DEVICE FOR PRODUCING THREE-DIMENSIONAL MODELS WITH SPECIAL BUILDING PLATFORMS AND DRIVE SYSTEMS

Abstract

The invention relates to a device for producing three-dimensional models in a continuous process, comprising a build surface which has a first end in the direction of movement and a second end in the direction of movement, at least one dosing device and at least one solidification unit, characterized in that the build surface is designed to transport heavy components, and the components are transportable over the build surface essentially without distortion, and also comprising a method therefor.

Claims

1-16. (canceled)

17. A method for producing three-dimensional models in a continuous process, comprising the steps: a) building the model in layers on a building platform in a first position, a first layer being applied; b) transferring the model from the first position to a second position by feeding after the first layer is built, the building platform, which has a first front end and a second rear end, being transported with the model; c) building a further layer on the model on the platform; d) transferring the model on the building platform to another position; and repeating steps a) through d).

18. A method for producing three-dimensional models according to claim 17, characterized in that the model on the building platform is transferred from the first position to the second position without distortion.

19. A method for producing three-dimensional models according to claim 17, characterized in that the building platform with the model is evenly transferred from the first position to the second position and any further position essentially without deviations in feed between the first and second ends of the building platform.

20. The method for producing three-dimensional models according to claim 19, characterized in that the deviation in feed between the first front end and the second rear end of the building platform from the first position to the second position and any further position is less than 0.1 mm.

21. The method of claim 17, wherein the step of transferring is carried out with the aid of a step conveyor.

22. The method of claim 17, wherein the step conveyor has lifting and thrusting grates.

23. The method of claim 20, wherein the deviation in feed between the first and second ends of the building platform from the first position to the second position and any further position is less than 0.03 mm.

24. The method of claim 19, wherein the build platform is transported on a conveyor, and the building of the model is on a build surface that is above a portion of the conveyor.

25. The method of claim 24, wherein the conveyor is a horizontal surface.

26. The method of claim 17, wherein the build platform moves in a linear direction.

27. The method of claim 17, wherein the build platform moves in a circular direction around a vertical axis.

28. The method of claim 17, wherein the first layer is applied with a doing unit and is selectively solidified using a solidification unit.

29. The method of claim 28, wherein the build platform is moved by the action of a drive component.

30. The method of claim 29, wherein the drive component includes a first support and a second support, wherein the first support moves from a first location to a second location while supporting the build platform, and the first support returns to the first location while the second support is supporting the build platform.

31. The method of claim 17, wherein the build platform includes a link conveyor.

32. A method for producing three-dimensional models in a continuous process, comprising steps of: i) applying a layer of a particulate material to a particulate material feedstock using a dosing unit, while the particulate material feedstock is on a build surface supported by one or more supports; ii) selectively solidifying the layer using a solidification unit; iii) advancing the build surface for the addition of another layer of the particulate material by moving a one or more first supports from a first position to a second position while the build surface is supported by the one or more first supports and then returning the one or more first supports to the first position while the build surface is supported by one or more second supports; and iv) repeating steps i), ii), and iii) until the three-dimensional model is completed.

33. The method of claim 32, wherein the one or more supports include the one or more first supports, the one or more second supports, or both.

34. The method of claim 33, wherein the method includes continuously building one three-dimensional model and then building another three-dimensional model.

35. The method of claim 34, wherein the three-dimensional models are different.

36. The method of claim 33, wherein the build surface is a portion of a conveyor belt.

Description

DESCRIPTION OF THE FIGURES

[0107] FIG. 1 shows a preferred structure according to the invention, including a closed conveyor belt (e.g., link conveyor) (7) and an open sealing belt (6). The conveyor belt is able to bear the great weight of the particulate material cake while the cover belt is being unrolled and should only prevent the conveyor belt from coming into contact with the particulate material cake. The conveyor belt is unrolled from a roller and rolled up again behind the conveyor belt. The cover belt may be fed by means of frictional engagement on the conveyor belt or by winding up.

[0108] FIG. 2 shows a preferred link conveyor according to the invention, including hinges which permit mobility only in one direction. The link conveyor is moved by a roller track in this case. Only one, multiple or all rollers may be driven.

[0109] FIG. 3a shows a preferred transport unit according to the invention, comprising conveyor belt (7) (preferably a link conveyor as in FIG. 2), which is driven laterally by driving rollers (14) and is supported on small rollers (15) in the middle.

[0110] FIG. 3b shows a similar structure, in which conveyor belt (7) rests on continuous driving rollers (17) over its complete width. To achieve a better frictional engagement between the driving rollers (14) or driving cylinders (17) and the conveyor belt (7), pressing rollers (13) press the conveyor belt onto the driving rollers (14) or driving cylinders (17).

[0111] FIGS. 4a and 4b show a preferred structure according to the invention, in which the driving rollers (14) are driven by a shared driving belt (18). Conveyor belt (7) may then rest on the driving belt and be additionally supported. In FIG. 4a, the middle of conveyor belt (7) is supported on sliding elements (19) made of, e.g., plastic. In FIG. 4b, the middle of the conveyor belt is carried by air cushions (20).

[0112] FIGS. 5a through 5c show a structure according to the invention, comprising a link conveyor (7), which has a gripping element (22) on each link. A gripper, which repeatedly grips and positions a gripping element, passes beneath the link conveyor. The sequence is gripping and positioning (FIG. 5a), opening the gripper (FIG. 5b), returning and regripping a link (FIG. 5c).

[0113] FIG. 6 also shows a structure according to the invention, including a link conveyor (7), which has a gripping element (22) on each link, according to the invention. In this case, gripping elements (22) are positioned by a rotating worm drive (24).

[0114] FIG. 7 shows an oblique view of a preferred feed system according to the invention, including raised grates according to the invention.

[0115] FIGS. 8a through 8c show the sequence of the feed system from FIG. 7, from the front and from the side in each case, according to the invention.

[0116] FIG. 8a shows the starting position when both lifting grate (26) and thrusting grate (27) carry the conveyor belt. In FIG. 8a, lifting grate (26) has been extended and thrusting grate (27) subsequently lowered.

[0117] In FIG. 8b, lifting grate (26) has been lowered so that only thrusting grate (27) carries conveyor belt (7). Thrusting grate (27) then moves conveyor belt (7) into its next position.

[0118] In the lowered state, thrusting grate (27) returns to its starting position, as illustrated in FIG. 8a.

[0119] FIG. 9 shows a preferred structure according to the present invention with self-propelled building platforms (31). They are moved into building device (32).

[0120] FIGS. 10a through 10c show additional preferred embodiments according to the invention. In this case, the feedstock is not produced linearly but rotatorily. The process begins at a first position or end and ends at a second position or end. FIG. 10b is a view of FIG. 10a from above. FIG. 10c is a side view of FIG. 10b of the cone printer according to the invention, on sectional plane A-A. (33) designates the outwardly oriented movement of coater (1) and solidification unit (2), which is indicated using directional arrows, the method being carried out on building platform (34), and a particulate material feedstock (3) being generated and components [produced], e.g., component (5), following solidification. For this purpose, round building platform (34) is rotated, while coater (1) and the print axis move away from the rotation axis. Coater (1) is rotated 90 with respect to the other preferred devices of the invention described above and may be operated continuously. Solidification unit (2) may also work continuously, whereby a plurality of components may be produced in this manner on one building platform (34) in one operation (batch). A build cone (21) may be used to start the system. The alpha angle may be changed, depending on the particulate material, and thus be optimally adapted to the particular particulate material used. This device type requires the data for the molds for the components to be produced to be skewed not only linearly but also on the basis of polar coordinates. The dimensions of the cone printer and the building platform as well as the device as a whole may be selected in such a way that both very small and very large and heavy components may be produced without distortion.

[0121] FIG. 11 shows a preferred building device (32) according to the invention, to the end of which an unpacking area, including a roller track (35), is connected. The finished components are deposited directly onto the roller track. Loose particulate material may run off between the rollers and thus support unpacking. The roller track may be driven or it may run passively.

[0122] FIG. 12 shows a preferred building device according to the invention with a rotating building platform (34). Coater (1) and solidification unit (2) move only translatorily, while building platform (34) continues to rotate layer by layer and thus continuously builds up material feedstock (3). In another preferred embodiment, the device in FIG. 12 may be configured in such a way that it is combined with an unpacking station or an unpacking operation in an arbitrary position. Finished components (5) are shifted to a position (36) inside or outside or below or above building platform (34) and freed of the remaining loose particulate material simultaneously or in another work step. The process begins at a first position or end, e.g., at the point of the first particulate material application, and ends at a second position or end, e.g., upon completion of the component or preferably at the point of unpacking. The loose particulate material may be resupplied cyclically to the further continuous process. The particulate material supply is thus limited to the quantities which are removed from circulation in the form of components and any non-reusable quantities.

[0123] FIGS. 13a through 13f show a drive for belts or link aprons with lifting grates (26) and thrusting grates (27) according to the principle of the step conveyor. Thrusting grate (27) moves on lever arms which swivel back and forth. Lifting grate (26) is raised on the return swiveling motion.

[0124] FIGS. 14a through 14d show a drive for belts or link aprons with lifting grates (26) and thrusting grates (27) according to the principle of the step conveyor. Thrusting grate (27) moves on rotating lever arms.

[0125] FIGS. 15a through 15d show a drive for belts or link aprons with lifting grates (26) and thrusting grates (27) according to the principle of the step conveyor. A vertical lifting of lifting grate (26) alternates with an inclined lifting of thrusting grate (27).

LIST OF REFERENCE NUMERALS

[0126] 1 Coater [0127] 2 Solidification unit [0128] 3 Powder cake/particulate material feedstock [0129] 4 Tunnel wall [0130] 5 Component (being built) [0131] 6 Roller for cover belt [0132] 7 Conveyor belt (e.g., link conveyor) [0133] 8 Linear unit [0134] 9 Build space [0135] 10 Link with hinge [0136] 11 Driving cylinder [0137] 12 Cylinder bearing [0138] 13 Pressing roller [0139] 14 Driving roller [0140] 15 Bearing roller [0141] 16 Motor [0142] 17 Conveyance direction [0143] 18 Driving belt (e.g., toothed belt) [0144] 19 Sliding element [0145] 20 Air cushion [0146] 21 Gripper [0147] 22 Gripping element [0148] 23 Linear feed [0149] 24 Worm wheel [0150] 25 Frame [0151] 26 Lifting grate [0152] 27 Thrusting grate [0153] 28 Linear bearing [0154] 29 Lifting unit for lifting grate [0155] 30 Lifting unit for thrusting grate [0156] 31 Self-propelled building platform [0157] 32 Building device [0158] 33 Direction of movement of the coater and the solidification unit [0159] 34 Rotating building platform [0160] 35 Roller track [0161] 36 Unpacking area