Narrow Passage Repair via Magnetic Microcapsule Deposition

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Solution Overview

Problem

Existing 3D printing techniques face challenges in repairing components with narrow interior passages due to difficulties in physically accessing and positioning the printer hardware to reach repair locations within these confined spaces.

Innovation Solution

A method involving the use of a carrier fluid mixed with a filler material and a controlled electromagnetic field, such as a magnetic field, to attract and deposit microcapsules containing the filler material into narrow passages, allowing for targeted repair by applying a magnetic field to guide the microcapsules to the repair location and solidifying the material once in place.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If traditional 3D printing hardware is used to repair components, then manufacturing capability is achieved, but accessibility to narrow interior passages is insufficient

Engineering Contradiction:

Improveaccessibility to repair locationVSAvoidprinter hardware positioning complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical 3D printing system with a magnetic field-based delivery system. Instead of using a physical printer nozzle to deposit material, the invention uses magnetic fields to guide microcapsules containing filler material to the repair location, eliminating the need for complex mechanical positioning in narrow spaces.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces microcapsules as an intermediary carrier to transport filler material to the repair location. These microcapsules can be delivered through narrow passages and then activated by a magnetic field to release the filler material at the target location, serving as a bridge between the material source and the repair site.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If filler material is delivered through narrow passages, then repair capability is achieved, but material flow control becomes difficult

Engineering Contradiction:

Improvematerial deposition precisionVSAvoidmaterial flow control

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The patent replaces mechanical material flow control with magnetic field control. Instead of using a nozzle to physically push or guide material through narrow passages, the invention uses magnetic fields to attract and position microcapsules containing filler material, providing precise control without mechanical contact.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state and delivery mechanism of the filler material from a continuous stream requiring mechanical flow control to discrete microcapsules that can be magnetically manipulated. This parameter change enables precise positioning by controlling the magnetic field rather than mechanical flow rates.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If excess filler material is used to ensure sufficient repair, then repair reliability is improved, but material waste increases

Engineering Contradiction:

Improverepair sufficiencyVSAvoidfiller material waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent employs magnetic field control as a feedback mechanism to precisely deliver filler material to the repair location. By adjusting the magnetic field strength and positioning, the system can control exactly how much material is deposited, ensuring sufficient repair without excessive material usage.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent changes the delivery mechanism from uncontrolled material flow to magnetically-guided microcapsules. This allows precise control over material placement, ensuring that filler material is deposited only where needed in the narrow passage, eliminating waste while guaranteeing sufficient repair coverage.

Inventive Principle:

Principle #35Parameter changes

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 efficient and precise repair of components with hard-to-reach areas by minimizing excess material flow and waste, allowing for uniform and sufficient deposition of filler material within the narrow passages.

Implementation Method 1

a ferromagnetic material with the filler material to form a microcapsule, wherein the ferromagnetic material is adapted to interact with the controlled electromagnetic field to attract the microcapsule to the repair location

Methodology Applied

Scientific EffectMagnetic field interaction: Magnetism

Data Source

PatentUS11707886B2Narrow passage repair using 3D printing

Publication Date: 2023.07.25 INTERNATIONAL BUSINESS MACHINE CORPORATION

AI summary

Aspects of this disclosure include a method for repairing a component having narrow passage, a three-dimensional printer, and composition for three-dimensional printing. One embodiment of the method may comprise mixing a filler material for three-dimensional printing with a carrier fluid, and applying a controlled electromagnetic field to bias the filler material towards a repair location in a narrow passage of a component. The method may further comprise coating a ferromagnetic material with the filler material to form a microcapsule, wherein the ferromagnetic material is adapted to interact with the controlled electromagnetic field to attract the microcapsule to the repair location. 3D printing techniques may be used to coat the ferromagnetic core with the filler material.