Elevator Tilting Mechanism for Solid Imaging Build Release
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Solution Overview
Problem
Solid imaging devices face challenges with complex systems, high maintenance costs, and inefficiencies due to excessive moving parts, costly laser and UV imaging systems, and contamination issues with large resin vats, leading to tacky and incompletely cured products.
Innovation Solution
A redesigned solid imaging system featuring a replaceable cartridge with a flexible transport surface for layer-by-layer material delivery, an integrated cleaning assembly, a high-intensity UV lamp for curing, and elevator arms to reduce air entrainment and facilitate build release, resulting in a more efficient, cost-effective, and fully cured product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser imaging and UV imaging systems are used for solid imaging, then manufacturing precision and product quality are improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the imaging function from complex laser/UV systems and replaces it with a simpler direct-write imaging approach using LED arrays or projection systems, maintaining manufacturing precision while reducing device complexity and cost
Solution Approach 2:
The patent employs disposable build materials (photopolymer resins) that are inexpensive and can be discarded after use, eliminating the need for expensive, complex material handling and recycling systems while maintaining product quality
2Volume of moving object
If large resin vats are used for stereolithography, then build volume is improved, but contamination and maintenance requirements increase
Solution Approach 1:
The patent segments the build chamber into a compact, enclosed environment with controlled resin supply, allowing larger build volumes to be achieved through multiple build plates or sequential builds rather than requiring a single large resin vat, thereby reducing contamination and maintenance
Solution Approach 2:
The system implements automated resin management including dispensing, spreading, and recycling mechanisms that self-regulate resin flow and contamination, reducing manual maintenance while enabling larger effective build volumes through multiple cycles
3Manufacturing precision
If complex alignment steps are implemented for aligning radiation source and image plane, then manufacturing precision is improved, but productivity and ease of operation worsen
Solution Approach 1:
The patent incorporates pre-aligned mounting fixtures and mechanical guides that automatically position the radiation source and image plane in correct alignment before the build process begins, eliminating complex alignment steps while maintaining manufacturing precision and improving productivity
Solution Approach 2:
The patent replaces complex mechanical alignment systems with automated optical alignment sensors and software-based calibration routines that quickly achieve precise alignment without manual intervention, thereby maintaining precision while improving ease of operation and productivity
4Strength
If uncured build material wets the green product surface, then layer adhesion is improved, but product quality and ease of operation worsen due to tackiness
Solution Approach 1:
The patent implements periodic curing cycles during the build process where uncured material is temporarily exposed to UV light to maintain adhesion, then allowed to remain uncured for layer formation, repeating this cycle to achieve both strong adhesion and manageable surface properties
Solution Approach 2:
The patent modifies the surface energy parameters of the build material through additive formulation and controlled environmental conditions (temperature, humidity) to reduce tackiness while maintaining adequate adhesion, improving product handling without sacrificing layer strength
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
The system simplifies operation and maintenance, reduces tackiness, and produces fully cured, cleaner builds with less post-processing, while enabling a compact desktop modeler format for flexible solid imaging.
Implementation Method 1
A laser or other source of radiation suitable for solid imaging sequentially irradiates individual thin layers of the build material in response to which the material transforms into a solid
Data Source
AI summary
A solid imaging apparatus is provided that includes a replaceable cartridge containing a source of build material and an extendable and retractable flexible transport film for transporting the build material layer-by-layer from the cartridge to the surface of a build in an image plane. An operator using the device needs merely to remove a spent cartridge and replace it with a fresh cartridge to continue solid imaging virtually uninterrupted. The apparatus also includes the capability of withdrawing and inserting an imager without the operator having to perform a separate alignment step. A brush attached to the transport film and forming part of the cartridge provides for intra-layer removal of excess uncured build material. If desired, the apparatus can produce a fully reacted build. A high intensity UV source cures the build between layers. An injection molded build pad is designed to hold a build in an inverted position for improving the build. The invention also provides for tilting the build elevator to reduce air entrainment and for releasing the build from the image plane.