3D-Printed Deflection Members with Embedded Reinforcement

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Solution Overview

Problem

Existing deflection members made via additive manufacturing lack durability and strength due to the absence of a separate reinforcing member, which is crucial for withstanding extreme temperatures, tensions, and pressures in papermaking and nonwoven processes, and cannot form complex shapes required for enhanced fibrous web properties.

Innovation Solution

The method involves using three-dimensional printing technology to create deflection members with a non-unitary reinforcing member by printing a polymer framework onto a separately manufactured reinforcing member, allowing for complex shapes and a strong bond between the resinous framework and the reinforcing member.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If additive manufacturing is used to make deflection members, then complex shapes can be formed, but durability and strength are reduced

Engineering Contradiction:

Improvecomplexity of shapeVSAvoiddurability

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The patent combines the reinforcing member and resinous framework into a single integrated deflection member structure. The reinforcing member is embedded within the resinous framework, creating a composite structure that merges the strength benefits of the reinforcing material with the complex shape capabilities of additive manufacturing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The deflection member uses composite construction with a reinforcing member (providing strength and durability) combined with a resinous framework (enabling complex shapes). This composite approach allows the final structure to exhibit both the structural integrity of reinforced materials and the geometric complexity of 3D-printed components.

Inventive Principle:

Principle #40Composite materials

2Strength

If a separate reinforcing member is added to enhance strength, then durability improves, but manufacturing complexity increases

Engineering Contradiction:

ImprovedurabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The manufacturing process merges the deposition of the reinforcing member and resinous framework into a single additive manufacturing operation. The system alternates between depositing reinforcing material and resinous material in programmed sequences, combining what would traditionally be separate manufacturing steps into one integrated process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The reinforcing member is partially formed and positioned in advance within the build chamber before the resinous framework is deposited around it. This preliminary placement of the reinforcing structure simplifies the overall manufacturing process by establishing the structural backbone before adding the complex resinous features.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If traditional manufacturing methods are used, then manufacturing precision is maintained, but complex shapes cannot be formed

Engineering Contradiction:

ImproveprecisionVSAvoidcomplexity

Core Design Contradiction:

Manufacturing precisionVSShape

Solution Approach 1:

The patent replaces traditional mechanical manufacturing methods (such as molding or machining) with additive manufacturing technology. This substitution enables the formation of complex three-dimensional shapes that would be difficult or impossible to achieve with conventional mechanical processes, while maintaining precision through computer-controlled material deposition.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The additive manufacturing process transitions from traditional two-dimensional or simple three-dimensional manufacturing to truly complex three-dimensional structure creation. The system can deposit materials in multiple directions and build intricate geometries that extend in all three dimensions, enabling shapes that cannot be achieved with conventional manufacturing approaches.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The resulting deflection members exhibit enhanced durability and longevity, capable of withstanding the evolving processing environment of fibrous web making machines while forming fibrous webs with desirable properties.

Implementation Method 1

A radiation source is used to cure the photopolymer resin

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS12365132B2Methods of making a deflection member

Publication Date: 2025.07.22 PROCTER & GAMBLE CO

AI summary

A method for manufacturing a deflection member is disclosed. The method may include the steps of: providing an additive manufacturing apparatus that comprises at least one radiation source and a vat comprising a photopolymer resin, providing a reinforcing member comprising a first surface and a second surface that is opposite the first surface, contacting at least the second surface of the reinforcing member with the photopolymer resin, and directing radiation from a first radiation source and a second radiation source toward the first surface of the reinforcing member.