Dry Particle Material Layer Formation for High-Density 3D Printing
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Solution Overview
Problem
Existing additive manufacturing methods for forming material layers in three-dimensional objects, such as all-solid-state batteries, result in reduced density of constituent materials due to the inclusion of non-essential components like binders and solvents in the inkjet process.
Innovation Solution
A method involving the arrangement of first particles in a pattern on a base material, followed by rubbing bearing materials carrying second particles against the base material to densely arrange the second particles in regions where the first particles are not present, utilizing adhesive forces to achieve high-density material layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If inkjet method is used to apply materials for forming material layers, then various materials can be arranged in predetermined patterns, but the density of constituent materials is reduced due to inclusion of binders, solvents, and dispersing agents
Solution Approach 1:
The invention extracts and removes the harmful components (binders, solvents, dispersing agents) from the material application process by using a dry particle arrangement method instead of inkjet deposition, thereby achieving high material density without compromising pattern formation capability
Solution Approach 2:
The invention replaces the inkjet mechanical deposition system with a magnetic field-based particle manipulation system, where magnetic particles carry functional materials to predetermined positions through magnetic forces, eliminating the need for liquid carriers and enabling direct solid material placement
2Adaptability or versatility
If multiple types of ink are used to form different material layers, then various functional materials can be deposited, but the process complexity increases and material density decreases
Solution Approach 1:
The invention creates a universal particle arrangement system where magnetic particles can carry different functional materials (electrode materials, electrolyte materials, etc.), allowing a single apparatus to perform multiple material deposition functions without requiring separate inkjet printers for each material type
Solution Approach 2:
The invention changes the fundamental parameter of material delivery from liquid-based inkjet deposition to solid particle magnetic transport, enabling versatile material placement while simplifying the overall process by eliminating solvent evaporation, drying, and complex ink formulation steps
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 material layers with predetermined patterns and high material density, enhancing the efficiency and effectiveness of additive manufacturing processes.
Implementation Method 1
utilizing adhesive forces to achieve high-density material layers
Data Source
AI summary
A method for manufacturing a material layer includes a first step S101 of arranging first particles P1 in a pattern on a base material 11 and a second step S102 of arranging second particles in regions in which the first particles P1 are not arranged on the base material 11. The second step S102 includes a step of rubbing bearing materials S2 that carry the second particles P2 against the base material 11 on which the first particles P1 are arranged.