Gradient Dielectric Lattice Structures via SLA Truss Parameter Changes
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Solution Overview
Problem
Existing methods for manufacturing dielectric structures with spatially varying dielectric constants, such as Luneburg lenses, are slow, complex, and difficult to adapt to different shapes and gradients.
Innovation Solution
A method using stereolithography (SLA) additive manufacturing to create polymer structures with spatially gradient dielectric constants by varying the diameter of trusses in unit cells, allowing for efficient production of structures with preselected dielectric constant gradients in various configurations and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional methods (drilling holes, layering composites) are used to create spatially varying dielectric structures, then dielectric gradient structures can be manufactured, but the manufacturing process is slow and complex
Solution Approach 1:
The patent uses stereolithography additive manufacturing to directly fabricate polymer structures with spatially varying dielectric constants by changing the physical parameters of the material distribution during manufacturing. The process varies the diameter of circular cross-sections along the length of the structure, creating continuous dielectric gradients without requiring post-manufacturing processing steps.
Solution Approach 2:
The patent replaces traditional mechanical manufacturing methods (drilling, layering, assembling) with a digital manufacturing approach using stereolithography. The process uses digital models and automated layer-by-layer deposition to create complex dielectric gradient structures that would be impossible or extremely difficult to manufacture using conventional mechanical methods.
2Adaptability or versatility
If traditional methods are used to manufacture dielectric structures with varying shapes and gradients, then some dielectric gradients can be achieved, but adaptation to different shapes and gradients is difficult
Solution Approach 1:
The patent creates a universal manufacturing platform using stereolithography that can produce various dielectric gradient structures (Luneburg lenses, Eaton-Guy lenses, etc.) with different shapes, sizes, and gradient profiles from a single process. By modifying digital models and manufacturing parameters, the same equipment can fabricate diverse structures without requiring different manufacturing tools or complex setup changes.
Solution Approach 2:
The patent enables dynamic adaptation of dielectric gradient structures by allowing continuous modification of the gradient profile through software control during the additive manufacturing process. The manufacturing parameters can be adjusted in real-time to create different gradient distributions, and the structure can be designed with varying cross-sectional geometries along its length to achieve different electromagnetic properties.
3Shape
If polymer jetting additive manufacturing is used to create varying shapes, then small structures can be manufactured, but overhangs cannot be present without support material
Solution Approach 1:
The patent overcomes the overhang limitation by changing the fundamental manufacturing approach from material jetting to stereolithography, where a laser selectively cures liquid photopolymer resin. This allows the formation of self-supporting structures with overhangs because the uncured resin provides natural support during the layer-by-layer curing process, eliminating the need for separate support materials.
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 method enables fast and efficient manufacture of polymer structures with spatially gradient dielectric constants, facilitating the production of complex shapes and gradients, and is suitable for applications in 5G technology.
Implementation Method 1
irradiating a portion of the liquid, radiation-curable composition with activating radiation in a pattern to form a layer of the polymer structure
Data Source
AI summary
A stereolithography method of manufacture of a polymer structure having a spatially gradient dielectric constant, including: providing a volume of a liquid, radiation-curable composition; irradiating a portion of the liquid, radiation-curable composition with activating radiation in a pattern to form a layer of the polymer structure; contacting the layer with the liquid, radiation-curable composition; irradiating the liquid, radiation-curable composition with activating radiation in a pattern to form a second layer on the first layer; and repeating the contacting and irradiating to form the polymer structure, wherein the polymer structure comprises a plurality of unit cells wherein each unit cell is integrally connected with an adjacent unit cell, each unit cell is defined by a plurality of trusses formed by the irradiation, wherein the trusses are integrally connected with each other at their respective ends, and the trusses of each unit cell are dimensioned to provide the spatially gradient dielectric constant.