3D Printed Functional Film for Heat-Sensitive Workpiece Surfaces
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Solution Overview
Problem
Current methods for functionalizing workpiece surfaces are costly and inflexible, particularly when it comes to achieving varied functionalities or incorporating heat-sensitive materials, as they often require high temperatures and pressures that can damage electronic components and limit material selection.
Innovation Solution
A process involving the use of 3D printing to selectively apply a polymeric material composition onto a film, which is then brought into contact with a workpiece surface to create a coherent or interlocking connection, allowing for the functionalization of surfaces without altering the underlying structure of the workpiece and enabling the use of a wide range of materials and complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molding processes are used to combine decorative or functional elements with plastic components, then mass production efficiency is improved, but heat-sensitive electronic functional elements and decorative effects suffer irrevocable damage due to high temperatures and pressures
Solution Approach 1:
The invention separates the functionalization process from the component manufacturing process. The film is functionalized independently through 3D printing, then applied to the workpiece surface in a separate step, avoiding exposure to high-temperature injection molding conditions that would damage heat-sensitive components
Solution Approach 2:
The film acts as an intermediary carrier that receives the functionalization composition through 3D printing and then transfers it to the workpiece surface. This intermediary approach allows functionalization to occur under gentle conditions while still achieving bonding to the workpiece
2Ease of manufacture
If injection molding processes are used for functionalization, then production costs are reduced through mass production, but material selection is restricted and flexibility for individualized components is lost
Solution Approach 1:
The 3D printing process enables locationally selective application of the functionalization composition onto specific portions of the film side, allowing different functional properties to be applied to different areas of the workpiece surface according to specific requirements
Solution Approach 2:
The film serves multiple functions: it acts as a carrier for the functionalization composition, provides a bonding interface to the workpiece surface, and can incorporate various materials and electronic elements without restriction, making the process universally applicable to different workpiece types and functional requirements
3Reliability
If conventional surface modification methods are used, then workpiece surfaces can be functionalized, but the underlying structure of the component must be altered significantly
Solution Approach 1:
The functionalization is extracted from the bulk material and concentrated into a surface-applied layer. The functionalization composition is applied only to the surface region through 3D printing, leaving the underlying workpiece structure unchanged while still achieving the desired surface properties
Solution Approach 2:
The invention transitions from bulk material modification to surface layer functionalization. By applying the functionalization composition in layers onto the film and then to the workpiece surface, the functionality is achieved in a two-dimensional surface context rather than requiring three-dimensional structural changes to the workpiece
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 process enables the creation of functionalized workpiece surfaces with varied functionalities, including mechanical, electrical, and optical properties, while shielding sensitive components and reducing production costs by decoupling functionalization from the workpiece manufacturing process, allowing for individualized and flexible production.
Implementation Method 1
functionalization at least of one film side by locationally selective application of a functionalization composition comprising a polymeric material by means of a 3D printing process in one or more layers onto a portion of the film side
Implementation Method 2
bringing the film into contact with at least one portion of the workpiece surface for development of a coherent or interlocking connection between the workpiece surface and the film functionalized in step c), the coherent or interlocking connection to the workpiece surface being achieved with a functionalized film side
Data Source
AI summary
The present invention relates to a method for functionalizing a workpiece surface, comprising the following steps: a) providing a workpiece; b) providing a film; c) functionalizing at least one film side by the location-selective application of a functionalization composition comprising a polymer material onto part of the film side in one or more layers by means of a 3D printing process; d) creating an integrally bonded or interlocking connection between the workpiece surface and the film functionalized in step c) by bringing the film into contact with at least part of the workpiece surface, wherein the integrally bonded or interlocking connection to the workpiece surface is achieved with a functionalized film side. The invention further relates to workpieces having a surface functionalized according to the invention.