Ventilation and cooling in selective deposition modeling

Claim 2

A ventilation and cooling system for capturing airborne contaminants in a selective deposition modeling apparatus dispensing a curable and flowable build material layer by layer to form a three-dimensional object, the ventilation and cooling system comprising: a containment chamber surrounding the selective deposition modeling apparatus, the containment chamber having a dispensing device for layerwise selective dispensing of the build material, a heat generating exposure system to cure the build material in each layer and at least one air inlet duct and at least one air exit duct, the containment chamber further having unsealed gaps; at least one air-moving device in communication with the air inlet of the containment chamber creating a first flow of air entering the apparatus; at least one air-moving device in communication with the air exit duct creating a second flow of air exiting the apparatus; a third flow of air that is drawn into the apparatus through the unsealed gaps at a flow rate which, when added to the flow rate of the first flow of air, substantially equals the flow rate of the second flow of a when a steady state condition is established between the first flow of air, the second flow of air, and the third flow of air; a filter in communication with the air exit duct for receiving the second flow of air to capture airborne contaminants from the second flow of air, the airborne contaminants comprising vapors of the curable build material; and wherein the second flow of air has a flow rate that is greater than the flow rate of the first flow of air.

Claim 3

The ventilation and cooling system of claim 1 wherein the pressure inside the containment chamber is less than atmospheric pressure when the steady state condition is established.

Claim 4

The ventilation and cooling system of claim 2 wherein the pressure inside the containment chamber when the steady state condition is established is between about 0.05 In H 2 O to about 1.0 In H 2 O less than atmospheric pressure.

Claim 5

The ventilation and cooling system of claim 2 further comprising: a pressure sensor in communication with the selective deposition modeling apparatus, the pressure sensor configured to determine the pressure difference between the pressure inside the containment chamber and atmospheric pressure when the steady state condition is established, wherein to pressure sensor shuts down the selective deposition modeling apparatus when the pressure difference determined indicates the ventilation and cooling system is not functioning properly.

Claim 6

The ventilation and cooling system of claim 4 wherein the ventilation and cooling system is not functioning properly when the pressure difference determined by the pressure sensor is about 0.05 In H 2 O less than atmospheric pressure.

Claim 7

The ventilation and cooling system of claim 2 further comprising: a pressure sensor in communication with the selective deposition modeling apparatus, the pressure sensor configured to determine the pressure difference between the pressure inside the containment chamber and atmospheric pressure when the steady state condition is established, wherein the pressure sensor signals the selective deposition modeling apparatus that the ventilation and cooling system is not functioning properly when the pressure difference determined indicates the ventilation and cooling system is not functioning properly.

Claim 8

The ventilation and cooling system of claim 6 wherein the ventilation and cooling system is not functioning properly when the pressure difference determined by the pressure sensor is about 0.05 In H 2 O less than atmospheric pressure.

Claim 9

The ventilation and cooling system of claim 2 further comprising: a pressure sensor in communication with the selective deposition modeling apparatus, the pressure sensor configured to determine the pressure difference between the second flow of air and atmospheric pressure when the steady state condition is established, the pressure difference being measured prior to the second flow of air being received by the filter, wherein the pressure sensor shuts down the selective deposition apparatus when the pressure difference determined by the pressure sensor is greater than a minimum allowable pressure difference indicating the filter needs to be replaced.

Claim 10

The ventilation and cooling system of claim 2 further comprising: a pressure sensor in communication with the selective deposition modeling apparatus, the pressure sensor configured to determine the pressure difference between the second flow of air and atmospheric pressure when the steady state condition is established, the pressure difference being measured prior to the second flow of air being received by the filter, wherein the pressure sensor signals the selective deposition modeling apparatus that the filter needs to be replaced when the pressure difference determined by the pressure sensor is greater than a minimum allowable pressure difference indicating the filter needs to be replaced.

Claim 11

The ventilation and cooling system of claim 1 wherein the filter is an activated charcoal filter.

Claim 12

The ventilation and cooling system of claim 1 having five air inlet ducts, each air inlet duct in communication with an air-moving device, wherein the first flow of air entering the apparatus comprises the air entering all five inlet ducts.

Claim 13

A selective deposition modeling apparatus for forming a three-dimensional object from a flowable and curable material in a build environment, the apparatus receiving data corresponding to layers of the three-dimensional object, the apparatus comprising: a support means affixed to the apparatus for supporting the three-dimensional object in the build environment; a dispensing means affixed to the apparatus and in communication with the support means for selectively dispensing the curable material in the build environment according to the computer data to form the layers of the three-dimensional object; a flash exposure means affixed to the apparatus for curing the dispensed material, the flash exposure means in communication with the support means; a ventilation and cooling system for capturing airborne contaminants in the apparatus, the ventilation and cooling system comprising: a) a containment chamber surrounding the selective deposition modeling apparatus, the containment chamber having at least one air inlet duct and one air exit duct and unsealed gaps; b) at least one air-moving device in communication with the air inlet of the containment chamber creating a first flow of air entering the apparatus; c) at least one air-moving device in communication with the air exit duct creating a second flow of air exiting the apparatus; d) a flash cooling system in communication with the flash exposure means for providing steady state cooling of the flash exposure means, the flash cooling system comprising an air duct receiving at least a portion of the first flow of air for cooling the flash exposure means and delivering the portion of the first flow of air to the second flow of air; e) a third flow of air drawn into the apparatus through the unsealed gaps in the containment chamber at a flow rate which, when added to the flow rate of the first flow of air, substantially equals the flow rate of the second flow of air when a steady state condition is established between the first flow of air, the second flow of air, and the third flow of air; f) a filter in communication with the air exit duct for receiving the second flow of air to capture airborne contaminants from the second flow of air, the airborne contaminants comprising vapors of the curable build material; and wherein the second flow of air has a flow rate that is greater than the flow rate of the first flow of air.

Claim 14

A selective deposition modeling apparatus for forming a three-dimensional object from a flowable and curable material in a build environment, the apparatus receiving data corresponding to layers of the three-dimensional object, the apparatus comprising: a support means affixed to the apparatus for supporting the three-dimensional object in the build environment; a dispensing means affixed to the apparatus and in communication with the support means for selectively dispensing the curable material in the build environment according to the computer data to form the layers of the three-dimensional object; a flash exposure means affixed to the apparatus for curing the dispensed material, the flash exposure means in communication with the support means; a ventilation and cooling system for capturing airborne contaminants in the apparatus, the ventilation and cooling system comprising: a) a containment chamber surrounding the selective deposition modeling apparatus, the containment chamber having at least one air inlet duct and one air exit duct and unsealed gaps; b) at least one air-moving device in communication with the air inlet of the containment chamber creating a first flow of air entering the apparatus; c) at least one air-moving device in communication with the air exit duct creating a second flow of air exiting the apparatus; d) a flash cooling system in communication with the flash exposure means for providing steady state cooling of the flash exposure means, the flash cooling system comprising an air duct receiving at least a portion of the first flow of air for cooling the flash exposure means and delivering the portion of the first flow of air to the second flow of air; e) a third flow of air drawn into the apparatus through the unsealed gaps in the containment chamber at a flow rate which, when added to the flow rate of the first flow of air, substantially equals the flow rate of the second flow of air when a steady state condition is established between the first flow of air, the second flow of air, and the third flow of air; f) a filter in communication with the air exit duct for receiving the second flow of air to capture airborne contaminants from the second flow of air, the airborne contaminants comprising vapors of the curable build material; and wherein the second flow of air has a flow rate that is greater than the flow rate of the first flow of air.

Claim 15

The apparatus of claim 12 wherein the pressure inside the containment chamber is less than atmospheric pressure when the steady state condition is established.

Claim 16

The apparatus of claim 13 wherein the pressure inside the containment chamber when the steady state condition is established is between about 0.05 In H 2 O to about 1.0 In H 2 O less than atmospheric pressure.

Claim 17

The apparatus of claim 13 further comprising; a pressure sensor in communication with the selective deposition modeling apparatus, the pressure sensor configured to determine the pressure difference between the pressure inside the containment chamber and atmospheric pressure when the steady state condition is established, wherein the pressure sensor shuts down the selective deposition modeling apparatus when the pressure difference determined indicates the ventilation and cooling system is not functioning properly.

Claim 18

The apparatus of claim 15 wherein the ventilation and cooling system is not functioning properly when the pressure difference determined by the pressure sensor is about 0.05 In H 2 O less than atmospheric pressure.

Claim 19

The apparatus of claim 13 farther comprising: a pressure sensor in communication with the selective deposition modeling apparatus, the pressure sensor configured to determine the pressure difference between the pressure inside the containment chamber and atmospheric pressure when the steady state condition is established, wherein the pressure sensor signals the selective deposition modeling apparatus that the ventilation and cooling system is not functioning properly when the pressure difference determined indicates the ventilation and cooling system is not functioning properly.

Claim 20

The apparatus of claim 17 wherein the ventilation and cooling system is not functioning properly when the pressure difference determined by the pressure sensor is about 0.05 In H 2 O less than atmospheric pressure.

Claim 21

The apparatus of claim 13 further comprising: a pressure sensor in communication with the selective deposition modeling apparatus, the pressure sensor configured to determine the pressure difference between the second flow of air and atmospheric pressure when the steady state condition is established, the pressure difference being measured prior to the second flow of air being received by the filter, wherein the pressure sensor shuts down the selective deposition apparatus when the pressure difference determined by the pressure sensor is greater than a minimum allowable pressure difference indicating the filter needs to be replaced.

Claim 22

The apparatus of claim 13 further comprising: a pressure sensor in communication with the selective deposition modeling apparatus, the pressure sensor configured to determine the pressure difference between the second flow of air and atmospheric pressure when the steady state condition is established, the pressure difference being measured prior to the second flow of air being received by the filter, wherein the pressure sensor signals the selective deposition modeling apparatus that the filter needs to be replaced when the pressure difference determined by the pressure sensor is greater than a minimum allowable pressure difference indicating the filter needs to be replaced.

Claim 23

The apparatus of claim 12 wherein the filter is an activated charcoal filter.

Claim 24

The apparatus of claim 12 having five air inlet ducts, each air inlet duct in communication with an air-moving device, wherein the first flow of air entering the apparatus comprises the air entering all five inlet ducts.