Conductive Polymer 3D Structures With Continuous Bead Sidewalls

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Solution Overview

Problem

The design and manufacture of 3D structures using metal-based materials are costly and prone to corrosion, with processes like stamping and brazing being expensive and challenging, and there are compatibility issues with certain fluids and environmental conditions, leading to long lead times and performance issues.

Innovation Solution

A method involving the formation of 3D structures using a conductive polymer-based material with metallic flakes, where a continuous bead of material is extruded along a path to form uninterrupted layers, facilitating the creation of mechanically desirable and economically viable structures with enhanced conductivity and watertight functionality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal-based materials are used to manufacture 3D structures, then structural strength and heat transfer capabilities are improved, but corrosion resistance deteriorates and manufacturing cost increases

Engineering Contradiction:

Improvestructural strengthVSAvoidcorrosion resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent employs composite materials consisting of metal flakes dispersed within a polymer matrix. This composite structure combines the advantageous properties of both materials: the metal flakes provide structural strength and thermal conductivity, while the polymer matrix provides corrosion resistance. The synergistic combination resolves the contradiction between needing metal for strength/heat transfer and avoiding metal for corrosion resistance.

Inventive Principle:

Principle #40Composite materials

2Strength

If traditional manufacturing processes like stamping and brazing are used, then structural integrity is improved, but manufacturing cost and lead time increase

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent applies local quality by selectively distributing metal flakes throughout the polymer matrix rather than using bulk metal. This localized placement of metal particles provides the necessary structural integrity and thermal conductivity only where needed within the 3D structure, enabling additive manufacturing without compromising strength while reducing manufacturing complexity and cost.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent replaces traditional mechanical manufacturing processes (stamping, brazing) with additive manufacturing technology. This substitution eliminates the need for complex tooling, multiple assembly steps, and expensive equipment while maintaining structural integrity through the continuous deposition of conductive polymer material with embedded metal flakes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If continuous bead deposition is used to form 3D structures, then manufacturing speed and cost are improved, but material uniformity and conductivity may deteriorate

Engineering Contradiction:

Improvemanufacturing speedVSAvoidmaterial uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-dispersing metal flakes uniformly within the polymer matrix before the extrusion process. This pre-mixing ensures that the conductive particles are already evenly distributed throughout the material, so when the continuous bead is deposited during additive manufacturing, the resulting structure maintains both manufacturing speed and material uniformity with consistent conductivity throughout.

Inventive Principle:

Principle #10Preliminary action

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 enables the formation of 3D structures with improved mechanical and manufacturing characteristics, such as high heat transfer capabilities and resistance to corrosion, while reducing production costs and lead times, and ensuring compatibility with various environmental conditions.

Implementation Method 1

a continuous bead of the extruded polymer-based material are stacked along the continuous path to form sidewalls of the 3D structure, wherein the width of the extruded bead corresponds to a width of the sidewall and the length of the extruded bead corresponds to a length of the sidewall, such that the sidewall has conductivity along the length that is within about 10% or about 20% of conductivity in a direction across the thickness of the sidewall

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11453158B23D structures and methods therefor

Publication Date: 2022.09.27 WISCONSIN ALUMNI RES FOUND

AI summary

Aspects of the disclosure are directed to methods and/or apparatuses involving one or more of a conductive polymer, deposition of a conductive polymer and 3D (three-dimensional) printing of a continuous bead of material. As may be implemented in accordance with one or more embodiments characterized herein, a 3D structure is formed as follows. A stacked layer is formed by depositing a continuous bead of material along an uninterrupted path that defines a first layer of the 3D structure. A sidewall of the 3D structure is formed with opposing surfaces respectively defined by successive stacked layers of the 3D structure by, for each stacked layer (including the first layer), depositing the continuous bead of material along the path and with a surface thereof in contact with a surface of the continuous bead of material of an adjacent one of the stacked layers.