3D Printed Aesthetic Particles for Complex Void Structures
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Solution Overview
Problem
Existing aesthetic particles in cleaning compositions are limited by simple designs due to traditional manufacturing methods like stamping or extruding, which restricts design complexity and dissolution rates in water.
Innovation Solution
Three-dimensional (3D) printing is used to create water dispersible aesthetic particles with complex designs, including multiple voids and non-linear through holes, enhancing surface area and dissolution rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional stamping or extruding techniques are used to manufacture aesthetic particles, then the manufacturing process is simple and easy to implement, but the design complexity of the particles is limited to simple shapes
Solution Approach 1:
The patent transitions from 2D stamping/extruding techniques to 3D printing technology, adding a dimensional aspect that enables complex internal structures, multiple through holes, and intricate geometries that cannot be achieved with traditional planar manufacturing methods
Solution Approach 2:
The invention changes the manufacturing process parameters by adopting 3D printing technology, which allows for variable design complexity, customizable geometries, and flexible production of particles with varying numbers of voids and through holes while maintaining manufacturing feasibility
2Productivity
If traditional stamping or extruding techniques are used to manufacture aesthetic particles, then the manufacturing process is straightforward, but the dissolution rate in water is reduced due to limited surface area
Solution Approach 1:
The patent creates particles with multiple voids and through holes, forming a porous structure that dramatically increases the surface area available for water contact, thereby accelerating the dissolution rate while maintaining structural integrity during the dissolving process
Solution Approach 2:
By utilizing 3D printing to create complex three-dimensional structures with internal voids and non-linear through holes, the particle surface area is maximized in a compact form, enabling rapid dissolution without requiring complex external processing
3Loss of substance
If stamping technique is used to create through holes in particles, then the process is simple, but it results in waste material from punch outs or cut-outs that need recycling
Solution Approach 1:
The patent replaces the mechanical stamping process with 3D printing technology, transitioning from a subtractive manufacturing method that generates waste to an additive manufacturing method that builds particles layer by layer without producing punch outs or cut-outs
Solution Approach 2:
The 3D printing process enables the creation of particles with complex geometries including multiple through holes without generating waste material, making the manufacturing process more sustainable and eliminating the need for recycling of cut-out waste
4Device complexity
If extrusion technique is used to manufacture aesthetic particles, then the manufacturing process is simple, but it does not allow for multiple through holes in the particles
Solution Approach 1:
The patent moves from 2D extrusion to 3D printing, enabling the creation of multiple through holes and complex internal structures that extend in three dimensions, which are impossible to achieve with traditional extrusion methods that produce only linear or planar features
Data Source
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AI summary
Three dimensionally printed aesthetic particles(1) that are water dispersible are provided. Each particle(1) has a first side(2) and an opposing second side(3), while the first side has a length from 0.2 mm to 20 mm. Further, such particle(1) comprises at least one wall separating a first void and a second void(5) contained between the first side and the second side, while the wall has a width ranging from 0.01 mm to 5 mm as measured in a cross sectional plane.