U.S. patent application number 17/019938 was filed with the patent office on 2021-01-07 for compact build tank for an additive manufacturing apparatus.
This patent application is currently assigned to Arcam AB. The applicant listed for this patent is Arcam AB. Invention is credited to Kristofer Karlsson.
Application Number | 20210001551 17/019938 |
Document ID | / |
Family ID | |
Filed Date | 2021-01-07 |
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United States Patent
Application |
20210001551 |
Kind Code |
A1 |
Karlsson; Kristofer |
January 7, 2021 |
COMPACT BUILD TANK FOR AN ADDITIVE MANUFACTURING APPARATUS
Abstract
Described is an additive manufacturing apparatus that includes a
telescopic build tank operatively connected at opposing ends to a
powder table and a build table. The telescopic build tank includes
at least two segments telescopically coupled to one another, each
of the at least two segments comprising a set of engagement grooves
located on an interior surface of the at least two segments and a
set of engagement pins located on an exterior surface of the at
least two segments. The set of engagement pins is configured to
engage with and travel along a corresponding set of engagement
grooves of another of the at least two segments, and each
engagement groove comprises a first axially extending channel
positioned along a single axis and having at least one closed end,
the at least one closed end being configured to impede separation
of the at least two segments relative to one another.
Inventors: |
Karlsson; Kristofer;
(Kungsbacka, SE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Arcam AB |
Molnlycke |
|
SE |
|
|
Assignee: |
Arcam AB
Molnlycke
SE
|
Appl. No.: |
17/019938 |
Filed: |
September 14, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16266576 |
Feb 4, 2019 |
10800101 |
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17019938 |
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62635941 |
Feb 27, 2018 |
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62782902 |
Dec 20, 2018 |
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Current U.S.
Class: |
1/1 |
International
Class: |
B29C 64/25 20060101
B29C064/25; B29C 64/245 20060101 B29C064/245; B23K 15/00 20060101
B23K015/00; B22F 3/105 20060101 B22F003/105; B23K 15/06 20060101
B23K015/06; B29C 64/268 20060101 B29C064/268; B33Y 30/00 20060101
B33Y030/00; B33Y 10/00 20060101 B33Y010/00; B33Y 50/02 20060101
B33Y050/02; B29C 64/153 20060101 B29C064/153; B22F 1/00 20060101
B22F001/00 |
Claims
1. An additive manufacturing apparatus for forming a
three-dimensional article layer by layer from a powder, the
additive manufacturing apparatus comprising: a powder table; a
build table; and a telescopic build tank operatively connected at
one end to the powder table and at an opposing other end a portion
of the build table, the telescopic build tank comprising at least
two segments telescopically coupled relative to one another, each
of the at least two segments comprising a set of engagement grooves
located on an interior surface of the at least two segments and a
set of engagement pins located on an exterior surface of the at
least two segments, wherein: the set of engagement pins of one of
the at least two segments is configured to engage with and travel
along a corresponding set of engagement grooves of another of the
at least two segments, and each engagement groove of the set of
engagement grooves comprises a first axially extending channel
positioned along a single axis and having at least one closed end,
the at least one closed end being configured to impede further
translation of a corresponding engagement pin and separation of the
at least two segments relative to one another.
2. The additive manufacturing apparatus according to claim 1,
wherein the set of engagement pins are each circumferentially
offset relative to the set of engagement grooves on each of the at
least two segments.
3. The additive manufacturing apparatus according to claim 1,
wherein the set of engagement pins on each of the at least two
segments includes three engagement pins and the set of engagement
grooves on each of the at least two segments includes three
engagement grooves.
4. The additive manufacturing apparatus according to claim 3,
wherein the three engagement pins and the set of engagement grooves
are equally spaced apart relative to one another around a
circumference of each of the at least two segments.
5. The additive manufacturing apparatus according to claim 3,
wherein the three engagement pins are each offset circumferentially
a distance from a corresponding one of the three engagement
grooves, so as to define three distinct groove and pin pairings on
each of the at least two segments.
6. The additive manufacturing apparatus according to claim 1,
wherein the set of engagement pins are positioned adjacent a lower
edge of each of the at least two segments.
7. The additive manufacturing apparatus according to claim 1,
wherein: the first axially extending channel of each engagement
groove has an open end adjacent to and intersecting a lower edge of
each of the at least two segments, and the first axially extending
channel of each engagement groove has a closed end opposite the
open end, adjacent to but non-intersecting an upper edge of each of
the at least two segments.
8. The additive manufacturing apparatus according to claim 7,
wherein: each engagement groove further comprises a second channel;
the second channel comprises a first portion parallel with and
spaced apart a spacing distance from the first axially extending
channel; and the second channel comprises a second portion
perpendicular to both the first portion and the first axially
extending channel, the second portion interconnecting the first
portion and the first axially extending channel at a point
intermediate the open end and the closed end of the first axially
extending channel.
9. The additive manufacturing apparatus according to claim 8,
wherein the engagement groove is substantially Y-shaped and the
second channel is substantially L-shaped.
10. The additive manufacturing apparatus according to claim 8,
wherein the first portion of the second channel has an open end
adjacent to and intersecting with the upper edge of the
segment.
11. The additive manufacturing apparatus according to claim 1,
wherein: the first axially extending channel of each engagement
groove has a closed end adjacent to but non-intersecting an upper
edge of each of the at least two segments; and each engagement
groove further comprises a second channel that intersects with the
first axially extending channel intermediate the closed end and a
lower edge of each of the at least two segments.
12. The additive manufacturing apparatus according to claim 11,
wherein: the second channel has an open end opposite an end of the
second channel that intersects with the first axially extending
channel; the first axially extending channel has an open end
opposite the closed end of the first axially extending channel; and
the open end of the first axially extending channel and the open
end of the second channel are circumferentially offset relative to
one another on the segment, such that an engagement pin travelling
in the first axially extending channel can only exit the open end
of the second channel following a combination of axial translation
and axial rotation.
13. The additive manufacturing apparatus according to claim 1,
wherein: the telescopic build tank is disposed in a build chamber
of the additive manufacturing apparatus; and the additive
manufacturing apparatus further comprises at least one bellows
assembly having a first portion operatively connected to a portion
of the build table and a second portion operatively connected to an
environment outside the build chamber.
14. The additive manufacturing apparatus according to claim 13,
wherein: the portion of the build table to which the at least one
bellows assembly is attached is an extension of the build table;
and a longitudinal axis of the at least one bellows assembly is
offset from a longitudinal axis of the telescopic build tank.
15. The additive manufacturing apparatus according to claim 1,
wherein said at least two segments comprises a plurality of
segments, and the set of engagement grooves define at least a
minimum overlap between said each adjacent segment.
16. The additive manufacturing apparatus according to claim 15,
wherein the set of engagement grooves on each of the plurality of
segments comprises a first axially-only extending channel having a
closed end substantially adjacent to but non-intersecting with a
top edge of the plurality of segments, the closed end limiting
travel of the set of engagement pins to provide the minimum
overlap.
17. The additive manufacturing apparatus according to claim 15,
wherein said minimum overlap is no more than 25 mm in fully
extracted position.
18. The additive manufacturing apparatus of claim 1, further
comprising energy beam source arranged for creating an energy
beam.
19. A telescopic build tank for an additive manufacturing apparatus
for forming a three-dimensional article layer by layer from a
powder, the telescopic build tank comprising: at least two segments
telescopically coupled relative to one another, each of the at
least two segments comprising a set of engagement grooves located
on an interior surface of the at least two segments and a set of
engagement pins located on an exterior surface of the at least two
segments, wherein: the set of engagement pins of one of the at
least two segments is configured to engage with and travel along a
corresponding set of engagement grooves of another of the at least
two segments, and each engagement groove of the set of engagement
grooves comprises a first axially extending channel positioned
along a single axis and having at least one closed end, the at
least one closed end being configured to impede further translation
of a corresponding engagement pin and separation of the at least
two segments relative to one another.
20. The telescopic build tank of claim 19, wherein one end of the
telescopic build tank is coupled to a powder table of the additive
manufacturing apparatus and an opposing other end of the telescopic
build tank is coupled to a portion of a build table of the additive
manufacturing apparatus.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present specification is a continuation of U.S. patent
application Ser. No. 16/266,576, filed on Feb. 4, 2019 which claims
priority to and the benefit of U.S. Provisional Patent Application
No. 62/635,941, filed on Feb. 27, 2018, and U.S. Provisional Patent
Application No. 62/782,902, filed on Dec. 20, 2018, the contents of
each of which as are hereby incorporated by reference in their
entirety.
BACKGROUND
Related Field
[0002] The invention relates to a build tank for an additive
manufacturing apparatus for forming a three-dimensional article
layer by layer from a powder material.
Description of Related Art
[0003] Freeform fabrication or additive manufacturing (AM) using
electron beam melting (EBM) or laser beam melting is a method for
forming a solid three-dimensional article from a powder. The
three-dimensional article is formed layer by layer by successive
fusion of selected areas of powder layers, which selected areas
correspond to successive layers of the three-dimensional article. A
layer of powder, such as metal powder, is deposited on a build area
and an electron beam or a laser beam is used to selectively melt
the powder layer of the build area. The melted material fuses with
under-laying layers and solidifies to form the top layer of the
solid three-dimensional article. A further layer of powder is
deposited onto the previous layer, and the electron or laser beam
is used to selectively melt the further powder layer of the build
area. The melted material solidifies and form another solid layer
fused onto the previous solid layer. This process is repeated for
multiple layers until the desired 3D geometry of the article is
achieved.
[0004] An apparatus for forming such a three-dimensional article
has a build table onto which the three-dimensional article is to be
formed, a powder distributor device for delivering powder to the
build table (build area) for the formation of the powder layers and
an electron beam source or a laser beam source for providing the
energy beam used for melting the powder. The build table is
arranged in a build tank which in turn is arranged in a build
chamber formed by a casing. When using EBM, the build chamber is a
vacuum chamber.
[0005] The build table is usually displaceable relative to the
build tank in the vertical direction for maintaining the level of
the top surface of the build layer (powder bed) when adding powder
layers. During the build process the powder applied should be
prevented from moving from the build area of the build table to a
position under the build table. For avoiding such powder leakage
between the build tank and the build table, a seal can be arranged
on the periphery of the build table. For high temperature powder,
such seals made from a ceramic material in form of a rope will
however often require a plurality of rounds of the rope around the
build table for achieving the sealing function. In laser based
additive machines the seals may be made of felt. Further, under
unfavorable conditions particles from the ceramic rope or the felt
can pollute the metal powder used for the build process. Such
solution with a build tank and a sealed build table is relatively
expensive to produce and is nevertheless sensitive to powder
leak.
BRIEF SUMMARY
[0006] An objective of the invention is to provide a build tank for
an additive manufacturing apparatus for forming a three-dimensional
article layer by layer from a powder, which is more or less
insensitive to powder leak and is cheaper to produce compared to
prior art solutions. Another objective of the invention is to
provide a compact machine for making high-content builds containing
many layers formed from the powder. Another objective of the
invention is to provide a build tank that eliminates vacuum seals
that conventionally can leak. Via the build tanks provided, access
to a bottom of the build table from outside of the chamber is also
facilitated even during an ongoing build operation.
[0007] The above-detailed objectives are achieved by a build
chamber for an additive manufacturing apparatus for forming a
three-dimensional article layer by layer from powder, the build
chamber comprising a build chamber base body and a build table,
wherein the build chamber base body is formed by at least two
segments telescopically coupled together. In certain embodiments,
the build chamber may also incorporate at least one vacuum bellows
assembly, which permits access to the bottom of the build table
from outside of the build chamber.
[0008] A non-limiting advantage is that the machine is easier to
load, less bulky and easier to levelling a start plate onto which
the three-dimensional article is to be built. Another advantage is
that there is a higher permissible dimension variations in the
present inventive build tank compared to the prior art solution.
Still another advantage is that the inventive build tank is more or
less insensitive to temperature variations. Still another advantage
is ease of access to the bottom of the build table from outside of
the build chamber. Still another advantage is a vacuum chamber
without use of conventional vacuum seals.
[0009] In another example embodiment of the present invention a top
segment fits inside a bottom segment. Powder leakage between
segments of the build chamber base body may be eliminated by
starting with the smallest dimension at the top and attach all
other segments outside each other. As the build table is moving in
a downward direction, powder has to be transferred upwards in order
to leak which is not likely if there is a sufficient overlap
between adjacent segments when the telescopic build tank is in a
fully extracted position.
[0010] In another example embodiment of the present invention the
top segment may be releasably attached to a powder table
surrounding the build chamber base body. The advantage of this
embodiment is that the top segment of the build chamber and the
powder table may be fixed to each other while the building of the
three-dimensional article takes place. This may also allow for a
safe extraction and contraction of the telescopically build chamber
without risking any powder spill between the build chamber and the
powder table.
[0011] In another example embodiment of the present invention the
bottom segment may be releasably attached to the build table. The
advantage of this embodiment is that the build table may be moved
up and down for extraction and contraction of the telescopically
build chamber without risking to lose contact between the build
tank and the build table. Once the three-dimensional article has
been finished, the build chamber may be detached from the powder
table together with the three-dimensional article and removed from
the additive manufacturing apparatus. The build table is fixed
relative to the bottom segment and there is no friction between the
build table and the inside of the build tank as in the prior art
solution.
[0012] In another example embodiment of the present invention at
least one stroke limitation wire may be attached between each two
adjacent segments of the build chamber for creating at least a
minimum overlap between the segments when the at least one stroke
limitation wire is at its full length. The advantage of this
embodiment is that the telescopic build chamber may not fall apart
during an extraction of the build chamber.
[0013] In another example embodiment of the present invention the
at least one stroke limitation wire is attached on the outside of
the segments. The advantage of this embodiment is that the wires if
attached to the outside may not interfere with the powder
material.
[0014] In still another example embodiment of the present invention
a segment x has a lower flange which extends radially outwards and
that an adjacent segment x+1 is having an upper flange which
extends radially inwards, where the lower flange and the upper
flange in the adjacent segments x and x+1 respectively limits the
stroke of the telescopically build tank in a downward direction
where segment x+1 is a larger segment compared to segment x. The
advantage of this embodiment is that the stroke limitation is built
in the segments from the beginning.
[0015] In yet another example embodiment of the present invention
the build chamber base body may have a circular, elliptical or a
polygonal shape. The advantage of this embodiment is that the
telescopic build tank may have any shape without risking powder
leakage.
[0016] In still another example embodiment of the present invention
the releasable attachment of the build tank to the powder table
and/or the build table is in the form of a bayonet joint or an
eccentric latch. The advantage of this embodiment is also that
different types of releasable attachments may be used.
[0017] In still another example embodiment of the present invention
the minimum overlap is at least 5 mm in a fully extracted position.
Powder leakage may be eliminated if the gap between an outer
dimension of segment x and an inner dimension of segment x+1 is
smaller than the overlap.
[0018] In another example embodiment, a build chamber is provided
for an additive manufacturing apparatus for forming a
three-dimensional article layer by layer from a powder, the build
chamber comprising: a powder table; a build table; and a telescopic
build tank operatively connected at one end to the powder table and
at an opposing other end a portion of the build table, the
telescopic build tank comprising at least two segments
telescopically coupled relative to one another, each of the at
least two segments comprising a set of engagement grooves located
on an interior surface of the at least two segments and a set of
engagement pins located on an exterior surface of the at least two
segments, wherein: the set of engagement pins of one of the at
least two segments is configured to engage with and travel along a
corresponding set of engagement grooves of another of the at least
two segments, and each engagement groove of the set of engagement
grooves comprises a first axially extending channel positioned
along a single axis and having at least one closed end, the at
least one closed end being configured to impede further translation
of a corresponding engagement pin and separation of the at least
two segments relative to one another.
[0019] In another example embodiment, a method is provided for
using a telescopic build tank for an additive manufacturing
apparatus for forming a three-dimensional article layer by layer
from a powder, the method comprising the steps of: positioning a
top surface of a build table of the build tank at a first location
spaced apart from a powder table; and during forming of the
three-dimensional article, moving the top surface from the first
location to at least a second location, the second location being
axially displaced from the first location, relative to the build
tank, and intermediate the first location and a location of the
powder table, wherein: the moving step causes collapse of a
telescopic build tank that comprises at least two segments
telescopically coupled together relative to one another, the build
tank being operatively connected to both the build table and the
powder table, the collapse of the telescopic build tank comprises
movement of the at least two segments translationally-only relative
to one another such that a set of engagement pins positioned on an
exterior surface of one of the two segments engage and travel along
a set of solely axially extending channels positioned on an
interior surface of another of the two segments, and the solely
axially extending channel has a closed end adjacent a top edge of
the another of the two segments, so as to limit travel of the set
of engagement pins and prevent axial separation of the two segments
relative to one another.
[0020] In another example embodiment, a computer program product is
provided that comprises at least one non-transitory
computer-readable storage medium having computer-readable program
code portions embodied therein, the computer-readable program code
portions comprising one or more executable portions configured
executing the method steps described above and elsewhere
herein.
[0021] In another example embodiment of the present invention,
utilized in conjunction with the build chambers described elsewhere
herein, a bellows assembly is provided that isolates a bottom of
the build table from the vacuum formed in the build chamber and
above the build table. The bellows assembly feature, as a
non-limiting example, facilitates cooling of the shaft or means
during the build, along with greasing of the shaft or means to
avoid wear. Contact of powder on the shaft or means is also
eliminated.
[0022] Further advantages and advantageous features of the
invention are disclosed in the following description and in the
dependent claims.
BRIEF DESCRIPTION OF THE FIGURES
[0023] With reference to the appended drawings, below follows a
more detailed description of embodiments of the invention cited as
examples.
[0024] In the drawings:
[0025] FIG. 1 is a schematic view of an AM apparatus having a build
tank according to the present invention,
[0026] FIG. 2 is a schematic cut view of one exemplary embodiment
of a telescopic build tank according to the present invention,
[0027] FIG. 3 is a schematic cut view of another embodiment of a
telescopic build tank according to the present invention,
[0028] FIG. 4 is a schematic cut view of a telescopic build tank
according to various embodiments of the present invention,
illustrated in a compressed state as compared to the expanded
states shown in FIGS. 2-3 and 5-6,
[0029] FIG. 5A is an exploded perspective view of a telescopic
build tank according to various embodiments of the present
invention, incorporating one or more interlocking features,
[0030] FIG. 5B is a perspective view of one section of the
telescopic build tank of FIG. 5A,
[0031] FIG. 5C is the perspective view of FIG. 5B, illustrating
relative movement arrows of the another section with the one
section illustrated,
[0032] FIG. 5D is a perspective view of the telescopic build tank
of FIG. 5A, in an expanded state similar to the expanded states
shown in FIGS. 2-3 and 6,
[0033] FIG. 5E is a schematic cut view of the telescopic build tank
of FIG. 5A, in a compressed state similar to the compressed state
shown in FIG. 4,
[0034] FIG. 6A is a schematic view of yet another embodiment of a
telescopic build tank according to the present invention,
emphasizing incorporation of at least one bellows assembly,
[0035] FIG. 6B is a schematic view of yet another embodiment of a
telescopic build tank according to the present invention,
emphasizing incorporation of at least one bellows assembly,
[0036] FIG. 7 is a block diagram of an exemplary system according
to various embodiments,
[0037] FIG. 8 is a schematic block diagram of an exemplary server
according to various embodiments, and
[0038] FIG. 9 is a schematic block diagram of an exemplary mobile
device according to various embodiments.
DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS
[0039] Various embodiments of the present invention will now be
described more fully hereinafter with reference to the accompanying
drawings, in which some, but not all embodiments of the invention
are shown. Indeed, embodiments of the invention may be embodied in
many different forms and should not be construed as limited to the
embodiments set forth herein. Rather, these embodiments are
provided so that this disclosure will satisfy applicable legal
requirements. Unless otherwise defined, all technical and
scientific terms used herein have the same meaning as commonly
known and understood by one of ordinary skill in the art to which
the invention relates. The term "or" is used herein in both the
alternative and conjunctive sense, unless otherwise indicated. Like
numbers refer to like elements throughout.
[0040] Still further, to facilitate the understanding of this
invention, a number of terms are defined below. Terms defined
herein have meanings as commonly understood by a person of ordinary
skill in the areas relevant to the present invention. Terms such as
"a", "an" and "the" are not intended to refer to only a singular
entity, but include the general class of which a specific example
may be used for illustration. The terminology herein is used to
describe specific embodiments of the invention, but their usage
does not delimit the invention, except as outlined in the
claims.
[0041] The term "three-dimensional structures" and the like as used
herein refer generally to intended or actually fabricated
three-dimensional configurations (e.g., of structural material or
materials) that are intended to be used for a particular purpose.
Such structures, etc. may, for example, be designed with the aid of
a three-dimensional CAD system.
[0042] The term "electron beam" as used herein in various
embodiments refers to any charged particle beam. The sources of
charged particle beam can include an electron gun, a linear
accelerator and so on.
[0043] FIG. 1 shows an exemplary AM apparatus 1 with an inventive
build tank 10 for forming a three-dimensional article layer by
layer by successive fusion of selected areas of a powder layers,
which selected areas correspond to successive layers of the
three-dimensional article. The apparatus 1 comprises an outer
casing 3 forming a build chamber 4, and the build tank 10 arranged
inside the casing 3 in the build chamber 4.
[0044] Further, the apparatus 1 comprises a powder hopper 6, a
powder distributor device 7, a powder table 17 and a build table 19
for receiving powder from the powder distributor device 7. The
build table 19 is arranged inside the build tank 10. The build
table 19 has a top surface 73 for receiving powder from the powder
distributor device 7. The top surface 73 of the build table 19 is
preferably flat and horizontal and is faced upwardly in a vertical
direction. In FIG. 1 the build table 19 is having a predetermined
thickness T. In an alternative embodiment the thickness T may be
decreased to zero meaning that the top surface 73 of the build
table 19 is entirely on the same level as a support surface 39.
[0045] A platform device 11 comprises means 50 for movement of the
build table 19 and support surface 39 in a vertical direction up or
down indicated by arrow A in FIG. 1. Such means may for instance be
a servo motor equipped with a gear, adjusting screws, or the like.
The powder distributor device 7 is arranged to lay down a thin
layer of the powder material on a build plate or powder bed in the
build tank 10, i.e., one may start to build on a powder bed
arranged on the build table 19 or directly on a removable build
plate (not shown) which may be in direct contact with its underside
with the build table 19 or there may be a powder layer in between
the build table 19 and the build plate. During a work cycle the
build table 19 will be lowered for maintaining the position of the
top surface of the powder bed relative to the build tank 10 when
adding powder layers to the powder bed.
[0046] The apparatus 1 has an energy beam source 13 arranged for
creating an energy beam. The energy beam is used for melting the
selected areas of the powder. The energy beam is scanned over the
surface of the current powder layer for melting the selected areas.
The selected areas of each layer can be based on a model dividing
the article to be manufactured in successive layers or slices. The
model may be a computer model generated by a CAD (Computer Aided
Design) tool.
[0047] In the example embodiment illustrated in FIG. 1, the energy
beam source is an electron beam source 13. The electron beam source
can be designed in a way well known to the person skilled in the
art. The electron beam source may have an electron gun 14 with an
emitter electrode which is connected to a high voltage circuit and
a current source for accelerating electrons and releasing electrons
from the emitter electrode. These electrons form the electron beam.
The electron beam source has also focusing coils and deflection
coils 15 for directing the electron beam to various positions of
the build layer surface.
[0048] The build chamber 4 can be arranged for maintaining a vacuum
environment by means of a vacuum system, which may comprise a
turbo-molecular pump, a scroll pump, an ion pump and one or more
valves. Such a vacuum system is known to the person skilled in the
art and is not further described or illustrated herein.
[0049] In another embodiment of the apparatus, any other suitable
energy beam source can be used. For example, a laser beam source.
The laser beam source can be designed in a way well known to the
person skilled in the art. The laser beam source may have a laser
emitter for emitting photons. These photons form the laser beam.
The laser beam source has also focusing units and deflection units
for directing the laser beam to various positions of the build
layer surface. The focusing units can comprise lenses and the
deflection units can comprise mirrors.
[0050] The build tank 10 comprises a top segment 12, an
intermediate segment 18, a bottom segment 20, the build table 19
and the support surface 39. The top segment 12 fits inside the
intermediate segment 18 which in turn fits inside the bottom
segment 20 and thereby forming a telescopic build tank 10.
[0051] The top segment 12 has a lower flange 33 which extends
radially outwards and the intermediate segment is having an upper
flange 32 which extends radially inwards. The lower flange 33
extending radially outwards in the top segment 12 and the upper
flange 32 extending radially inwards in the intermediate segment 18
limit the stroke of the telescopically build tank in a downward
direction since an outer dimension of the lower flange 33 is larger
than an inner dimension of the upper flange 32.
[0052] In a similar manner the intermediate segment 18 has a lower
flange 36 which extends radially outwards and the bottom segment 20
is having an upper flange 35 which extends radially inwards. The
lower flange 36 extending radially outwards in the intermediate
segment 18 and the upper flange 35 extending radially inwards in
the bottom segment 20 limit the stroke of the telescopically build
tank in a downward direction since an outer dimension of the lower
flange 36 is larger than an inner dimension of the upper flange
35.
[0053] In FIG. 1 only 3 segments are shown, however instead of just
using one intermediate segment more than one intermediate segment
is also possible if one wants a larger stroke of the build tank,
i.e., one needs to build objects with a larger height.
[0054] Optional flange 31 in the intermediate segment 18 extending
radially outwards may limit the contraction of the telescopically
build tank in an upward direction. The build tank as depicted in
FIG. 1 may be manufactured by additive manufacturing. Alternatively
the flange 31 may have a number of recesses building a pattern
adapted to fit into the flange 34. Assembly may be performed by
aligning the intermediate segment and the bottom segment with each
other so that the flanges may pass each other. By rotating the
intermediate segment and the bottom segment a predetermined angle
relative to each other, the two segments may not pass each
other.
[0055] The support surface 39 may be protruding from the bottom
section of the build table 19. The support surface 39 has the
functionality of pushing the segments 12, 18, 20 in an upward
direction. An optional wall section 37 is extending in an upward
direction from the support surface 39. The wall section 37 and the
support surface 39 is forming a recess prohibiting powder from
falling out from the build tank 10. In an alternative embodiment
the top surface 73 of the build table 19 is at the same level as
the support surface 39. The bottom part of the bottom segment 20
seals to the support surface 39 or the optional wall section 37.
The bottom segment is releasably attached to the support surface 39
and/or the optional wall section 37. The intermediate section and
the top section is not attached to the support surface and/or the
optional wall section 37.
[0056] The build table 19 and support surface 39 may be fixed to
the bottom segment 20, 220. This means that there are no friction
between the inside of the build tank 10 and the build table 19 or
the support surface 39. Since there is always a gap between
adjacent segments in the telescopical build tank 10, which gap may
be chosen to be several mm, there is more or less no mechanical
contacts between individual moving elements in the inventive build
tank but is will nevertheless prohibit powder from falling out from
the build tank. The telescopical build tank 10 with the overlap
between adjacent segments and that the bottom segments is fixed to
the support surface will prohibit powder to escape from the
telescopical build tank 10.
[0057] The bottom segment 20 may be releasably attached to the
build table. The releasably attachment may be in the form of a
bayonet joint or an eccentric latch. The bottom segment 20 may or
may not be equipped with a flange 38. The bayonet joint may be
provided in the wall section 37 and in a part of the bottom segment
20 facing towards the wall section 37.
[0058] In a similar manner the top segment 12 may be releasably
attached to the powder table 17 by means of a bayonet joint or an
eccentric latch. FIGS. 1 and 2 depicts a first example embodiment
of attaching the top segment 12 to the powder table 17. The powder
table 17 may comprise a collar 75 extending in a downward direction
from the powder table and with an inner dimension adapted to fit
inside the top segment 12. On the outside of the collar 75, 275 the
bayonet joint may be arranged. On an inside of the top segment
facing towards the collar 75 a corresponding part of the bayonet
joining may be arranged. Alternatively, a first part of an
eccentric latch is attached to the underside of the powder table 17
and a second part of the eccentric latch is attached to the outside
of the top segment 12.
[0059] The platform device 11 may be releasably attached to the
build table 19 allowing for the build table to move up and down
without risking to lose contact with each other. The releasable
attachment maybe in the form of a bayonet joint or eccentric
latch.
[0060] The telescopic build tank 10 may be made of the same
material as the material for forming the three-dimensional article
inside the telescopic build tank 10. The telescopic build tank may
have a circular cross section, an elliptical cross section a
triangular cross section a rectangular cross section or any
particular shape which is suitable for allowing segments of similar
shape but slightly different dimension to slide into each
other.
[0061] The gap (minimum distance between surfaces moving relative
to each other) between adjacent segments may be in the range of 1-5
mm. The minimum overlap between adjacent segments may be in the
range of a few mm to 20 mm in maximum protracted position. In an
example embodiment the overlap in relation to the gap may be 1:1
for gaps in the range of 0.1-25 mm.
[0062] FIG. 2 depicts another example embodiment of the inventive
telescopic build tank 210. This telescopic build tank 210 comprises
a top segment 212 and a bottom segment 220. In between the top and
bottom segments are arranged a first intermediate segment 214, a
second intermediate segment 216, a third intermediate segment 218
and a fourth intermediate segment 219. Each segment 212, 214, 216,
218, 219, 220 is provided with an upper flange 292, 294, 296, 298,
299, 291 respectively, which extends radially outwards. The top
segment 212 is having the smallest outer dimension and the bottom
segment 220 is having the largest outer dimension. At least one
string or wire 282 is attached between the upper flange 292 of the
top segment 212 and the upper flange 294 of the first intermediate
segment 214. This string or wire is having a length adapted for
prohibiting the top segment 212 and the first intermediate segment
214 to detach from each other. The length of the string or wire is
adapted as a protraction limitation of adjacent segments in the
telescopical build tank 210. When the string or wire 282 is
extended to its full length the top segment 212 is overlapping the
first intermediate segment 214 with a predetermined distance
denoted with O in FIG. 2. In a similar manner at least one string
or wire 284 is attached between the upper flange 294 of the first
intermediate segment 214 and the upper flange 296 of the second
intermediate segment 216. At least one string or wire 286 is
attached between the upper flange 296 of the second intermediate
segment 216 and the upper flange 296 of the third intermediate
segment 218. At least one string or wire 288 is attached between
the upper flange 298 of the third intermediate segment 218 and the
upper flange 299 of the fourth intermediate segment 219. At least
one string or wire 289 is attached between the upper flange 299 of
the fourth intermediate segment 219 and the upper flange 291 of the
bottom segment 220.
[0063] As in the previous example embodiment, the top segment 212
may be releasably attached to the powder table 217. In FIG. 2 the
upper flange 292 is arranged at the underside of the powder table
217. A bayonet joint may be provided at the upper flange 292 and a
surface of the powder table facing towards the upper flange 292.
Alternatively the bayonet flange may be provided at a collar
section 275 extending in a downward direction from the powder table
217. A corresponding part of the bayonet joint may be provided on
the top segment facing towards the collar section 275.
[0064] The overlap denoted by O in FIG. 2 may be in the range of a
few mm to 10 mm. A gap between adjacent segments, for instance a
top segment 212 and a first intermediate segment 214, may be in the
range of a few mm to 10 mm. The gap between adjacent segments may
be equal for all adjacent segments or different for different
adjacent segments in a single telescopical build tank 210. The sum
of all thicknesses of the segments 212, 214, 216, 218, 219 and 220
plus the gap in between the segments is smaller than the recess 239
in the build table 269. The build table 269 may be releasably
attached to the bottom segment 220. This may be in the form of a
bayonet joint provided at an inside portion of a wall section 237
extending in an upward direction. A corresponding part of the
bayonet joint is provided in the bottom segment 220 facing towards
the wall section 237.
[0065] FIG. 3 depicts still another example embodiment of the
telescopical build tank 210. The only difference compared to the
embodiment as shown in FIG. 2 is how the top segment 212 is
attached to the powder table 217 and the attachment of the at least
one string or wire 282 for limiting the stroke of the first
intermediate segment 214. In FIG. 3 the upper flange 292 of the top
segment 212 is arranged on the upper side of the powder table 217.
The flange is so to say hanging on the powder table 217. The powder
table may have a recess with about the same dimension as the flange
292 resulting in a top surface of the powder table 217 and the
flange 292 at the same height. The at least one string or wire 282
for restricting the elongation of the first intermediate segment
214 relative to the top segment 212 is as in FIG. 2 attached to
with a first end to the upper flange of the first intermediate
segment 214. The second end of the at least one string or wire is
attached to the bottom side of the powder table 217. The attachment
of the string at both the first and second ends may be a releasably
attachment. For instance, a slot may be provided for the string in
the flange and powder table. The slot is about the same width as
the string or wire. The string may at its end be provided with an
enlarged portion large enough for not passing through the slot. The
slot may have an opening or entrance for the string and the
enlarged portion of the string, which opening or entrance is
arranged at a position spaced apart from an operating position
where the string or wire is restricting the elongation of the
telescopical build chamber 210.
[0066] FIG. 4 depicts the telescopical build tank 210 in a
compressed state. In FIG. 4 the top surface 213 of the build table
269 is provided at a predetermined distance F from a top surface of
the powder table when in a fully compressed state. The
predetermined distance F may be set at any desirable distance
between 0-100 mm. The at least one string or wires are left out for
clarity reasons only. As can be seen, all bottom portions of the
segments will fit inside the recess 239 between the build table 269
and the wall section 237.
[0067] When the three-dimensional article has been finished, the
cooling time inside the additive manufacturing apparatus may be
decreased if the build table 269 is detached from the build tank
210. When detaching the build table 269 from the build tank 210,
non-sintered powder may fell out of the build tank while the
three-dimensional article may be exposed to cooler ambient
atmosphere compared to the hot powder material.
[0068] The build table 19, 269 is displaceable in an axial
direction A as depicted in FIG. 1. The top surface 73, 213 is faced
upwards for receiving powder material for manufacturing the
three-dimensional article. The shape of the build table 19, 269 may
be suitably adapted to the smallest segment, i.e., the top segment,
of the build tank 210. In the present invention the bottom segment
is sealing powder from falling out of the build tank 210 by means
of flange 239 and/or wall section 237. Powder is prohibited from
falling out between the segments due to a predetermined overlap
between adjacent segments. In the present invention the powder
table 269 is not sealing against the inner wall of the build tank,
i.e., the inner walls of the different segments. This means that
the build table is not in mechanical contact with the inner walls
of the segments.
[0069] In an example embodiment the flanges 292, 294, 296, 298, 299
and 291 and the corresponding segments 212, 214, 216, 218, 219, 220
are made in one piece. Alternatively the flange may be releasable
attached to the segments. The flange and the segment may be made of
the same material or different materials.
[0070] FIGS. 5A-E depict another example embodiment of the
inventive telescopic build tank 310. This telescopic build tank 310
comprises a top segment 312 and a bottom segment 320. In between
the top and bottom segments are arranged a first intermediate
segment 314 and a second intermediate segment 316; additional or
fewer intermediate segments may also be provided, as with other
embodiments described herein. In at least the embodiment
illustrated, each segment 312, 314, 316, 320 may be provided with
an upper flange 392 (for the top segment 312), 394 (for the
remaining segments; see FIG. 5B flange 394 illustrated on
intermediate segment 314), which extend radially outwards. Notably,
the flanges 392 and/or 394 are optional, such that one or both may
not be present in certain embodiments. In those embodiments having
one or both of the upper flanges 392, 394, the same may be
similarly shaped and sized; in still other embodiments--such as
that illustrated, at least the upper flange 392 may be differently
dimensioned (e.g., larger) than the remaining upper flanges 394.
According to various embodiments, the upper flange 392 is shaped
and/or sized so as to facilitate support of the build tank 310
relative to an associated powder table (see powder table 217 of
FIG. 2 for purposes of analogy), while the upper flanges 394 are
shaped and sized--as a non-limiting example--to facilitate nesting
thereof when in the collapsed configuration (see FIG. 5D).
[0071] As in the previous example embodiments, the top segment 312
may be releasably attached to an associated powder table (see
powder table 217 of FIG. 2 for purposes of analogy). In FIG. 2,
also by way of analogy, the upper flange 292 is arranged at the
underside of the powder table 217; the upper flange 392 of the
build tank 310 of FIG. 5A may be similarly positioned and/or
located. A bayonet joint may be provided at the upper flange 392
and a surface of the powder table facing towards the upper flange
392. Alternatively the bayonet flange may be provided at a collar
section (see collar section 275 by way of analogy) extending in a
downward direction from the powder table. A corresponding part of
the bayonet joint may be provided on the top segment facing towards
the collar section.
[0072] Alternatively, the top segment 312 may be attached to an
associated powder table in a manner analogous to that described
with respect to FIG. 3, such that at least a portion thereof is
positioned on an upper side of an associated powder table (see
powder table 217 for purposes of analogy). In these and other
embodiments, the powder table may have a recess with about the same
dimension as the flange 392 resulting in a top surface of the
powder table and the flange being positioned at the same
height.
[0073] As may be seen from a combination of FIGS. 5A-C the segments
312, 314, 316, 320 may be selectively attached to and securely
retained relative to one another via a pin and groove structure.
Due to the structure of the pin and groove assembly, unintentional
separation of the segments relative to one another is prevented.
Specifically, separation (and/or joining) of the segments relative
to one another requires imposed axial rotation of adjacent segments
relative to one another. Telescoping of the build tank 310,
however, is provided via a purely axial translation movement, along
a primary linear channel 338 formed on each segment. As
illustrated, with reference to FIG. 5B in particular, each segment
314, 316, 320 may have a set of three, equally spaced engagement
grooves 336 (comprising a dogleg channel 337 for axial rotation and
a linear channel 338, as detailed further below). Offset radially
from each of the grooves 336 are engagement pins 332, also as will
be described in further detail below. It should be understood,
however, that in certain embodiments, more or less than three
engagement grooves and/or pins may be provided on any particular
segment; still further, dependent upon the number of grooves and/or
pins provided, all need not necessarily be equally spaced or
distributed around a circumference of the particular segment in
question.
[0074] From FIGS. 5A and 5D is may be understood also that each
segment 314, 316, 320 (by way of non-limiting example), may have a
different number of engagement grooves 336. For example, as
illustrated, the segment 314 has three total grooves 336, each
equally spaced around a circumference of the segment. The segment
316 has six total grooves 336, however, provided in pairs of
grooves, with each pair being equally spaced around a circumference
of the segment. Similarly, as illustrated, segment 320 has nine
total grooves 336, provided in sets of three grooves, with each set
being equally spaced around a circumference of the segment. Where
nesting of the segments 314, 316, 320--again by way of non-limiting
example--is provided, each further outward segment in the next must
not only have at least one groove 336 configured to accept a
corresponding pin 332, but also corresponding grooves 336
configured to accept grooves of an adjacently positioned
segment.
[0075] From FIG. 5B, it may be understood that generally the
engagement pin 332 (or set of engagement pins) are provided
substantially adjacent a bottom edge 314B of each of the segments
(as illustrated, segment 314) and on an outer surface of the
primary annular ring 314C defined by the exemplary segment 314.
Although FIG. 5B illustrates in particular segment 314, it should
be understood that any further provided segments for a particular
build tank 310, as described elsewhere herein, may be provided
according to various embodiments with analogous and/or identical
pin and groove structural features. It should be understood that
while differing numbers of pins and/or grooves (i.e., other than
the three each illustrated in FIG. 5B) may be provided, the number
of pins and/or grooves--along with their circumferential placement
on each segment must generally be the same across each of the
segments; otherwise selective engagement would be hampered, in
particular due to differing spacing circumferentially of the pins
and/or grooves.
[0076] Returning now with focus on FIG. 5B, also evident therefrom
is the provided engagement groove 336, which comprises a dogleg
channel 337 and a linear channel 338, respectively. The dogleg
channel 337 has two portions, namely a first portion that extends
from adjacent (or substantially adjacent) a top edge 314A of the
segment 314 opposite the bottom edge 314B described previously
herein to a location intermediate the top and bottom edges 314A,
314B. In various embodiments, the dogleg channel 337 has a second
portion that extends substantially perpendicular to the first
portion. In at least the illustrated embodiment, the dogleg channel
337 is substantially L-shaped; in other embodiments, though, shapes
other than an "L" may be formed by the dogleg channel, provided the
shape is configured to provide pathways of movement for a
corresponding engagement pin 332 in both translational and
rotational manners. In certain embodiments, two pathways of
movement substantially perpendicular to one another should be
provided by the dogleg channel 337, as may be understood also from
FIG. 5C and the rotational-providing directional arrow 342R.
[0077] From FIG. 5B, it should be understood that the dogleg
channel 337, from its beginning at the top edge 314A with an open
end 338A, extends to an intersection point 336A, at which point the
dogleg channel intersects with a linear channel 338 that extends
from the bottom edge 314B to substantially adjacent the top edge
314A, as will be described in further detail below. The
intersection point 336A defines another open end (not numbered
separately) of the dogleg channel 337, permitting an engagement pin
332 located within and travelling along the dogleg channel to move
from the dogleg channel into the linear channel 338. The
intersection point 336A is according to various embodiments located
intermediate a midpoint between the bottom and top edges 314A, B of
the segment 314 and the top edge. In certain embodiments, a
distance is defined by a spacing of the bottom and top edges 314A,
B relative to one another, and the intersection point 336A is
spaced from the top edge 314A no more than 1/2 the defined
distance. In other embodiments, the spacing between the top edge
and the intersection point is between 1/4 and 1/3 of the defined
distance. This configuration provides a relatively short pathway
for the dogleg channel, at least as compared to that of the linear
channel, given the usefulness of the dogleg channel for
specifically intended engagement and disengagement (i.e.,
separation) of the segments relative to one another, as
desired.
[0078] Remaining with FIG. 5B, also illustrated therein is the
linear channel 338 of the engagement groove 336. The linear channel
338 extends from its intersection with the bottom edge 314B of the
segment 314 at an open end 338A of the channel to an opposing and
closed end 338B that is substantially adjacent--but
non-intersecting with--the top edge 314 of the segment. The entire
linear channel 338 extends along a single axis; the single axis is
parallel with, but spaced apart from the first portion of the
dogleg channel 337. Specifically, the spacing between the linear
channel 338 and the first portion of the dogleg channel 337 is
defined by a length of the second portion of the dogleg channel,
namely that extending circumferentially (versus axially) on the
segment 314. Intermediate the opposing ends 338A, 338B of the
linear channel 338, the channel intersects the dogleg channel 337,
specifically at the intersection point 336A, as described
previously herein.
[0079] FIG. 5B also illustrates the manner in which the engagement
groove 336 (comprising the dogleg channel 337 and the linear
channel 338) are inset from an interior surface (not numbered) of
the segment 314. As a result, the engagement groove 336 is offset
(i.e., extends outward from) an exterior surface (not numbered) of
the segment 314 as well. Notably, though, the distance inset (or
offset, depending on how viewed) is less than a distance that the
lip 392 of extends outward radially from the annual ring surface
314C of the segment. Stated otherwise, the lip 392 is the most
outwardly protruding portion of the segment 314.
[0080] Although illustrated in FIGS. 5A-E as being substantially
circular (or circular-truncated) in shape, the engagement pins 332
may be otherwise shaped and/or sized, provided they are able to
smoothly (e.g., with minimal resistance) travel along the various
pathways defined by the dogleg channel 337 and the linear channel
338 of a corresponding engagement groove 336. As illustrated, the
engagement pins 332 protrude also outward from the exterior surface
of the segment 314. Like the engagement groove 336, though, the
pins 332 protrude outwardly a distance less than that which the lip
392 extends. In this manner, the pins 332 and the groove 336 are
correspondingly sized and shaped relative to one another, so as to
facilitate engagement and travel of the pins in the groove and its
respective channels.
[0081] In addition to depth and height correlations between the
pins 332 and the grooves 336, it should also be understood that
generally speaking a width of each groove--including widths of the
respective channels 337, 338--corresponds substantially with a
defined width (or diameter) of an associated pin 332. According to
various embodiments, the grove width(s) are minimally greater than
that of the pin, so as to not impose undue resistance upon travel
and/or movement of the pin along the pathways defined by the
distinct channels and/or groove.
[0082] The pin and groove structure illustrated in FIGS. 5A-E is
configured so as to provide axial translation only during
telescoping of the build tank 310 from respective expanded and
compressed states (see also FIGS. 5C-D). For attachment, with
reference in particular to FIG. 5B, respective engagement pins 332
on one segment should be aligned with the open end 337A of the
dogleg channel 337 on an adjacent segment. Travel of the pin
downward relative to the dogleg channel causes the pin to first
translate and then axially rotate into the intersection point 336A
between the dogleg channel 337 and the linear channel 338. This may
be understood with reference also to the directional arrow 342R of
FIG. 5C. Once so positioned, axial rotation ceases and purely axial
translation of the pin 332 occurs along the linear channel 338, in
either of the directions of travel denoted by the directional
arrows 342T, in FIG. 5C. Travel is restricted at the top edge 314A
of--for example--the illustrated segment 314. While the bottom of
the linear channel 338 is an open end 338A, the pin 332 will not
travel beyond the same due, in part, to the limited travel of the
pin 332 of an adjacent segment abutting simultaneously a respective
closed end 338B of the adjacent segment's linear channel. During
telescoping of the build tank 310 from expanded to compressed
states, as discussed below, travel of the pin--and thus each of the
segments relative to one another and associated components--is
purely translational in nature; no axial rotation of any segment
relative to another occurs, unless such rotation is intentionally
imposed by an external force so as to facilitate separation of the
segments, as detailed below.
[0083] FIGS. 5D and 5E illustrate the telescopic build tank 310 in
expanded and compressed states, respectively. As with the
embodiment of FIG. 4, the top surface of an associated build table
may be provided at a predetermined distance F from a top surface of
an associated powder table when the build tank 310 is in the
compressed state. The predetermined distance F may be set at any
desirable distance between 0-100 mm. It may also be any desirable
distance, greater than 100 mm or otherwise. Travel from the
compressed to the expanded states occurs via movement of the
respective engagement pins 332 along the linear channels 338 of
each of the segments 314, 316, 320. Notably, the closed end 338B at
the respective upper ends of the linear channels 338 provides a
stop for the engagement pins 332 of an adjacent segment. Separation
of the segments 312, 314, 316, 320 relative to one another is thus
only possible via an axial rotation of two adjacent segments
relative to one another at a position intermediate the opposing
ends 338A, 338B of the linear channel 338 of the engagement groove
336. Specifically, separation requires movement of the pin 332 into
the dogleg channel 337 at the intersection point 336A between the
dogleg channel and the linear channel, as may be best understood
with reference to FIG. 5B.
[0084] Additional aspects of the build tank 310 depicted in FIGS.
5A-E may be substantially as described in any of FIGS. 1-4. For
example, a build table 369 (see FIG. 5A) and/or a support surface
(see FIG. 1) may be fixed to the bottom segment 320. As another
example, the build tank 310 may be provided in an environment such
as that described in any of FIGS. 1-4 and/or 6, with means for
movement of an associated build table and support surface in a
vertical direction (see e.g., FIG. 1), powder distributor devices,
powder hoppers, powder tables, and the like, with all (or at least)
part of the same being provided inside a build tank and/or build
chamber, which may be provided under vacuum-like conditions.
[0085] FIG. 6A depicts another example embodiment of the inventive
telescopic build tank 410. This telescopic build tank 410 comprises
a top segment 412 and a bottom segment 420. In between, at least
two intermediate segments 414, 416 are provided. It should be
understood, though, that fewer (as in FIGS. 1-2) or more (as in
FIG. 3) intermediate segments may be provided without departing
from the scope of this embodiment. Still further, although
illustrated without any flanges, it should be understood that any
of the segments 412, 414, 416, 420 of this embodiment may be
provided with flanges analogous to those described elsewhere herein
with reference to any of FIGS. 1-4. Any of the segments may also be
secured relative to one another as described elsewhere herein with
reference to the segments 312, 314, 316, 320 of FIGS. 5A-E. It
should also be understood that the segments 412, 414, 416, 420 may
be configured in a fashion analogous to the segments described
previously herein with respect to any of FIGS. 1-5E, with regard to
any aspect or combination of aspects thereof. In other embodiments,
though, it should be understood that the segments 412, 414, 416,
420 may be configured different from those segments described in
FIGS. 1-5E.
[0086] Also illustrated in FIG. 6A is a build table 469, which may
in certain embodiments be releasably attached to the bottom segment
420, in a manner analogous to--as a non-limiting example--that
described elsewhere herein with respect to build table 269 and
bottom segment 220. The bottom segment 420 may additionally or
alternatively be selectively secured to the bottom segment 420 in a
fashion analogous to that described previously herein with
reference to the bottom segment 320 and build table 369. In certain
embodiments, the build table 469 may be integral with the bottom
segment 420, as may be desirable. The embodiment of FIG. 6A also
includes a powder table 417, which may be attached to at least the
top segment 412 in a manner analogous to any of the means described
elsewhere herein with respect to the embodiments of FIGS. 1-5E.
Likewise provided in the embodiment of FIG. 6A is a chamber floor
403, which forms a portion of the larger build chamber (not
numbered) that is present in this embodiment in a fashion analogous
to the build chamber 4 of FIG. 1 (as a non-limiting example), but
for the provision of a gap between two portions of the chamber
floor 403, via which atmospheric 1001 exposure is provided to
certain components (i.e., shaft 460 or analogous means for raising
and/or lowering the build table 469 in a vertical direction), as
detailed further below.
[0087] Also illustrated in FIG. 6A is a shaft 460 or analogous
means for raising and/or lowering the build table 469 in a vertical
direction. The shaft 460 may be configured substantially the same
as means 50 for movement provided in and described relative to the
embodiment of FIG. 1. Although not illustrated specifically in FIG.
6A, the shaft 460 may be coupled to a servo motor, equipped with a
gear, adjusting screw, or the like, such that the build table may
be selectively--and precisely--moved during a build, as powder
layers are distributed. As described relative to the embodiment of
FIG. 1, it should be understood that during a work cycle the build
table 469 may be lowered for maintaining a position of the top
surface of the powder bed relative to the build tank, when adding
powder layers to the powder bed. The shaft 460 may be utilized,
along with bellows assembly 450 (discussed further below) with any
of the embodiments of FIGS. 1-5E.
[0088] FIG. 6A also illustrates according to certain embodiments a
bellows assembly 450 positioned adjacent to and/or substantially
enclosing the shaft 460 and/or any means for raising/lowering the
build table associated therewith. As may be understood from FIG.
6A, the bellows assembly 450 is operatively coupled to both the
build table 469 and two portions of the build chamber, namely the
chamber floor portions 403. With provision of a gap between the two
floor portions 403, an area surrounding the shaft 460 is at
atmospheric state 1001, as compared to the vacuum-induced state
1002 provided within the build chamber and on opposing sides of the
bellows assembly 450. Advantageously, with the shaft 460 provided
at atmospheric state 1001, easy access is permitted to the bottom
of the build table, even during conducting of a build with
layer-by-layer powder distribution. Still further, beyond
accessibility to the shaft 460 for maintenance (i.e., greasing or
otherwise) even during operation, provision thereof at atmospheric
state 1001 facilitates cooling of the shaft, thus minimizing wear
incurred. Contact of any powder with the shaft is also minimized
and/or substantially eliminated.
[0089] In certain embodiments, the bellows assembly 450 of FIG. 6A
may be a vacuum bellow and/or a bellow-like structure configured to
translate (e.g., via an actuator) so as to move with the build
table 469 in a desirable manner, in particular as the build table
is raised or lowered during a build operation. For example, as the
shaft and thus the build table 469 move back and forth in a manner
analogous to that described relative to FIG. 1, the bellows
assembly 450 may be configured to correspondingly expand and
contract, such that a vacuum is maintained internal to the build
chamber. Still further, in certain embodiments, the bellows
assembly 450 may provide additional (or alternative) support for
the build table 469, thereby simplifying construction of the build
chamber.
[0090] In certain embodiments, it may be understood from FIG. 6A
that, as the bellows assembly 450 expands or contracts, due to
movement of the build table 469, the associated telescopic build
tank 410 will undergo corresponding movement. Specifically, as the
build table moves toward the powder table 417, the telescopic build
tank 410 will collapse (i.e., as illustrated in FIG. 4, by way of
non-limiting example), as described elsewhere herein.
[0091] In certain embodiments, the bellows assembly 450 may be
constructed of a metal material. This enables a seal to be formed
inherently around and by the bellows, thus making the interface
more or less insensitive to temperature. At a minimum, the bellows
assembly 450 is constructed of a material (even if non-metallic in
nature) that resists higher temperatures than would a conventional
vacuum seal, as oftentimes utilized with conventional process
chamber walls and the like.
[0092] According to various embodiments including bellows assembly
(450), a further and exemplary non-limiting advantage provided is
that the passage(s) through the build chamber (i.e., for receipt of
support structure component(s), guide assembly components, or the
like) need not be sealed with the degree of precision described
elsewhere herein, for example with reference to the embodiments of
FIGS. 1-3. This is because the bellows assembly itself functions as
a seal, providing a vacuum environment within its enclosed volume,
which includes the support structure component(s) and/or any
associated tubes or internal channels for distribution/transport of
the cooling media. As a result, in certain embodiments, the support
structure component(s) and or guide component(s) may pass through
large holes in the process chamber. Integral sealing around those
holes may be eliminated.
[0093] FIG. 6B depicts another example embodiment of the inventive
telescopic build tank 510. This telescopic build tank 510 comprises
a top segment 512 and a bottom segment 520. In between, at least
two intermediate segments 514, 516 are provided. It should be
understood, though, that fewer (as in FIG. 2) or more (as in FIG.
3) intermediate segments may be provided without departing from the
scope of this embodiment. Still further, although illustrated
without any flanges, it should be understood that any of the
segments 512, 514, 516, 520 of this embodiment may be provided with
flanges analogous to those described elsewhere herein with
reference to any of FIGS. 2-5E. It should also be understood that
the segments 512, 514, 516, 520 may be configured in a fashion
analogous to the segments described previously herein with respect
to any of FIGS. 1-5E, with regard to any aspect thereof. In other
embodiments, though, it should be understood that the segments 512,
514, 516, 520 may be configured different from those segments
described in FIGS. 1-5E.
[0094] Also illustrated in FIG. 6B is a build table 569, which may
in certain embodiments be releasably attached to the bottom segment
520, in a manner analogous to that described elsewhere herein with
respect to build table 269 and bottom segment 220. In certain
embodiments, the build table 569 may be integral with the bottom
segment 520, as may be desirable. The embodiment of FIG. 6B also
includes a powder table 3, which may be attached to at least the
top segment 512 in a manner analogous to any of the means described
elsewhere herein with respect to the embodiments of FIGS. 1-4.
Likewise provided in the embodiment of FIG. 6B is a chamber floor
503, which forms a portion of the larger build chamber (not
numbered) that is present in this embodiment in a fashion analogous
to the build chamber 4 of FIG. 1 (as a non-limiting example), but
for the provision of a hole or opening in the portion of the
chamber floor 503, via which atmospheric 1001 exposure is provided
to certain components (i.e., linear guide 560, ball screw mechanism
550, and/or analogous means for raising and/or lowering the powder
table 517 and/or the build table 569 in a vertical direction), as
detailed further below.
[0095] Also illustrated in FIG. 6B is a guide assembly that
generally includes a linear guide 560 and a ball screw mechanism
550. The linear guide 560 and the ball screw mechanism 550 are,
according to various embodiments, operatively connected to and
supported by the powder table 517 and an extension 570 of the build
table 569. The extension 570 of the build table 569 is preferably,
in certain embodiments, an integral part of the build table; in
other embodiments, however, it may be a separate component
operatively attached to and thus movable in connection with
movement of the build table (or vice versa). For example, as the
linear guide 560 and/or the ball screw mechanism 550 are actuated
(e.g., selectively by a user during the course of a build), the
extension 570 may translate along an axis defined by the linear
guide 360 and/or the ball screw mechanism 550, such that the
extension 570 is raised or lowered in a vertical direction (i.e.,
closer to or further away from the powder table 517. Corresponding
movement of the build table 569 occurs, due to the
interconnectivity (or integral bond) between the extension 570 and
the build table 569. As actuation of the linear guide 560 and/or
the ball screw mechanism 550 occurs toward the powder table, as
described elsewhere herein, the telescopic build tank 510 will
likewise collapse (i.e., as illustrated in FIG. 4, by way of
non-limiting example).
[0096] The linear guide 560 and/or the ball screw mechanism 550 may
each (or both) be provided with an interface element 562, 552,
respectively, which element may be configured to define an
operative seal as between a top and a bottom surface of the
extension 570 of the build table 569. In these embodiments, first
portions 550a, 560a of the ball screw mechanism and the linear
guide, respectively, may extend from the top surface of the
extension 570 and toward the powder table 517, while second
portions 550b, 560b thereof extend from the bottom surface of the
extension. In certain embodiments, the second portions 550b, 560b
are thus provided at an atmospheric state 1001, as compared to a
vacuum state 1002 provided elsewhere within the build chamber.
[0097] Provided in conjunction with the linear guide 560 and/or the
ball screw mechanism 550 of FIG. 6B may be a pair of bellows
assemblies 540, 545. In certain embodiments, the bellows assembly
545 may be positioned adjacent to and/or substantially enclosing
the second portions 560b, 550b of the linear guide 560 and/or the
ball screw mechanism 550. As a result as may be understood from
FIG. 6B, the bellows assembly 545 is operatively coupled to both
the extension 570 of the build table and a portion of the build
chamber, namely a chamber floor portion 503 adjacent to which an
opening or hole is provided. With provision of a hole, opening, or
gap in the floor portion 303, an area surrounding the second
portions 560b, 550b is at atmospheric state 1001, as compared to
the vacuum-induced state 1002 provided elsewhere within the build
chamber and on opposing sides of the bellows assembly 545.
[0098] Advantageously, with the second portions 560b, 550b provided
at atmospheric state 1001, easy access is permitted to the bottom
of at least the extension of the build table, even during
conducting of a build with layer-by-layer powder distribution.
Still further, beyond accessibility to the second portions 560b,
550b for maintenance (i.e., greasing or otherwise) even during
operation, provision thereof at atmospheric state 1001 facilitates
cooling of the portions, thus minimizing wear incurred there-upon.
Contact of any powder with the portions is also minimized and/or
substantially eliminated.
[0099] In certain embodiments, the bellows assembly 545 of FIG. 6B
may be a vacuum bellow and/or a bellow-like structure configured to
translate (e.g., via an actuator) so as to move with the build
table 569 (or the extension 570 thereof) in a desirable manner, in
particular as the build table is raised or lowered during a build
operation. For example, as the linear guide 560 and/or the ball
screw mechanism 550 and thus the build table 569 move back and
forth in a manner analogous to that described relative to FIG. 1,
the bellows assembly 545 may be configured to correspondingly
expand and contract, such that a vacuum is maintained internal to
the build chamber. Still further, in certain embodiments, the
bellows assembly 545 may provide additional (or alternative)
support for the build table 569 (i.e., via the extension 570),
thereby simplifying construction of the build chamber.
[0100] In certain embodiments, it may be understood from FIG. 6B
that, as the bellows assembly 545 expands or contracts, due to
movement of the build table 569, the associated telescopic build
tank 510 will undergo corresponding movement. Specifically, as the
build table moves toward the powder table 517, the telescopic build
tank 510 will collapse (i.e., as illustrated in FIG. 4, by way of
non-limiting example), as described elsewhere herein.
[0101] In certain embodiments, the bellows assembly 545 may be
constructed of a metal material. This enables a seal to be formed
inherently around and by the bellows, thus making the interface
more or less insensitive to temperature. At a minimum, the bellows
assembly 545 is constructed of a material (even if non-metallic in
nature) that resists higher temperatures than would a conventional
vacuum seal, as oftentimes utilized with conventional process
chamber walls and the like.
[0102] FIG. 6B also illustrates a second in the pair of bellows
assemblies, namely bellows assembly 540. This bellows assembly 540
is positioned adjacent to and/or substantially surrounding the
first portions 550a, 560a of the linear guide and the ball screw
mechanism, above the extension 570 of the build table 569. As may
be understood from FIG. 6B, the bellows assembly 540 is operatively
coupled to both the powder table 517 and the extension 570 of the
build table 569. Specifically, the bellows assembly 540 is coupled
to a top of the extension 570, such that it provides an enclosure
of the linear guide 560 and the ball screw mechanism 550
intermediate the extension 570 and the powder table 517.
[0103] In certain embodiments, via utilization of the bellows
assembly 540, the first portions 550a, 560a may likewise (i.e.,
analogous to the area adjacent bellows assembly 545) be provided at
atmospheric state 1001. In certain other embodiments, however, via
utilization of the bellows assembly 540, the first portions 550a,
560a may be provided at a state intermediate the provided vacuum
state 1002 and atmospheric 1001. In these and other embodiments, a
cooling media, which could be in the form of a cooling gas or a
cooling liquid, may be transported and/or otherwise provided within
the enclosure defined by bellows assembly 545. In this manner, a
separate vacuum internal to the bellows assembly 545 may be
provided, as compared to any vacuum provided generally within the
build chamber.
[0104] It should be understood that the cooling media may be
injected within bellows assembly 545 via one or more cooling media
inlets (not illustrated) adjacent to or integral with the interface
elements 552, 562 described elsewhere herein. A cooling media tank
(also not illustrated) may also be provided. So enclosed by the
bellows assembly 545, the first portions 550a, 560a of the linear
guide and the ball screw assembly are provided with an environment
that facilitates cooling thereof, thus minimizing wear incurred
thereon. Contact of any powder with these components is also
minimized and/or substantially eliminated.
[0105] In certain embodiments, the bellows assembly 540 of FIG. 6B
may be a vacuum bellow and/or a bellow-like structure configured to
translate (e.g., via an actuator) so as to move with the build
table 569 in a desirable manner, in particular as the build table
is raised or lowered during a build operation. For example, as the
guide assembly (linear guide 560 and ball screw mechanism 550) and
thus the build table 569 move back and forth in a manner analogous
to that described relative to FIG. 1, the bellows assembly 540 may
be configured to correspondingly expand and contract, such that a
vacuum is maintained internal to the build chamber. Still further,
in certain embodiments, the bellows assembly 540 may provide
additional (or alternative) support for the build table 569 and/or
the powder table 517, thereby simplifying construction of the build
chamber.
[0106] In certain embodiments, it may be understood from FIG. 6B
that, as the bellows assembly 540 expands or contracts, due to
movement of the build table 569 (via the extension 570 thereof),
the associated telescopic build tank 510 will undergo corresponding
movement. Specifically, as the build table moves toward the powder
table 517, the telescopic build tank 510 will collapse (i.e., as
illustrated in FIGS. 4 and/or 5E, by way of non-limiting example),
as described elsewhere herein.
[0107] In certain embodiments, the bellows assembly 540 may also be
constructed of a metal material. This enables a seal to be formed
inherently around and by the bellows, thus making the interface
more or less insensitive to temperature. At a minimum, the bellows
assembly 540 is constructed of a material (even if non-metallic in
nature) that resists higher temperatures than would a conventional
vacuum seal, as oftentimes utilized with conventional process
chamber walls and the like. Also, it should be understood that an
expansion coefficient of the bellows assembly 540 may be (as
illustrated in FIG. 6B) different from that of bellows assembly
545. In other embodiments, though, the expansion coefficient of
each may be substantially the same, as may be desirable. It should
also be understood that outside the bellows assemblies 540, 545, a
vacuum state is provided; inside the bellows assemblies 540, 545,
however, a non-vacuum state is provided. In certain embodiments,
the area inside one or both of the bellows assemblies 540, 545 is
provided at atmospheric state or filled with ambient air.
[0108] In another aspect of the invention it is provided a program
element configured and arranged when executed on a computer to
implement a method for forming a three-dimensional article
utilizing the build chamber as detailed elsewhere herein. The
program may be installed in a computer readable storage medium. The
computer readable storage medium may be a distinct control unit.
The computer readable storage medium and the program element, which
may comprise computer-readable program code portions embodied
therein, may further be contained within a non-transitory computer
program product. Further details regarding these features and
configurations are provided, in turn, below.
[0109] As mentioned, various embodiments of the present invention
may be implemented in various ways, including as non-transitory
computer program products. A computer program product may include a
non-transitory computer-readable storage medium storing
applications, programs, program modules, scripts, source code,
program code, object code, byte code, compiled code, interpreted
code, machine code, executable instructions, and/or the like (also
referred to herein as executable instructions, instructions for
execution, program code, and/or similar terms used herein
interchangeably). Such non-transitory computer-readable storage
media include all computer-readable media (including volatile and
non-volatile media).
[0110] In one embodiment, a non-volatile computer-readable storage
medium may include a floppy disk, flexible disk, hard disk,
solid-state storage (SSS) (e.g., a solid state drive (SSD), solid
state card (SSC), solid state module (SSM)), enterprise flash
drive, magnetic tape, or any other non-transitory magnetic medium,
and/or the like. A non-volatile computer-readable storage medium
may also include a punch card, paper tape, optical mark sheet (or
any other physical medium with patterns of holes or other optically
recognizable indicia), compact disc read only memory (CD-ROM),
compact disc compact disc-rewritable (CD-RW), digital versatile
disc (DVD), Blu-ray disc (BD), any other non-transitory optical
medium, and/or the like. Such a non-volatile computer-readable
storage medium may also include read-only memory (ROM),
programmable read-only memory (PROM), erasable programmable
read-only memory (EPROM), electrically erasable programmable
read-only memory (EEPROM), flash memory (e.g., Serial, NAND, NOR,
and/or the like), multimedia memory cards (MMC), secure digital
(SD) memory cards, SmartMedia cards, CompactFlash (CF) cards,
Memory Sticks, and/or the like. Further, a non-volatile
computer-readable storage medium may also include
conductive-bridging random access memory (CBRAM), phase-change
random access memory (PRAM), ferroelectric random-access memory
(FeRAM), non-volatile random-access memory (NVRAM),
magnetoresistive random-access memory (MRAM), resistive
random-access memory (RRAM), Silicon-Oxide-Nitride-Oxide-Silicon
memory (SONOS), floating junction gate random access memory (FJG
RAM), Millipede memory, racetrack memory, and/or the like.
[0111] In one embodiment, a volatile computer-readable storage
medium may include random access memory (RAM), dynamic random
access memory (DRAM), static random access memory (SRAM), fast page
mode dynamic random access memory (FPM DRAM), extended data-out
dynamic random access memory (EDO DRAM), synchronous dynamic random
access memory (SDRAM), double data rate synchronous dynamic random
access memory (DDR SDRAM), double data rate type two synchronous
dynamic random access memory (DDR2 SDRAM), double data rate type
three synchronous dynamic random access memory (DDR3 SDRAM), Rambus
dynamic random access memory (RDRAM), Twin Transistor RAM (TTRAM),
Thyristor RAM (T-RAM), Zero-capacitor (Z-RAM), Rambus in-line
memory module (RIMM), dual in-line memory module (DIMM), single
in-line memory module (SIMM), video random access memory VRAM,
cache memory (including various levels), flash memory, register
memory, and/or the like. It will be appreciated that where
embodiments are described to use a computer-readable storage
medium, other types of computer-readable storage media may be
substituted for or used in addition to the computer-readable
storage media described above.
[0112] As should be appreciated, various embodiments of the present
invention may also be implemented as methods, apparatus, systems,
computing devices, computing entities, and/or the like, as have
been described elsewhere herein. As such, embodiments of the
present invention may take the form of an apparatus, system,
computing device, computing entity, and/or the like executing
instructions stored on a computer-readable storage medium to
perform certain steps or operations. However, embodiments of the
present invention may also take the form of an entirely hardware
embodiment performing certain steps or operations.
[0113] Various embodiments are described below with reference to
block diagrams and flowchart illustrations of apparatuses, methods,
systems, and computer program products. It should be understood
that each block of any of the block diagrams and flowchart
illustrations, respectively, may be implemented in part by computer
program instructions, e.g., as logical steps or operations
executing on a processor in a computing system. These computer
program instructions may be loaded onto a computer, such as a
special purpose computer or other programmable data processing
apparatus to produce a specifically-configured machine, such that
the instructions which execute on the computer or other
programmable data processing apparatus implement the functions
specified in the flowchart block or blocks.
[0114] These computer program instructions may also be stored in a
computer-readable memory that can direct a computer or other
programmable data processing apparatus to function in a particular
manner, such that the instructions stored in the computer-readable
memory produce an article of manufacture including
computer-readable instructions for implementing the functionality
specified in the flowchart block or blocks. The computer program
instructions may also be loaded onto a computer or other
programmable data processing apparatus to cause a series of
operational steps to be performed on the computer or other
programmable apparatus to produce a computer-implemented process
such that the instructions that execute on the computer or other
programmable apparatus provide operations for implementing the
functions specified in the flowchart block or blocks.
[0115] Accordingly, blocks of the block diagrams and flowchart
illustrations support various combinations for performing the
specified functions, combinations of operations for performing the
specified functions and program instructions for performing the
specified functions. It should also be understood that each block
of the block diagrams and flowchart illustrations, and combinations
of blocks in the block diagrams and flowchart illustrations, could
be implemented by special purpose hardware-based computer systems
that perform the specified functions or operations, or combinations
of special purpose hardware and computer instructions.
[0116] FIG. 7 is a block diagram of an exemplary system 1320 that
can be used in conjunction with various embodiments of the present
invention. In at least the illustrated embodiment, the system 1320
may include one or more central computing devices 1110, one or more
distributed computing devices 1120, and one or more distributed
handheld or mobile devices 1300, all configured in communication
with a central server 1200 (or control unit) via one or more
networks 1130. While FIG. 7 illustrates the various system entities
as separate, standalone entities, the various embodiments are not
limited to this particular architecture.
[0117] According to various embodiments of the present invention,
the one or more networks 1130 may be capable of supporting
communication in accordance with any one or more of a number of
second-generation (2G), 2.5G, third-generation (3G), and/or
fourth-generation (4G) mobile communication protocols, or the like.
More particularly, the one or more networks 130 may be capable of
supporting communication in accordance with 2G wireless
communication protocols IS-136 (TDMA), GSM, and IS-95 (CDMA). Also,
for example, the one or more networks 1130 may be capable of
supporting communication in accordance with 2.5G wireless
communication protocols GPRS, Enhanced Data GSM Environment (EDGE),
or the like. In addition, for example, the one or more networks 130
may be capable of supporting communication in accordance with 3G
wireless communication protocols such as Universal Mobile Telephone
System (UMTS) network employing Wideband Code Division Multiple
Access (WCDMA) radio access technology. Some narrow-band AMPS
(NAMPS), as well as TACS, network(s) may also benefit from
embodiments of the present invention, as should dual or higher mode
mobile stations (e.g., digital/analog or TDMA/CDMA/analog phones).
As yet another example, each of the components of the system 1320
may be configured to communicate with one another in accordance
with techniques such as, for example, radio frequency (RF),
Bluetooth.TM., infrared (IrDA), or any of a number of different
wired or wireless networking techniques, including a wired or
wireless Personal Area Network ("PAN"), Local Area Network ("LAN"),
Metropolitan Area Network ("MAN"), Wide Area Network ("WAN"), or
the like.
[0118] Although the device(s) 1110-3100 are illustrated in FIG. 7
as communicating with one another over the same network 1130, these
devices may likewise communicate over multiple, separate
networks.
[0119] According to one embodiment, in addition to receiving data
from the server 1200, the distributed devices 1110, 1120, and/or
1300 may be further configured to collect and transmit data on
their own. In various embodiments, the devices 1110, 1120, and/or
1300 may be capable of receiving data via one or more input units
or devices, such as a keypad, touchpad, barcode scanner, radio
frequency identification (RFID) reader, interface card (e.g.,
modem, etc.) or receiver. The devices 1110, 1120, and/or 1300 may
further be capable of storing data to one or more volatile or
non-volatile memory modules, and outputting the data via one or
more output units or devices, for example, by displaying data to
the user operating the device, or by transmitting data, for example
over the one or more networks 1130.
[0120] In various embodiments, the server 1200 includes various
systems for performing one or more functions in accordance with
various embodiments of the present invention, including those more
particularly shown and described herein. It should be understood,
however, that the server 1200 might include a variety of
alternative devices for performing one or more like functions,
without departing from the spirit and scope of the present
invention. For example, at least a portion of the server 1200, in
certain embodiments, may be located on the distributed device(s)
1110, 1120, and/or the handheld or mobile device(s) 1300, as may be
desirable for particular applications. As will be described in
further detail below, in at least one embodiment, the handheld or
mobile device(s) 1300 may contain one or more mobile applications
1330 which may be configured so as to provide a user interface for
communication with the server 1200, all as will be likewise
described in further detail below.
[0121] FIG. 8 is a schematic diagram of the server 1200 according
to various embodiments. The server 1 200 includes a processor 1230
that communicates with other elements within the server via a
system interface or bus 1235. Also included in the server 1200 is a
display/input device 1250 for receiving and displaying data. This
display/input device 1250 may be, for example, a keyboard or
pointing device that is used in combination with a monitor. The
server 1200 further includes memory 1220, which typically includes
both read only memory (ROM) 1226 and random access memory (RAM)
1222. The server's ROM 1226 is used to store a basic input/output
system 1224 (BIOS), containing the basic routines that help to
transfer information between elements within the server 1200.
Various ROM and RAM configurations have been previously described
herein.
[0122] In addition, the server 1200 includes at least one storage
device or program storage 1210, such as a hard disk drive, a floppy
disk drive, a CD Rom drive, or optical disk drive, for storing
information on various computer-readable media, such as a hard
disk, a removable magnetic disk, or a CD-ROM disk. As will be
appreciated by one of ordinary skill in the art, each of these
storage devices 1210 are connected to the system bus 1235 by an
appropriate interface. The storage devices 1210 and their
associated computer-readable media provide nonvolatile storage for
a personal computer. As will be appreciated by one of ordinary
skill in the art, the computer-readable media described above could
be replaced by any other type of computer-readable media known in
the art. Such media include, for example, magnetic cassettes, flash
memory cards, digital video disks, and Bernoulli cartridges.
[0123] Although not shown, according to an embodiment, the storage
device 1210 and/or memory of the server 1200 may further provide
the functions of a data storage device, which may store historical
and/or current delivery data and delivery conditions that may be
accessed by the server 1200. In this regard, the storage device
1210 may comprise one or more databases. The term "database" refers
to a structured collection of records or data that is stored in a
computer system, such as via a relational database, hierarchical
database, or network database and as such, should not be construed
in a limiting fashion.
[0124] A number of program modules (e.g., exemplary modules
1400-1700) comprising, for example, one or more computer-readable
program code portions executable by the processor 1230, may be
stored by the various storage devices 1210 and within RAM 1222.
Such program modules may also include an operating system 1280. In
these and other embodiments, the various modules 1400, 1500, 1600,
1700 control certain aspects of the operation of the server 1200
with the assistance of the processor 1230 and operating system
1280. In still other embodiments, it should be understood that one
or more additional and/or alternative modules may also be provided,
without departing from the scope and nature of the present
invention.
[0125] In various embodiments, the program modules 1400, 1500,
1600, 1700 are executed by the server 1200 and are configured to
generate one or more graphical user interfaces, reports,
instructions, and/or notifications/alerts, all accessible and/or
transmittable to various users of the system 1320. In certain
embodiments, the user interfaces, reports, instructions, and/or
notifications/alerts may be accessible via one or more networks
1130, which may include the Internet or other feasible
communications network, as previously discussed.
[0126] In various embodiments, it should also be understood that
one or more of the modules 1400, 1500, 1600, 1700 may be
alternatively and/or additionally (e.g., in duplicate) stored
locally on one or more of the devices 1110, 1120, and/or 1300 and
may be executed by one or more processors of the same. According to
various embodiments, the modules 1400, 1500, 1600, 1700 may send
data to, receive data from, and utilize data contained in one or
more databases, which may be comprised of one or more separate,
linked and/or networked databases.
[0127] Also located within the server 1200 is a network interface
1260 for interfacing and communicating with other elements of the
one or more networks 1130. It will be appreciated by one of
ordinary skill in the art that one or more of the server 1200
components may be located geographically remotely from other server
components. Furthermore, one or more of the server 1200 components
may be combined, and/or additional components performing functions
described herein may also be included in the server.
[0128] While the foregoing describes a single processor 1230, as
one of ordinary skill in the art will recognize, the server 1200
may comprise multiple processors operating in conjunction with one
another to perform the functionality described herein. In addition
to the memory 1220, the processor 1230 can also be connected to at
least one interface or other means for displaying, transmitting
and/or receiving data, content or the like. In this regard, the
interface(s) can include at least one communication interface or
other means for transmitting and/or receiving data, content or the
like, as well as at least one user interface that can include a
display and/or a user input interface, as will be described in
further detail below. The user input interface, in turn, can
comprise any of a number of devices allowing the entity to receive
data from a user, such as a keypad, a touch display, a joystick or
other input device.
[0129] Still further, while reference is made to the "server" 1200,
as one of ordinary skill in the art will recognize, embodiments of
the present invention are not limited to traditionally defined
server architectures. Still further, the system of embodiments of
the present invention is not limited to a single server, or similar
network entity or mainframe computer system. Other similar
architectures including one or more network entities operating in
conjunction with one another to provide the functionality described
herein may likewise be used without departing from the spirit and
scope of embodiments of the present invention. For example, a mesh
network of two or more personal computers (PCs), similar electronic
devices, or handheld portable devices, collaborating with one
another to provide the functionality described herein in
association with the server 200 may likewise be used without
departing from the spirit and scope of embodiments of the present
invention.
[0130] According to various embodiments, many individual steps of a
process may or may not be carried out utilizing the computer
systems and/or servers described herein, and the degree of computer
implementation may vary, as may be desirable and/or beneficial for
one or more particular applications.
[0131] FIG. 9 provides an illustrative schematic representative of
a mobile device 1300 that can be used in conjunction with various
embodiments of the present invention. Mobile devices 1300 can be
operated by various parties. As shown in FIG. 9, a mobile device
1300 may include an antenna 1312, a transmitter 1304 (e.g., radio),
a receiver 1306 (e.g., radio), and a processing element 1308 that
provides signals to and receives signals from the transmitter 1304
and receiver 1306, respectively.
[0132] The signals provided to and received from the transmitter
1304 and the receiver 1306, respectively, may include signaling
data in accordance with an air interface standard of applicable
wireless systems to communicate with various entities, such as the
server 1200, the distributed devices 1110, 1120, and/or the like.
In this regard, the mobile device 1300 may be capable of operating
with one or more air interface standards, communication protocols,
modulation types, and access types. More particularly, the mobile
device 1300 may operate in accordance with any of a number of
wireless communication standards and protocols. In a particular
embodiment, the mobile device 1300 may operate in accordance with
multiple wireless communication standards and protocols, such as
GPRS, UMTS, CDMA2000, 1.times.RTT, WCDMA, TD-SCDMA, LTE, E-UTRAN,
EVDO, HSPA, HSDPA, Wi-Fi, WiMAX, UWB, IR protocols, Bluetooth
protocols, USB protocols, and/or any other wireless protocol.
[0133] Via these communication standards and protocols, the mobile
device 1300 may according to various embodiments communicate with
various other entities using concepts such as Unstructured
Supplementary Service data (USSD), Short Message Service (SMS),
Multimedia Messaging Service (MMS), Dual-Tone Multi-Frequency
Signaling (DTMF), and/or Subscriber Identity Module Dialer (SIM
dialer). The mobile device 300 can also download changes, add-ons,
and updates, for instance, to its firmware, software (e.g.,
including executable instructions, applications, program modules),
and operating system.
[0134] According to one embodiment, the mobile device 1300 may
include a location determining device and/or functionality. For
example, the mobile device 1300 may include a GPS module adapted to
acquire, for example, latitude, longitude, altitude, geocode,
course, and/or speed data. In one embodiment, the GPS module
acquires data, sometimes known as ephemeris data, by identifying
the number of satellites in view and the relative positions of
those satellites.
[0135] The mobile device 1300 may also comprise a user interface
(that can include a display 1316 coupled to a processing element
1308) and/or a user input interface (coupled to a processing
element 1308). The user input interface can comprise any of a
number of devices allowing the mobile device 300 to receive data,
such as a keypad 1318 (hard or soft), a touch display, voice or
motion interfaces, or other input device. In embodiments including
a keypad 1318, the keypad can include (or cause display of) the
conventional numeric (0-9) and related keys (#, *), and other keys
used for operating the mobile device 1300 and may include a full
set of alphabetic keys or set of keys that may be activated to
provide a full set of alphanumeric keys. In addition to providing
input, the user input interface can be used, for example, to
activate or deactivate certain functions, such as screen savers
and/or sleep modes.
[0136] The mobile device 1300 can also include volatile storage or
memory 1322 and/or non-volatile storage or memory 1324, which can
be embedded and/or may be removable. For example, the non-volatile
memory may be ROM, PROM, EPROM, EEPROM, flash memory, MMCs, SD
memory cards, Memory Sticks, CBRAM, PRAM, FeRAM, RRAM, SONOS,
racetrack memory, and/or the like. The volatile memory may be RAM,
DRAM, SRAM, FPM DRAM, EDO DRAM, SDRAM, DDR SDRAM, DDR2 SDRAM, DDR3
SDRAM, RDRAM, RIMM, DIMM, SIMM, VRAM, cache memory, register
memory, and/or the like. The volatile and non-volatile storage or
memory can store databases, database instances, database mapping
systems, data, applications, programs, program modules, scripts,
source code, object code, byte code, compiled code, interpreted
code, machine code, executable instructions, and/or the like to
implement the functions of the mobile device 1300.
[0137] The mobile device 1300 may also include one or more of a
camera 1326 and a mobile application 1330. The camera 1326 may be
configured according to various embodiments as an additional and/or
alternative data collection feature, whereby one or more items may
be read, stored, and/or transmitted by the mobile device 1300 via
the camera. The mobile application 1330 may further provide a
feature via which various tasks may be performed with the mobile
device 1300. Various configurations may be provided, as may be
desirable for one or more users of the mobile device 1300 and the
system 1320 as a whole.
[0138] The invention is not limited to the above-described
embodiments and many modifications are possible within the scope of
the following claims. Indeed, a person of ordinary skill in the art
would be able to use the information contained in the preceding
text to modify various embodiments of the invention in ways that
are not literally described, but are nevertheless encompassed by
the attached claims, for they accomplish substantially the same
functions to reach substantially the same results. Therefore, it is
to be understood that the invention is not limited to the specific
embodiments disclosed and that modifications and other embodiments
are intended to be included within the scope of the appended
claims. Although specific terms are employed herein, they are used
in a generic and descriptive sense only and not for purposes of
limitation.
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