Modular Powder Application Device for Multilayer Stiffening Elements
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Solution Overview
Problem
Existing devices for producing stiffening elements from powdery material are limited in their ability to easily produce different types of stiffening elements with varying properties, such as thickness and material composition.
Innovation Solution
A device comprising two powder application devices and two connecting devices, with intermediate and additional element arrangement capabilities, allows for the production of multilayer stiffening elements with different material thicknesses and compositions by applying and connecting powders with heat and pressure, and optionally incorporating intermediate elements like fabrics or RFID chips, and features a modular structure for flexible production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single powder application device is used, then the device structure is simple, but the ability to produce different types of stiffening elements with varying properties is limited
Solution Approach 1:
The device is divided into multiple independent powder application devices (first and second powder application devices), each capable of applying different powder mixtures. This segmentation allows each device to be optimized for specific powder types while collectively providing versatility in producing different stiffening element variants.
Solution Approach 2:
Each powder application device is designed with universal functionality to handle different powder mixtures through interchangeable powder containers and adjustable templates. This multi-functionality enables the same device structure to produce various stiffening element types by changing powder composition and application parameters rather than requiring entirely different devices.
2Adaptability or versatility
If multiple powder layers are applied to achieve different thicknesses and compositions, then product versatility is improved, but the number of application steps increases
Solution Approach 1:
Multiple powder application operations are merged into a single integrated device structure where the first and second powder application devices operate in sequence without requiring intermediate handling or setup changes. The conveyor belt system continuously transports the substrate through both application stages, combining what would otherwise be separate production steps into one streamlined process.
Solution Approach 2:
The first powder application device applies a base layer of powder mixture that is partially connected before the second powder application device adds additional layers. This preliminary action creates a stable foundation that facilitates subsequent powder application and connecting operations, enabling efficient multi-layer construction without requiring complete cooling or handling between layers.
3Strength
If heat and pressure are applied to connect the powder, then the stiffening element achieves sufficient strength, but energy consumption increases
Solution Approach 1:
The connecting devices utilize phase change of the binder material as a key parameter change mechanism. By heating the powder mixture to the melting point of the binder component, the material transitions from solid to liquid state, enabling flow and connection. This phase-based approach allows effective connecting at relatively low temperatures compared to complete melting methods, reducing energy consumption while achieving sufficient bond strength.
Solution Approach 2:
The powder mixture is designed as a composite material containing meltable binder components mixed with non-meltable structural powders. This composite structure enables connecting through selective melting of the binder phase while maintaining the structural integrity of the non-meltable components, achieving strong bonds with lower energy input than would be required to melt the entire powder mixture.
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 simple and efficient production of stiffening elements with varied properties, including different thicknesses and material compositions, and allows for additional features like calibration and quality control, enhancing production flexibility and quality.
Implementation Method 1
The first connecting device can, for example, have a heating element to cause the at least partially meltable powder material to melt or smelt
Implementation Method 2
The heat can be introduced into the material, for example, by a laser, thermal radiation from a lamp and/or another heating element
Implementation Method 3
A pressing device is provided downstream of the second connecting device in order to apply pressure to the stiffening element produced
Data Source
Figure 1
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AI summary
The invention relates to a device for producing reinforcement elements for shoes, bags or orthopaedic applications, comprising a first powder application device (10), at least one first connection device (20) located downstream thereof, a further second powder application device (26) and a second connection device (30). Such a modular structure allows various types of reinforcement elements to be produced in a simple manner.