Additively Printed Deflection Members With Integrated Reinforcement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing deflection members used in papermaking and nonwoven processes lack durability and strength due to the absence of a separate reinforcing member, which is crucial for withstanding extreme temperatures, tensions, and pressures in modern fibrous web production machines, and they cannot form complex shapes required for enhanced fibrous web properties.
Innovation Solution
Utilizing three-dimensional printing technology to create deflection members with a non-unitary reinforcing member, where a resinous framework is printed onto a separately manufactured reinforcing member, allowing for complex shapes and a strong bond between the two components, enhancing durability and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional deflection members are made with a resinous framework joined to a reinforcing member, then they can withstand extreme temperatures and tensions, but they lack durability and strength in modern fibrous web production machines
Solution Approach 1:
The patent combines the resinous framework and reinforcing member into a unitary structure where the framework is directly formed as an integral part of the reinforcing member, eliminating separation and improving both durability and strength
Solution Approach 2:
The patent uses composite materials by integrating the resinous framework with the reinforcing member through additive manufacturing, creating a unified composite structure that enhances both durability and strength properties
2Shape
If traditional deflection members are made with a unitary structure, then they are simpler to manufacture, but they cannot form complex shapes required for enhanced fibrous web properties
Solution Approach 1:
The patent changes the manufacturing parameters by using additive manufacturing technology, which enables the creation of complex three-dimensional shapes that were not achievable with traditional manufacturing methods
Solution Approach 2:
The patent transitions from traditional two-dimensional or simple three-dimensional structures to complex three-dimensional shapes enabled by additive manufacturing, allowing for enhanced fibrous web properties through intricate geometries
3Strength
If deflection members are made without a separate reinforcing member, then the structure is simpler, but they lack the strength to withstand extreme temperatures, tensions, and pressures
Solution Approach 1:
The patent merges the reinforcing member and resinous framework into a single unitary structure, eliminating the need for separate components while maintaining the strength benefits of the reinforcing member
Solution Approach 2:
The patent creates a composite material structure where the reinforcing member and resinous framework are integrally combined through additive manufacturing, achieving high strength without requiring complex assembly of separate parts
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 improved durability and longevity, capable of withstanding the evolving processing environment of fibrous web making machines while enabling the formation of fibrous webs with desirable properties through complex shapes.
Implementation Method 1
a resinous framework is printed onto a separately manufactured reinforcing member, allowing for complex shapes and a strong bond between the two components
Data Source
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/or a second radiation source toward the first surface of the reinforcing member.