阅读说明：本技术 用于生成地制造构件的设施和方法 (Installation and method for the generative production of components ) 是由 D·霍尔兹 M·肖普夫 M·瓦尔特 A·S·费舍尔 M·温特尔 于 2020-01-13 设计创作，主要内容包括：本发明涉及一种用于由材料粉末生成地制造构件(2)的设施(1),具有用于构造构件(2)的构造平台(11)、用于将粉末层(12)涂覆到构造平台(11)上的至少一个涂覆区段、用于选择性地照射粉末层(12)的至少一个照射区段(17)、运输单元(7),其中运输单元(7)构造为,使构造平台(11)在设施空间(4)中沿着运输路径运动和/或移动,其中涂覆区段和照射区段(13)沿着运输路径间隔开和/或相邻。(The invention relates to a plant (1) for the generative production of components (2) from material powder, having a construction platform (11) for constructing the component (2), at least one coating section for coating a powder layer (12) onto the construction platform (11), at least one irradiation section (17) for selectively irradiating the powder layer (12), a transport unit (7), wherein the transport unit (7) is designed to move and/or move the construction platform (11) in a plant space (4) along a transport path, wherein the coating section and the irradiation section (13) are spaced apart and/or adjacent along the transport path.)

1. A plant (1) for producing components (2) from material powder,

having a construction platform (11) for constructing the component (2),

having at least one coating section for applying a powder layer (12) onto a build platform (11),

having at least one irradiation section (17) for selectively irradiating the powder layer (12),

characterized by a transport unit (7), wherein the transport unit (7) is configured for moving and/or displacing the build platform (11) in a facility space (4) along a transport path, wherein the coating section and the irradiation section (13) are spaced apart and/or adjacent along the transport path.

2. The plant (1) according to claim 1, characterized by a plurality of coating sections and a plurality of irradiation sections (13), wherein said coating sections and said irradiation sections (13) are spaced apart along said transport path.

3. The plant (1) according to claim 2, wherein at least one coating section is arranged between two irradiation sections (13).

4. The plant (1) according to any one of the preceding claims, characterized by first coating means (10, 10a, 10 b) for coating a first material powder in a first one of said coating sections and second coating means (10, 10b, 10 c) for coating a second material powder in a second one of said coating sections, wherein the first and second material powders are differently constituted and/or composed.

5. The plant (1) according to any one of the preceding claims, wherein the component (2) forms a multilayer component and consists of a number of layers, wherein the plant (1) has at least one number of layers of the irradiated section (13) and/or at least one number of layers of the coated section.

6. The plant (1) according to any one of the preceding claims, wherein the construction platform (11) is comprised by the transport unit (7) and/or the construction platform (11) forms the transport unit (7).

7. The plant (1) according to any one of the preceding claims, wherein the transport unit (7) and/or the construction platform (11) form a conveyor belt.

8. The plant (1) according to any one of the preceding claims, characterized by a process chamber, wherein at least one of said irradiation sections (13) and at least one of said coating sections are arranged in said process chamber.

9. The plant (1) according to claim 8, wherein the processing chamber has an inlet sluice section (9) and an outlet sluice section (10), wherein the transport path leads from the inlet sluice section (9) to the outlet sluice section (10).

10. The plant (1) according to any one of the preceding claims, characterized by at least one powder removal unit (18, 18 a-c) for removing unused material powder.

11. The plant (1) according to claim 10, wherein the de-powdering unit (18, 18 a-c) is arranged between two coating sections for material change.

12. The plant (1) according to any one of the preceding claims, wherein said transport unit (7) is configured to move said building platform (11) continuously and/or at a constant speed.

13. The plant (1) according to any one of the preceding claims, wherein said elements (2) form flat elements.

14. The plant (1) according to any one of the preceding claims, wherein said components (2) form bipolar plates.

15. Method for manufacturing a component (2), in particular a component (2) with a plant (1) according to one of the preceding claims, wherein a powder layer (12) is applied onto a build platform (11), wherein the powder layer (12) is subsequently selectively irradiated, wherein the application of the powder layer and the irradiation of the powder layer (12) are carried out spatially separately.

Background

A plant (inlay) for producing components from powder-like material powder in a generative manner has a build platform for building the component, at least one coating section for coating a powder layer onto the build platform, at least one irradiation section for selectively irradiating (Bestrahlen) the powder layer.

Powder bed-based facilities for additively constructing components, such as 3D printing, are known in the art. This installation is constructed linearly, that is to say the powder coating acts in translation in the process chamber and causes downtimes which significantly reduce the overall productivity of the additive manufacturing process. In order to increase the selectivity, multi-laser systems are used in the prior art, for example, in which a plurality of laser beams are used simultaneously for the construction of a plurality of components in a process chamber.

Document DE 102016211799 a1, which may constitute the closest prior art, describes a device for manufacturing workpieces from powder material. The device has a carrier device with at least one forming container for the powdery material, from which workpieces can be produced by selective melting and subsequent solidification by means of a processing beam. At least one storage container has a separate dispensing element which can be rotated about an axis relative to a positionally fixedly arranged carrier means.

The invention is based on the consideration that a facility is provided in which the construction time of the components and the downtime and waiting time of the facility are reduced.

Disclosure of Invention

The invention relates to a plant for the generative production of components having the features of claim 1. Furthermore, a method for the generative production of a component is proposed having the features of claim 15. Preferred and/or advantageous embodiments of the invention result from the dependent claims, the description and the drawings.

The invention relates to a plant for producing components from a powdery material powder. The installation is in particular configured for carrying out a powder bed-based construction method, preferably a powder bed-based printing method. The facility forms, for example, a 3D printing facility. The component and/or material powder may comprise and/or form a metallic material, a ceramic material and/or a plastic material. Specifically, the facility is configured as a selective laser melting facility (SLM), an electron beam-based construction facility (EBM), or an ion beam construction method. The installation has in particular an installation space. The facility space may be enclosed and/or defined by a housing of the facility, for example. The member is preferably a layer member and comprises more than two layers and/or less than 100 layers. Preferably, the member forms a flat member. The powdery material powder is, for example, a metal powder, a ceramic powder or a plastic powder. In particular, the material powder may comprise a binder.

The installation comprises at least one construction platform for constructing the component. The build platform has at least one planar section. The formation platform and/or the flat portion thereof is preferably formed flat. In particular, the build platform may form a metal carrier. For example, the build platform is constructed as a metal plate, a plastic plate or a ceramic plate. The build platform can be constructed in particular as a continuous material, for example as a sheet of material configured as rollers.

The installation has at least one coating section. In particular, the coating section is a surface section or a volume section of the installation space. In particular, the coating section and the build platform have an overlap at least temporarily. In the coating section, a powder layer may be coated onto the build platform. In particular, the powder layer may be applied to an intermediate layer between the build platform and the free surface. For example, a previous powder layer has been irradiated and/or hardened, thereby coating the powder layer onto the previous powder layer. For example, the facility has a powder coating mechanism for this purpose. The powder coating device can have a reservoir for material powder and/or powder. The powder layer is in particular made of a material powder. For this purpose, in particular, the material powder in powder form is applied in a planar manner. In particular, the coating device has a doctor blade and/or a smoothing coater (Gleitstreicher) for this purpose. The powder layer may completely fill the build platform, alternatively the powder layer is only coated on a partial area of the build platform. The powder layer has in particular a powder layer thickness. In particular, the coating section is arranged in the installation space.

Furthermore, the installation has at least one irradiation section. The illumination section is preferably a planar section in the installation space, alternatively the illumination section is a volumetric section of the illumination space. The structuring platform and/or the applied powder layer are preferably arranged at least temporarily and/or arrangeable in the irradiated section. The facility has, for example, an irradiation mechanism that can selectively irradiate the powder layer. Such irradiation may be performed, for example, as irradiation with a laser beam, an ion beam, or an electron beam. For example, the irradiation means have a laser, an ion source or an electron source for this purpose. By selective irradiation, the powder layer is melted, in particular selectively, in a punctiform, linear and/or planar manner. After irradiation, a solidification step is preferably performed so that the melted powder layer can be solidified and solidified.

The facility has a transportation unit. The transport unit is configured for moving, displacing and/or displacing the build platform in the facility space. By means of the transport unit, the build platform can be moved and/or displaced along the transport path. The transport path is preferably a straight path, alternatively and/or additionally the transport path may form a bent, curved and/or branched transport path. Preferably, the transport path is arranged completely in the facility space. Alternatively, it can be provided that the parts of the transport path are arranged outside the installation space. The transport unit is configured to transport the build platform from the coating section to the irradiation section. If the installation has a plurality of coating sections and/or a plurality of irradiation sections, the transport unit is in particular configured to transport the build platform from one coating section to an irradiation section and from the irradiation section further to other coating sections and/or irradiation sections.

According to the invention, the coating section and the irradiation section are spaced apart from one another, arranged one after the other and/or arranged adjacent to one another. In particular, the coating section and the irradiation section are spaced apart along the transport path. The coated section and the irradiated section may be separated from each other by another section, alternatively the irradiated section and the coated section may abut each other without a transition.

One consideration of the present invention is to provide a facility for more efficiently and/or more quickly manufacturing components by means of the resulting manufacturing method. In particular, reducing and/or shortening downtime, replacement time, and/or preparation time is a consideration. This is achieved in particular by the coating and the irradiation being decoupled from one another in time and/or space. Instead of the build platform being held in a fixed position during the build process and the plate only being lowered if necessary, it is possible to arrange and use the powder sequentially inside the facility during build by displacement of the build platform. In particular, the duration of the structuring of each component does not exceed the pure sum of all coating and exposure processes, but is determined only by the duration of the individual exposure processes.

One embodiment of the invention provides that the installation has a plurality of coating sections and a plurality of irradiation sections. Preferably, the number of coating sections corresponds to the number of irradiation sections. For example, all coating sections and all irradiation sections are arranged within a common housing of the installation and thus in a common installation space. The coating section and the irradiation section are arranged along a transport path. In particular, the coating sections and the irradiation sections are arranged alternately along the transport path. In particular, the transport path leads from a first coating section to a first irradiation section, from the first irradiation section to a second coating section, via possible further irradiation sections and coating sections, to a final irradiation section. The irradiation section and the coating section are arranged in particular along a linear and/or straight transport path. The transport unit connects the plurality of coating sections with the plurality of irradiation sections.

It is particularly preferred that at least one coating section is arranged between each of the two irradiation sections. Alternatively, it can be provided that one irradiation section is followed by another irradiation section, for example in order to further process, melt and/or structure the powder layer by means of, for example, another laser beam having another wavelength or power.

It is particularly preferred that the installation has a first coating device for coating a powder layer with a first material powder and a second coating device for coating a powder layer with a second material powder in a second coating section. In particular, the installation can be configured for using different material powders in the first and second coating sections. The first material powder and the second material powder have different physical properties, chemical properties and/or compositions. This embodiment is based on the consideration that a facility is provided in which the components can be produced from different powder layers, in particular material powders, wherein the different material powders are applied to different coating sections which are spaced apart from one another over the transport path. In particular, mixing of material powders can thereby be avoided.

In particular, the component forms a multilayer component comprising a number of layers. The number of layers corresponds in particular to the number of powder layers required for the construction of the component. Preferably, the number of layers is greater than 2 and in particular greater than 5. Furthermore, it is preferably provided that the number of layers is less than 20. Optionally, the facility has a number of irradiation sections and/or coating sections equal to the number of layers of the component. This embodiment is based on the consideration that a production facility is provided such that all layers required for the construction of the component can be produced and/or produced in one production line.

One embodiment of the invention provides that the build platform is comprised by the transport unit and/or the build platform forms the transport unit. For example, the platforms are designed for this purpose to be connected by mechanical means, for example, by links or cables, in such a way that they are displaceable, movable and/or displaceable in the installation space. In particular, the construction platform comprised by the transport unit is a reusable construction platform which, after construction of one component, can be used again for construction of a new further component. For example, the build platform is again provided and/or used at the beginning of the transport path after successful component construction.

It is particularly preferred that the transport unit and/or the build platform form a conveyor belt. For example, the build platform forms a metal strip onto which a powder layer is applied and on which the component is built. The building platform and/or the conveyor belt thus form, in particular, a continuous belt which is arranged in an endless and/or closed manner. It is particularly preferred that the build platform is configured for direct coating and/or building of components thereon. For example, the base material and/or the base layer of the building platform and/or the conveyor belt forming member. For example, the constructed components may be subsequently stamped out of and/or separated from the construction platform and/or conveyor belt.

The facility preferably has a process chamber. The processing chamber is formed, for example, by the housing of the installation. The installation space is arranged in particular in the process chamber. For example, it is provided that at least and/or all of the irradiation sections are arranged in the process chamber. Furthermore, it is preferably provided that at least one or all of the coating sections are arranged in the process chamber. In particular, it is provided that a protective gas atmosphere is present inside the process chamber. For example, the facility has for this purpose an atmosphere provision means for introducing and/or removing protective gas. The process chamber forms in particular a barrier for the protective gas atmosphere with respect to the surroundings and/or the atmosphere. Preferably, the conveying path and/or the entire conveying path is arranged inside the processing chamber.

In one embodiment of the invention, the process chamber has an inlet lock section and an outlet lock section. The transport path preferably extends from the inlet sluice section to the outlet sluice section. The inlet sluice section and/or the outlet sluice section are/is configured, for example, as slots in the housing and/or the processing chamber. Preferably, the height of the gap is dimensioned such that the construction platform can enter at the entry sluice section and the component can exit at the exit sluice section on the transport unit. The inlet and outlet lock sections serve to open the process chamber relative to the surroundings, wherein they simultaneously serve to maintain a protective gas atmosphere. For example, an overpressure of protective gas is present in the process chamber, so that the inlet sluice section and the outlet sluice section are used for the overpressure and/or for the outflow of protective gas, so that a protective gas atmosphere is always present in the process chamber.

It is particularly preferred that the installation has at least one powder removal unit. For example, the powder removing unit is configured as a suction unit or a magnetization unit or a unit for generating an electric field. Preferably, the removal powder unit is arranged after the irradiation section. By means of the powder removal unit, unfused and/or unused powder can be removed and/or sucked away. In particular, it can be provided that, instead of and/or in addition to the removal of the powder by suction, in the case of metals and/or other powders, the removal can take place by charging and/or separation and by magnetization. This embodiment is based on the consideration that a resource-saving facility is provided, so that unused powder material powder, for example, can be reused and put into use later.

It is optionally provided that the removal powder unit is arranged between coating sections in which a plurality of different material powders or material powders are used. For example, a first material powder is used in a first coating section and a further material powder is used in a second coating section, wherein after the irradiation section for the first material powder, the removal powder unit sucks away the unused first material powder and only then coats the further material powder. This embodiment is based on the consideration that, when material powders are exchanged in the installation, a mixing of the types of material powders can be avoided, so that in particular each type of material powder can be used and/or recycled further.

It is particularly preferred that the transport unit is configured for continuously carrying out the transport of the build platform. The build platform is here conveyed continuously along the transport path, for example at a constant speed. This design is based on the consideration that continuous processing can be achieved and/or slipping, sliding and/or smearing of the powder layer can be avoided. Alternatively, it is provided that the transport unit is designed for the discontinuous, for example stepwise, transport of the building platform. The transport of the build platform takes place here, for example, along a predefined translational path in a predefined and/or settable length.

It is optionally provided that the component forms a flat component, wherein the facility forms a facility for producing the flat component. In this case, the facility is oriented and/or set up in particular for the case in which the outlet and/or inlet lock sections are set up on the flat component. Examples of flat members are, for example, members having less than ten layers and/or having a height of less than five centimeters. In particular, the component forms a structural component, a surface and/or a cooling body.

It is particularly preferred that the component forms a bipolar plate and/or a flow field for a fuel cell. The component is, for example, a bipolar plate for a PEM fuel cell. For example, a flow field and/or bipolar plate for a PEM fuel cell includes five to ten layers. In this context, it is conceivable, for example, to produce fuel cell components and/or bipolar plates in a plant with a cycle time of one to two seconds per bipolar plate.

A method for manufacturing a component in a regenerative manufacturing process forms another subject of the invention. In particular, as previously described, the method is performed with the facility. To manufacture the component, a powder layer is applied to the build platform and then selectively irradiated. In this method, the powder coating is carried out spatially separately and/or at intervals from the irradiation. For this purpose, the build platform is transported, for example, from a coating section to an irradiation section. According to the method, for example, it is provided that the powder coating and the exposure are spatially separated, so that a reduced processing time is possible.

Drawings

Further advantages, functions and embodiments emerge from the drawing and the description thereof. Shown here are:

FIG. 1 shows one embodiment of a facility for generatively manufacturing a component;

FIG. 2 shows another embodiment of a facility for generatively manufacturing a component;

fig. 3 shows a third embodiment of a plant for the generative production of components.

Detailed Description

Fig. 1 schematically shows a first exemplary embodiment of a plant 1 for the generative production of components 2. The facility is configured as a facility for carrying out a powder bed-based manufacturing method and/or an additive manufacturing method. For example, the installation 1 is designed as an installation for selective laser melting. The installation 1 is designed here as an installation for linearly transporting and/or producing the component 2, such as a production installation. The component 2 here preferably forms a flat component consisting of a plurality of layers. The layers may have the same or different material compositions. The component 2 forms a 3D component with a particularly three-dimensional structure. The component 2 forms, for example, a bipolar plate for a fuel cell.

The plant 1 has a housing 3 defining a processing chamber. The housing defines a facility space 4 which is located inside the housing 3. The housing 3 has an inlet sluice section 5 and an outlet sluice section 6. The inlet sluice section 5 and the outlet sluice section 6 are designed as openings in the housing 3 and are preferably constructed in a slotted manner. The dimensioning of the outlet sluice opening 6 is selected in particular such that the height of the gap is greater than the height of the component 2 to be produced, but preferably has a height which is less than twice the height of the component 2.

The installation 1 has a transport unit 7. The transport unit 7 is configured as a conveyor belt. The conveyor belt is conveyed by a conveying mechanism 8. The actual conveyor belt is preferably conveyed continuously at a uniform speed. The conveyor belt and/or transport unit 7 extends in particular from the entry sluice section 5 to the exit sluice section 6. The protective gas atmosphere is located in the housing 3 and thus in the installation space 4. For this purpose, the protective gas 9 is usually supplied by means of a protective gas generating device, so that a continuous protective gas atmosphere is present in the process chamber and/or in the installation space. In particular, the protective gas atmosphere and/or the supply of protective gas 9 is selected such that an overpressure is present, so that a slight outflow of protective gas is achieved at the inlet and outlet sluice sections 5, 6.

The installation 1 comprises three coating units 10, which are arranged in the installation space 4 and along the transport path. The transport path is defined and/or determined by the transport unit 7 and in particular by the conveyor belt. The transport path extends from the entry gate section 5 to the exit gate section 6. The coating means 10 are configured to apply the material powder as a powder layer onto the transport unit and in particular onto the build platform 11. The construction platform is, for example, a metal, plastic or ceramic plate, which serves as a structural base for the component 2. The build platform 11 is arranged on a conveyor belt and transported by the transport unit 7 along a transport path. The coating mechanisms 10 coat the powder layers 12, respectively. A first coating means 10 on the transport path coats a powder layer onto the build platform, and a subsequent coating means 10 coats a powder layer onto the previous powder layer and, if necessary, onto the melted powder layer. The height profile of the powder layer increases with each coating means 10 from the inlet sluice section to the outlet sluice section, in particular the coating means are arranged in steps in the height profile. The application of the material powder takes place continuously with the application mechanism 10, for example, while the build platform 2 is continuously transported by the transport unit 7 at a constant speed.

The facility 1 has an irradiation unit 13. The irradiation unit 13 is configured here as a laser which outputs a main laser beam 14. The laser beam 14 is guided at least in sections inside the housing 3 and/or in the installation space 4. The installation 1 has a scanning mechanism 15 which is designed to divide the laser beam 15 into partial laser beams 16. Part of the laser beam, also referred to simply as laser beam, is directed into the irradiation section 17. The irradiation sections 17 are in particular each located after a coating section. In the irradiation section 17, the powder layer 12 is selectively melted by the laser beam 16. The molten powder is then cooled and allowed to solidify. On the cooled and/or solidified section and on the unmelted powder layer, the next powder layer is applied in the subsequent coating mechanism 10 and subsequently irradiated and/or melted in the next irradiated section 17. By arranging the coating section and the irradiation section 17 one after the other and using a plurality of irradiation sections and/or a plurality of coating sections, the component 2 can be processed and/or manufactured more quickly.

The plant 1 comprises a powder removal unit 18. The removal powder unit 18 is disposed in the housing 3. In particular, the removal powder unit 18 is arranged along the transport path after the last irradiation section 17. The powder removal unit 18 is configured to suck away unused, melted and/or recyclable material powder. Thereby enabling exposure and/or removal of the component 2. Furthermore, by sucking off and/or removing the coating powder by means of the removal powder unit 18, a recovery of the material powder is achieved, which can be returned to the coating means 10.

Fig. 2 shows a further embodiment of the installation 1. The installation 1 is constructed essentially identically to the installation 1 in fig. 1. The facility 1 in fig. 2 differs essentially in that the build platform 11 is used directly as a conveyor belt for the transport unit 7. In this case, the base sheet is transported as a build platform 12 directly along the transport path. The base metal sheet 2 is guided through the coating units 10, wherein the powder layer is applied directly from the first coating unit 10 onto the conveyor belt, in this case the base metal sheet. In the irradiation section 17 after the first coating means 10, the powder layer is melted. In this case, the melted powder layer is in particular partially connected to the base metal sheet and thus to the build platform 12. The base sheet then forms part of the component 2 to be manufactured in this case. Subsequently, additional powder layers are applied and further melting is continued on the previously applied powder layers and/or melted sections. After the last melting section, the component 2 is powder-removed with a powder-removal unit 18. The component 2 is then guided out of the processing chamber along a transport path. After removal of the powder and removal, the component 2 is separated from the base plate or from the construction platform. For example, the component 2 is punched, cut or otherwise separated for this purpose. In particular, the separation, cutting and/or punching is carried out in such a way that a part of the base sheet or of the construction platform remains part of the component 2. This embodiment is based on the consideration that the build platform is transported directly, for example, by means of a drive with a motor, traction or propulsion. Thus, separate conveyor belts and their wear are avoided. In particular, the base sheet material may be provided as a continuous material and the components then obtained by separating and/or stamping/cutting.

Fig. 3 shows a third embodiment of a plant 1 for the generative production of components 2. The installation 1 in fig. 3 is constructed substantially similarly to the two other embodiments in fig. 2 and 1. The main difference from the previous embodiments is that the application devices 10a, 10b and 10c are designed for applying correspondingly different material powders. Thus, the first coating mechanism 10a coats the first material powder as a powder layer. The powder layer melts in the irradiated section. After such irradiation, the unused first material powder is sucked away by the removal powder unit 18 a. Unused material powder is removed by the removal powder unit 18a and can therefore be directed back to the coating means 10a purely. After the removal of the powder unit 18a, a second material powder is applied to the powder-removed segment using the coating mechanism 10 b. The second material powder differs from the material powder that has been used before in its composition and/or its physicochemical properties. The powder layer of the second material powder applied in this way is melted, in particular selectively melted, in the subsequent irradiation. After melting and, if necessary, cooling, unused second material powder is removed from the removal powder unit 18 b. The material powder removed by the removal powder unit 18b is again of a pure kind and can be returned to the coating means 10 b. In the next coating mechanism 10c, the third material powder is coated as a powder layer. The composition and/or physicochemical properties of the third material powder are in particular different from those of the second material powder. The applied powder layer of the third material powder is then likewise selectively melted and/or irradiated. The unused third material powder is removed by the removal powder unit 18 c. The removed third material powder may be introduced back to the coating mechanism 10c by the removal powder unit 18 c.

This embodiment is based on the consideration that a component having a plurality of layers can be produced, wherein the layers have different material compositions and/or properties. By arranging the coating means 10a, 10b and 10c one after the other, powder and/or material exchange can be saved and the process can be continuously controlled. A pure reuse of the type of powder can be ensured by sucking away the unconsumed powder after the respective melting.