Discharge Apparatus for Precise Particle Fixation
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Solution Overview
Problem
In three-dimensional prototyping techniques, complex shapes face issues with residual binder removal and thermal expansion defects, while aerosol-based methods struggle to precisely fix particles to small areas due to spread and uneven distribution.
Innovation Solution
A discharge apparatus with a first dispenser for aerosol and a second dispenser for gas, where the gas overlaps and accelerates the aerosol to improve particle fixation control, allowing for precise positioning and removal of unfixed particles using a cleaning unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If aerosol is sprayed from dispenser toward substrate, then particles can be fixed to substrate, but particle distribution becomes uneven with large spacing variation over relatively large region
Solution Approach 1:
The invention divides the single aerosol discharge function into two separate dispensers: one for aerosol and one for gas. This segmentation allows independent control of particle delivery and acceleration, enabling precise positioning by overlapping their discharge regions to fix particles only in the intersection area.
Solution Approach 2:
The gas discharged from the second dispenser acts as an intermediary that accelerates the aerosol particles from the first dispenser. This gas intermediary enables precise control of particle fixation position by adjusting the overlap region between aerosol and gas discharge, solving the positioning precision problem.
2Productivity
If aerosol is sprayed at high rate to fix particles, then fixation efficiency improves, but spread increases making it difficult to limit to desired small area
Solution Approach 1:
The invention applies local quality by creating a localized acceleration zone where gas and aerosol discharge regions overlap. This allows high-rate particle fixation to occur only in the specific overlapping area, while other regions remain unaffected, thus achieving both high efficiency and precise area control.
Solution Approach 2:
The invention adds a spatial dimension control mechanism by using the overlap of two discharge regions (aerosol and gas) to define the fixation area. This dimensional approach allows precise control of where particles are fixed by adjusting the relative positioning and discharge parameters of the two dispensers.
3Shape
If complex three-dimensional shape is formed using stereolithography, then shaping capability improves, but binder residue removal becomes insufficient and thermal defects occur
Solution Approach 1:
The invention extracts and eliminates the binder component from the traditional stereolithography process. By using direct particle fixation through aerosol collision without binder, the method removes the source of residue problems and thermal expansion defects, achieving complex shape formation with improved reliability.
Solution Approach 2:
The invention replaces the thermal-mechanical process of stereolithography (binder deposition, drying, sintering) with a direct mechanical particle fixation process. Aerosol particles are directly accelerated and fixed to the substrate, substituting the multi-step thermal process with a single-step mechanical deposition that avoids binder-related defects.
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
Enhances the controllability and precision of particle fixation, reducing thermal defects and binder-related issues, enabling precise three-dimensional shaping without heat treatment or binders, and allowing for cost-effective room temperature processing.
Implementation Method 1
a first dispenser for discharging an aerosol containing the particle toward the fixed surface
Implementation Method 2
a second dispenser for discharging a gas toward the fixed surface... to accelerate at least a portion of the aerosol toward the fixed surface
Data Source
Figure 1~2
Figure 3~3(d)
Figure 4~4(d)
AI summary
A discharge apparatus, a forming apparatus, a method of operating the discharge apparatus, and a method of producing a formed body are disclosed herein. In some embodiments, a discharge apparatus is used to collide a particle with a fixed surface to fix the particle to the fixed surface, the discharge apparatus includes a first dispenser for discharging an aerosol containing the particle toward the fixed surface at a first discharge rate, and a second dispenser for discharging a gas toward the fixed surface at a second discharge rate faster than the first discharge rate, and the second dispenser discharges the gas so that the gas at least partially overlaps with the aerosol to accelerate at least a portion of the aerosol toward the fixed surface to fix the particle to the fixed surface.