3D-Printed Conductor-Integrated Resin Parts in One Build
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Solution Overview
Problem
Conventional methods for manufacturing conductor-integrated resin parts require separate facilities for wiring material and resin part production, leading to inefficiencies in time, cost, and complexity.
Innovation Solution
A method where a wiring material and a resin part are manufactured in the same process using a 3D printer, with the wiring material made of copper alloy or electroconductive resin and the resin part formed by laminating multiple layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate facilities are used for manufacturing wiring material and resin part, then manufacturing precision and reliability are maintained, but device complexity and manufacturing time increase
Solution Approach 1:
The patent combines the manufacturing of wiring material and resin part into a single integrated process. The resin composition contains both resin components and conductive components, allowing both the insulating resin part and the wiring material to be formed simultaneously in one molding operation, eliminating the need for separate facilities and subsequent assembly steps.
Solution Approach 2:
The resin composition serves multiple functions simultaneously: it provides the insulating resin matrix and contains the conductive components that form the wiring material. This multi-functional material allows a single molding process to produce both the structural resin part and the functional wiring material, reducing overall system complexity.
2Manufacturing precision
If separate facilities are used for manufacturing wiring material and resin part, then manufacturing precision is maintained, but productivity decreases
Solution Approach 1:
The patent merges the manufacturing of wiring material and resin part into a single integrated molding process. By incorporating conductive components within the resin composition, both the wiring material and resin part are formed simultaneously, eliminating multiple production steps and significantly improving manufacturing efficiency while maintaining precision through controlled material distribution.
Solution Approach 2:
The conductive components are pre-distributed within the resin composition before molding. This preliminary arrangement ensures that when the resin part is formed, the wiring material is already in its final position and configuration, eliminating the need for subsequent wiring assembly operations and improving both precision and productivity.
3Reliability
If conventional manufacturing methods are used, then product reliability is ensured, but loss of time and increased cost occur
Solution Approach 1:
The patent combines multiple manufacturing operations into a single molding process. The resin composition contains both resin components and conductive components, allowing the resin part and wiring material to be formed simultaneously, thereby reducing manufacturing time and eliminating the need for separate facilities while maintaining product reliability.
Solution Approach 2:
The patent uses a composite resin composition that integrates both insulating resin and conductive materials. This composite approach allows a single material system to fulfill multiple functional requirements, enabling simultaneous formation of both resin part and wiring material in one process, thus reducing time and cost while ensuring reliability.
4Manufacturing precision
If conventional manufacturing methods are used, then product quality is maintained, but manufacturing cost increases
Solution Approach 1:
The patent merges the manufacturing of wiring material and resin part into a single integrated process using a resin composition containing both resin and conductive components. This eliminates the need for separate facilities and assembly operations, reducing manufacturing cost while maintaining product quality through controlled material distribution and single-step molding.
Solution Approach 2:
The patent employs a composite resin composition that integrates insulating resin and conductive materials. This composite material approach allows both the resin part and wiring material to be formed in one molding operation, eliminating subsequent assembly steps and reducing overall manufacturing cost while ensuring product quality.
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 approach simplifies the manufacturing process, reduces costs, and improves efficiency by integrating the production of wiring material and resin part into a single process, suitable for both high and low-volume production.
Implementation Method 1
a 3D printer outputting process for forming a wiring material and a resin part by laminating in a plurality of layers by ejecting at least one of the 3D printer copper alloy or the 3D printer electroconductive resin constituting the wiring material, and the 3D printer resin constituting a resin part, from a 3D printer head
Data Source
AI summary
The conductor-integrated resin part includes a wiring material that is electroconductive, and a resin part for holding the wiring material. The wiring material and the resin part are formed by laminating in a plurality of layers, and the wiring material is made of at least one of a copper alloy or an electroconductive resin.