Mobile Electron Beam Cross-Linking for Voxel-Based 3D Features
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Solution Overview
Problem
Current industrial electron accelerators are not cost-effective, simple, versatile, and efficient enough for widespread industrial applications, particularly in producing high-average beam power and creating complex three-dimensional features using electron beams.
Innovation Solution
A method and system utilizing mobile electron accelerators to deliver precise electron beam irradiation for in situ cross-linking of materials, allowing for the creation of arbitrary three-dimensional features by defining discrete voxels with assigned irradiation values and adjusting the accelerator's duty factor, enabling efficient surface treatment and material strengthening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional industrial electron accelerators are used to produce high-average beam power, then material treatment capability is improved, but cost-effectiveness and device complexity worsen
Solution Approach 1:
The patent divides the continuous electron beam into discrete pulses, allowing the accelerator to operate at lower average power while achieving the same material treatment effect through controlled peak power delivery. This segmentation of the beam in time domain resolves the contradiction by reducing overall device complexity and cost while maintaining effective beam power for material modification.
Solution Approach 2:
The patent employs periodic pulsed operation of the electron accelerator, where the beam is delivered in repeated cycles with controlled duty factors. This periodic action allows the system to achieve high peak power for effective material treatment while maintaining low average power consumption, thereby resolving the contradiction between beam power capability and device complexity/cost.
2Speed
If continuous electron beam irradiation is used for material treatment, then processing speed is improved, but energy efficiency and precision control worsen
Solution Approach 1:
The patent uses periodic pulsed electron beam delivery with variable duty factors to control both processing speed and energy efficiency. By adjusting the pulse frequency and width, the system maintains high processing speed through rapid sequential scanning while improving energy efficiency by delivering beams only when and where needed, avoiding continuous energy expenditure.
Solution Approach 2:
The patent implements dynamic control of the electron beam parameters including pulse width, frequency, and intensity based on real-time processing requirements. This dynamic adjustment allows the system to optimize the balance between processing speed and energy efficiency for different material treatment stages and regions, resolving the contradiction by adapting beam delivery to actual processing needs.
3Productivity
If high duty factor accelerator operation is used for rapid material processing, then productivity is improved, but energy consumption and heat generation worsen
Solution Approach 1:
The patent employs periodic pulsed operation with optimized duty factors that balance productivity and energy consumption. By delivering electron beams in controlled pulses rather than continuous operation, the system achieves high processing throughput through rapid sequential scanning while allowing cooling periods between pulses that reduce average energy consumption and heat generation in the accelerator components.
4Ease of manufacture
If uniform electron beam irradiation is applied to the target area, then processing simplicity is improved, but manufacturing precision and feature complexity worsen
Solution Approach 1:
The patent applies local quality control by varying electron beam parameters (intensity, pulse width, scanning speed) across different regions of the target area. This allows precise control of irradiation dose for each discrete voxel, enabling complex three-dimensional feature creation with high manufacturing precision while maintaining relatively simple overall processing through automated parameter adjustment based on pre-programmed patterns.
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
Enables the cost-effective production of complex three-dimensional features and material strengthening by precisely controlling electron beam irradiation, improving material properties and reducing operational costs through efficient energy delivery and targeted material treatment.
Implementation Method 1
delivering a dose of irradiation to each of the at least one discrete voxels according to the assigned irradiation value... delivering the dose of irradiation with an accelerator... directing an electron beam accelerator mounted to a vehicle through the target area
Implementation Method 2
in situ cross-linking of materials to produce arbitrary functional or ornamental three-dimensional features using electron beams provided by mobile accelerators... depositing a cross-linking material in the target area
Implementation Method 3
rapid and deep pre-heating of surfaces, surface preparation, treating, and strengthening materials... delivering a dose of irradiation to each of the at least one discrete voxels
Implementation Method 4
improving material properties and reducing operational costs through efficient energy delivery and targeted material treatment... adjusting a duty factor of the accelerator according to the assigned irradiation value
Data Source
AI summary
A method and system for in situ cross-linking of polymers, Bitumen, and other materials to produce arbitrary functional or ornamental three-dimensional features using electron beams provided by mobile accelerators comprises defining a desired pattern for imparting on a target area, mapping the target area, defining at least one discrete voxel in the target area according to the desired pattern to be imparted on the target area, assigning an irradiation value to each of the at least one discrete voxels, and delivering a dose of irradiation to each of the at least one discrete voxels according to the assigned irradiation value.