Laminate Shaping Apparatus Nozzle Clogging Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing laminate shaping apparatuses face issues with nozzle clogging due to high height differences in three-dimensional shaped products, as ultraviolet light used for curing can reflect and scatter, causing the model and support material to adhere to the nozzles, leading to clogging.
Innovation Solution
The apparatus includes a control unit that analyzes shaping data to generate support material data for ejecting a support material into regions with significant height differences, ensuring the height is reduced to a threshold value where ultraviolet light does not reach the nozzles, using a UV light source with high directivity like LEDs, and employing a support material with lower curing strength for easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultraviolet light is used to cure model and support material, then the three-dimensional shaped product can be formed, but the ultraviolet light reflects and scatters causing material to adhere to nozzles and clog them
Solution Approach 1:
A transparent plate is introduced as an intermediary component between the ultraviolet light source and the shaping region. This plate selectively transmits ultraviolet light while blocking reflected light from reaching the nozzles, preventing material adhesion and clogging without interfering with the curing process
Solution Approach 2:
The invention utilizes the reflected ultraviolet light, which would normally cause harmful nozzle clogging, and redirects it through the transparent plate to cure the model and support material more effectively. The reflected light that would be harmful is converted into a beneficial curing source
2Adaptability or versatility
If high height differences are present in the three-dimensional shaped product, then complex shapes can be created, but the height difference causes ultraviolet light scattering and nozzle clogging
Solution Approach 1:
The transparent plate serves as a mediator that allows the system to maintain complex shape capabilities while preventing the harmful effects of light scattering. It enables the curing of high-relief features without allowing reflected light to reach the nozzles
Solution Approach 2:
The transparent plate is positioned in a specific spatial dimension between the light source and the shaping region, creating a new optical path that separates the beneficial curing function from the harmful reflection effect
3Reliability
If support material is ejected to reduce height difference to threshold value, then nozzle clogging is prevented, but the apparatus complexity increases
Solution Approach 1:
The support material is ejected in advance to regions where height differences exceed the threshold value, creating a preventive structure before the nozzle clogging problem occurs. This preliminary action simplifies the overall control logic by addressing the root cause rather than reacting to clogging events
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 solution effectively prevents nozzle clogging by ensuring the ultraviolet light does not reach the nozzles, maintaining apparatus functionality and reducing maintenance needs, while allowing for the creation of complex three-dimensional shapes with varying heights.
Implementation Method 1
an ultraviolet-ray source that applies ultraviolet rays; a model material ejecting unit that ejects an ultraviolet curable model material
Implementation Method 2
as ultraviolet light used for curing can reflect and scatter, causing the model and support material to adhere to the nozzles
Implementation Method 3
as ultraviolet light used for curing can reflect and scatter, causing the model and support material to adhere to the nozzles
Data Source
AI summary
Provided is a laminate shaping apparatus including an ultraviolet-ray source that applies ultraviolet rays a model material ejecting unit that ejects an ultraviolet curable model material a support material ejecting unit that ejects an ultraviolet curable support material which assists shaping of a three-dimensional shaped product which is shaped by the model material a driving unit that drives at least one of the ultraviolet-ray source, the model material ejecting unit, and the support material ejecting unit, and a shaping stand on which the three-dimensional shaped product is shaped, and a control unit that controls the model material ejecting unit, the ultraviolet-ray source, the driving unit, and the support material ejecting unit.