3D Printed Functional Element Structure Body
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Solution Overview
Problem
Existing methods for producing functional element structure bodies, such as heaters, resistors, and capacitors, face instability due to surface contact or adhesive bonding between functional element sections and insulating members, leading to potential property deterioration and increased production costs.
Innovation Solution
A three-dimensional production method involving layer formation and solidification of flowable compositions containing first and second particles, where the materials are systematically connected and bonded without seams, ensuring integral bonding and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If surface contact or adhesive bonding is used to assemble functional element section and insulating member, then production is simpler, but the holding state becomes unstable and adhesion deteriorates over time
Solution Approach 1:
The functional element section and insulating member are merged into a single integrated structure through three-dimensional shaping, eliminating the need for separate assembly steps. The materials are systematically connected and bonded without seams during the shaping process, achieving both manufacturing simplicity and structural stability simultaneously.
Solution Approach 2:
The mechanical assembly process (surface contact or adhesive bonding) is replaced by a three-dimensional shaping process that directly forms the integrated structure. This substitution eliminates the inherent weaknesses of mechanical assembly while maintaining ease of manufacture.
2Ease of manufacture
If adhesive bonding is used to connect functional element section and insulating member, then assembly is easier, but adhesion state deteriorates over time increasing cost
Solution Approach 1:
The adhesive bonding step is completely extracted from the manufacturing process. The three-dimensional shaping method directly forms the integrated structure without requiring adhesives, thereby eliminating adhesion deterioration issues while maintaining assembly ease.
Solution Approach 2:
The bonding between functional element section and insulating member is performed preliminarily during the three-dimensional shaping process itself, rather than as a subsequent assembly step. This preliminary bonding ensures long-term durability while keeping the overall process simple.
3Reliability
If dedicated adhesive is used for functional element section, then bonding effectiveness is improved, but production complexity and workload increase
Solution Approach 1:
The three-dimensional shaping process serves multiple functions simultaneously: it forms both the functional element section and insulating member, and creates their integrated bonding structure in one operation. This eliminates the need for dedicated adhesives and reduces production complexity.
4Adaptability or versatility
If separate production and assembly of functional element section and insulating member is performed, then manufacturing flexibility is maintained, but number of assembling workloads increases
Solution Approach 1:
The production of functional element section and insulating member is merged into a single three-dimensional shaping process. This combination eliminates multiple assembly workloads while maintaining the ability to produce different configurations by adjusting the shaping parameters.
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
This method stabilizes the functional element structure body by eliminating seam-related instability and adhesive deterioration, reducing production complexity and costs.
Implementation Method 1
a solidification step of performing solidification by applying energy to the first particles and the second particles in the layer
Data Source
AI summary
A three-dimensional production method for a functional element structure body according to the invention is a three-dimensional production method for a functional element structure body, which includes an electrical functional element section having a terminal and an insulating member provided on the periphery of the functional element section in a state where at least the terminal is exposed to the outside, and includes a layer formation step of forming one layer in a layer forming region by supplying a first flowable composition containing first particles for the functional element section from a first supply section, and supplying a second flowable composition containing second particles for the insulating member from a second supply section, a shaping step of shaping the functional element structure body by repeating the layer formation step, and a solidification step of performing solidification by applying energy to the first particles and the second particles in the layer.