304  Bearing 
       400  Rigid wall 
       401  (Felt) seal 
       402  Flexible wall 
       500  Positioning unit 
       501  Guides 
       700  Return roller 
       701  Printing and coater plane 
       800  Free deflection 
       900  Sliding surface 
       901  Rollers 
       1200  Housing 
       1201  Base 
       1202  Aluminum link chain 
       1210  Short side 
       1212  Long side 
       1300  Counter-weight