Inkjet Printed Composite Layers for High Resolution Thermo-Mechanical Properties
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Solution Overview
Problem
Additive manufacturing processes face challenges in producing complex articles with high resolution below 0.2 mm and achieving composite components with improved thermo-mechanical properties without performance deterioration under various conditions.
Innovation Solution
The method involves using an inkjet printing system with two dielectric ink compositions, one being organically modified silicate-based ceramic co-monomers, to create alternating layers of different thermo-mechanical properties within a composite material, controlled by a computer-aided manufacturing module to form reinforced 3D dielectric sections with enhanced properties such as tensile strength and dielectric breakdown strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additive manufacturing processes use traditional single-material or simple composite approaches, then manufacturing complexity is reduced, but the thermo-mechanical properties and resolution below 0.2 mm cannot be achieved
Solution Approach 1:
The patent divides the composite material into distinct phases: a continuous matrix material and dispersed reinforcement materials with different thermo-mechanical properties. This segmentation allows each material to be optimized for specific functions while achieving high resolution printing below 0.2 mm through controlled deposition of each phase separately during the additive manufacturing process
Solution Approach 2:
The patent employs multi-material composite formulations combining matrix materials (such as photopolymer resins) with reinforcement materials (such as ceramics, metals, or high-strength polymers) in specific ratios and distributions. This composite approach enables the final component to exhibit enhanced thermo-mechanical properties including improved strength, thermal stability, and resolution while managing the complexity through integrated printing system design
2Strength
If composite materials are used to improve thermo-mechanical properties, then strength and thermal resistance are enhanced, but the process complexity and material selection difficulty increase
Solution Approach 1:
The patent systematically varies key parameters including the volume fraction of reinforcement materials (from 10-90%), the size and shape of reinforcement particles or fibers, the chemical composition of matrix and reinforcement materials, and the printing parameters (layer thickness, curing energy, deposition speed). By optimizing these parameters, the process achieves enhanced tensile strength and thermal resistance while maintaining reasonable fabrication complexity through controlled experimentation and process modeling
3Strength
If high reinforcement content is used to improve mechanical properties, then tensile strength and dielectric breakdown strength increase, but the manufacturing precision and material homogeneity decrease
Solution Approach 1:
The patent performs preliminary actions including pre-mixing reinforcement materials with matrix materials to create homogeneous composite inks or resins before printing, pre-calculating the optimal reinforcement distribution patterns based on the desired stress fields and dielectric requirements, and pre-calibrating the multi-material printing system to ensure consistent material deposition. These preliminary steps enable high reinforcement content (up to 90% in some regions) while maintaining manufacturing precision and material distribution uniformity throughout the component
Solution Approach 2:
The patent incorporates feedback mechanisms including real-time monitoring of material deposition rates, reinforcement particle distribution during printing, and post-printing characterization of material homogeneity. This feedback is used to adjust printing parameters, material formulation, and process conditions to maintain uniform material distribution even at high reinforcement contents, ensuring consistent dielectric breakdown strength and mechanical properties across the component
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 approach enables the fabrication of composite components with improved mechanical and thermal properties, including increased tensile strength and dielectric breakdown strength, while maintaining structural integrity under various thermos-mechanical conditions.
Implementation Method 1
The disclosure is directed to methods, systems and compositions for the fabrication of composite components having improved thermo-mechanical properties, using for example, inkjet printing
Implementation Method 2
The ink compositions are UV curable and the cured ink forms a solid or semi-solid layer
Data Source
Figure 1A~1B
Figure 1C
Figure 2A~2B
AI summary
The disclosure relates to systems, methods and compositions for fabricating composite component using additive manufacturing (AM). Specifically, the disclosure is directed to methods, systems and compositions for the fabrication of composite components having improved or modulated thermo-mechanical properties, as well as derivative dielectric strength, using for example, inkjet printing.