Composite Body Structure for Beam-Melted Functional Component Protection
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Solution Overview
Problem
Integrating functional components into shaped bodies produced by beam melting of metallic powders is challenging due to the high temperatures generated, which can impair the functionality of the components.
Innovation Solution
A composite body is created by connecting a functional component to a metallic or ceramic support structure, surrounded by a thermally insulating ceramic layer and a thermally conductive metal or metal oxide layer, allowing for energy transfer while maintaining the component's functionality through careful control of the beam melting process to avoid excessive temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If beam melting is used to produce shaped bodies from metallic powder, then geometrically complex workpieces can be produced with series-identical properties, but very high temperatures are generated that can impair the functionality of integrated functional components
Solution Approach 1:
The patent divides the shaped body into multiple segments: a support structure made of heat-resistant material (metallic or ceramic), and functional components made of temperature-sensitive materials. This segmentation allows different parts to withstand different temperature conditions during beam melting, protecting functional components from thermal damage while enabling complex geometry production.
Solution Approach 2:
The support structure acts as an intermediary between the laser beam and functional components. It absorbs and dissipates the thermal energy from the beam melting process, preventing direct heat transfer to temperature-sensitive functional components while still allowing the beam melting process to proceed for creating the overall complex structure.
2Adaptability or versatility
If functional components are integrated into shaped bodies produced by beam melting, then multifunctional components can be created, but the high temperatures during beam melting can damage the functional components
Solution Approach 1:
The patent segments the composite body into a support structure and functional components, allowing each to be optimized for its specific function and temperature requirements. The support structure handles thermal and mechanical loads from beam melting, while functional components perform their specialized functions without direct thermal exposure.
Solution Approach 2:
Different regions of the composite body have different material properties tailored to local requirements. The support structure uses heat-resistant materials to withstand beam melting temperatures, while functional components use materials optimized for their specific functions (electronic, optical, mechanical) that would be damaged by high temperatures.
3Productivity
If a single manufacturing process is used to integrate functional components into shaped bodies, then production efficiency can be improved, but the high temperatures prevent successful integration of temperature-sensitive components
Solution Approach 1:
The patent segments the manufacturing process into stages: first creating the support structure and its interface regions using beam melting, then integrating functional components that are sensitive to high temperatures. This segmented approach allows the heat-resistant support structure to be formed by beam melting while protecting subsequent integration of temperature-sensitive functional components.
Solution Approach 2:
The support structure and its connection interfaces are prepared in advance using beam melting before functional components are integrated. This preliminary creation of the thermal and mechanical framework allows functional components to be added subsequently under controlled temperature conditions, maintaining both production efficiency and component integrity.
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 configuration enables the integration of functional components into shaped bodies produced by beam melting, ensuring chemical and mechanical protection, thermal insulation, and energy equilibrium, while preventing overheating and maintaining the component's functionality.
Implementation Method 1
the at least one functional component is surrounded at least in some region or regions by at least one thermally insulating layer composed of a ceramic material
Implementation Method 2
at least one thermally conductive layer lying above the latter and composed of a metal or metal oxide
Implementation Method 3
A shaped body is produced additively by solidification in layers at selected locations by means of a locally defined energy input into powdered fusible materials. Here, the energy is input by means of an energy beam, in particular a laser beam or electron beam.
Data Source
AI summary
The invention relates to a composite body, wherein at least one functional component is integrated into a shaped product, and to a method for producing the same. The shaped product can especially be an implant, a prosthesis, an industrial component or a multifunctionally useful sensor platform for the monitoring of materials, components and/or structural systems.