Gradient Porosity Substrate with Coating for Structural Integrity
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Solution Overview
Problem
There is a need for a structure with a new shape and a production method that can achieve a specific intensity and rigidity by varying the void ratio dimensionally and aligning voids regularly, while allowing for easy coating material application through communication holes.
Innovation Solution
A substrate with a decreasing void ratio from the inner to the outer side, coated with a material that includes a metal layer or resin, and a production method using an energy beam to form the substrate with voids and communication holes for coating material application, ensuring high accuracy and intensity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a honeycomb structure is formed inside a molded article, then uncured liquid can be discharged easily through communication holes, but the structure lacks sufficient intensity and rigidity
Solution Approach 1:
The patent applies local quality by creating a gradient void ratio structure where the inner side has larger voids for liquid discharge functionality, while the outer side has smaller voids to maintain structural intensity and rigidity. This spatial variation in void characteristics allows each region to optimize for its specific function.
Solution Approach 2:
The patent uses a composite structure combining voids of different sizes and ratios in specific spatial arrangements. The combination of large voids (for liquid discharge) and small voids (for structural strength) creates a composite architecture that achieves both functional and mechanical requirements simultaneously.
2Strength
If the void ratio is decreased from the inner side toward the outer side of the substrate, then intensity and rigidity are enhanced, but coating material application becomes more difficult
Solution Approach 1:
The patent applies preliminary action by forming communication holes before coating material application. These pre-formed channels provide pathways for coating material to reach the inner regions of the substrate, ensuring complete and uniform coating despite the decreasing void ratio that would otherwise hinder material penetration.
Solution Approach 2:
The communication holes act as intermediaries that facilitate the transfer of coating material from the outer surface to the inner regions of the substrate. These channels bridge the gap created by the void ratio gradient, allowing coating material to navigate through the structure and achieve uniform distribution.
3Ease of manufacture
If communication holes are formed to allow coating material application, then coating can be applied with ease, but the structural intensity may be reduced
Solution Approach 1:
The patent applies local quality by positioning communication holes strategically in regions where they provide coating access while minimizing structural compromise. The holes are distributed to ensure coating penetration without creating excessive structural weaknesses, optimizing the balance between manufacturability and 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 structure achieves enhanced intensity and rigidity by varying the void ratio and using a coating material, allowing for various functional properties such as heat resistance and hydrophobicity, and can be formed with high accuracy and ease using the described method.
Implementation Method 1
supplying a material of a substrate that cures by an energy of an energy beam to a supply area. By irradiating the energy beam onto an area selected from an entire area of the material supplied to the supply area, the substrate that includes a plurality of voids and a surface on which at least the plurality of voids are formed is formed
Data Source
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AI summary
A structure including a substrate and a coating material. The substrate includes a plurality of voids and a surface on which at least the plurality of voids are formed, and is formed such that a void ratio of the plurality of voids decreases one of 2-dimensionally and 3-dimensionally from an inner side of the substrate toward an outer side thereof. The coating material is formed on the surface of the substrate.