Dry Powder Screen Patterning for Uniform High-Speed Deposition
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Solution Overview
Problem
Current powder deposition systems face challenges in achieving uniform and precise control of dry powder deposition, particularly at high speeds, leading to non-uniformity and limited material options, and require multiple smoothing and conditioning processes, which are time-consuming and inefficient.
Innovation Solution
A dry powder screen printing system that uses a patterning device with a screen and stencil configuration to directly deposit patterned dry powder onto a target substrate, utilizing a blade to force powder through openings and a controlled energy system for precise patterning and transfer, eliminating the need for multiple smoothing rollers and complex hopper configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If current material dispensers with hopper or feeder are used to deposit powder onto substrate, then powder deposition can be achieved, but the deposited powder is non-uniform and requires multiple smoothing and conditioning processes
Solution Approach 1:
The patent applies preliminary action by pre-patterning the powder on the screen before transfer to the substrate. The screen is prepared with the desired pattern already formed on its surface, and powder is deposited only in the required pattern areas during the transfer process. This eliminates the need for post-deposition smoothing and conditioning operations, directly resolving the contradiction between powder uniformity and processing time.
2Productivity
If hopper geometry, surface coating, agitation, and dispensing mechanism are adjusted to improve deposition speed and powder surface uniformity, then consistent powder mass flow rate can be obtained, but the powder still requires further smoothing and conditioning
Solution Approach 1:
The patent introduces an intermediary screen as a mediator between the powder source and the substrate. The screen receives powder in a controlled manner and holds the patterned powder temporarily before transfer. This intermediary allows the system to achieve both high deposition speed (by direct transfer) and high surface uniformity (by pattern control on the screen), resolving the contradiction between productivity and manufacturing precision.
3Productivity
If material dispenser mechanically agitates or actuates powder for high-speed deposition onto substrate, then deposition speed can be increased, but precise control of powder deposition is lost resulting in non-uniform powder deposition
Solution Approach 1:
The patent applies segmentation by separating the powder handling into distinct functional zones: the screen preparation zone where powder is statically patterned, and the transfer zone where patterned powder is deposited onto the substrate. This segmentation allows precise control during pattern formation and maintains that precision during high-speed transfer, resolving the contradiction between deposition speed and deposition control.
4Quantity of substance
If recoater, roller, blade or horizontal bar is used to deposit powder particles in 3D printing systems, then powder can be deposited, but larger particle sizes lead to thick layers and rough surfaces limiting feature sizes and printing resolution
Solution Approach 1:
The patent uses a thin screen film as the powder carrier and pattern definition medium. The screen's thin structure allows for precise pattern definition and control of powder layer thickness. By controlling the screen properties and powder deposition on the screen, the system achieves fine feature sizes and high printing resolution while maintaining appropriate layer thickness, resolving the contradiction between quantity of substance and manufacturing precision.
Data Source
AI summary
Systems, methods, and other embodiments associated with high speed, high precision direct deposition of patterned dry powder. In one embodiment, an example apparatus includes a patterning device and a powder delivery system delivering dry powder onto an interior surface of the patterning device. The interior surface of the patterning device is configured to include a screen having top and bottom surfaces and a plurality of openings positioned between the top and bottom surfaces, whereby each opening is configured to contain a portion of the received dry powder. The bottom surface of the screen forming the exterior surface of the patterning device. The interior surface includes a blade configured to be positioned adjacent to the interior surface of the screen to force the portion of dry powder through the interior surface and into a corresponding opening of the screen thereby patterning each portion of dry powder.