Paper Cylinder Treating Plates with Two-Scan Polymer Sintering
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Solution Overview
Problem
Existing methods for creating treating profiles on paper processing industry items face limitations in precision, uniformity, and efficiency due to the use of expensive materials and processes like FDM and laser sintering of metallic powders, which result in uneven sintering and require costly curing procedures.
Innovation Solution
A method using selective laser sintering of thermoplastic polymeric powder, with a preparatory scan to create a rough surface on the support, followed by two laser scans to uniformly premelt and sinter the powder, ensuring precise and uniform profile formation without the need for additional curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser sintering of metallic powders is used to create treating profiles, then precision and accuracy in arrangement of profile elements is improved, but cost increases and production time increases due to expensive materials and costly curing procedures
Solution Approach 1:
The patent changes the material parameter from metallic powder to thermoplastic polymeric powder, and changes the processing parameter by eliminating the curing step. This allows the treating profiles to be formed directly through laser sintering of the polymeric powder, which melts and bonds the powder particles together without requiring subsequent curing procedures, thereby reducing production time and cost while maintaining precision
Solution Approach 2:
The patent uses thermoplastic polymeric powder as a disposable material that can be easily deposited and sintered without requiring expensive metallic powders or complex curing processes. The polymeric powder serves its purpose during manufacturing and can be easily replaced, eliminating the need for costly curing procedures and reducing overall production time
2Productivity
If FDM or 3D printing processes are used to create treating profiles, then production speed is improved, but manufacturing precision deteriorates due to restrictions on obtainable shape from extrusion section
Solution Approach 1:
The patent replaces the mechanical extrusion system with a laser-based additive manufacturing system. Instead of using a physical extrusion section that limits shape possibilities, the laser selectively sinteres powder material according to a digital model, allowing for greater shape freedom and precision while maintaining production speed
Solution Approach 2:
The patent changes the manufacturing approach from mechanical extrusion to laser-based selective sintering. This parameter change allows the treatment profiles to be created directly from digital models without being constrained by physical extrusion section geometry, thereby improving both shape versatility and manufacturing precision while maintaining productivity
3Manufacturing precision
If powder material is sintered by laser beam into treating profiles, then precision is improved, but uniformity of fusion deteriorates due to unevenness between overlapping layers of powder
Solution Approach 1:
The patent applies a preliminary action by pre-heating the thermoplastic polymeric powder layer before the main laser sintering process. This preliminary heating ensures that the powder is at an optimal temperature for uniform sintering, preventing uneven fusion between overlapping layers and ensuring consistent material properties throughout the treating profile
Solution Approach 2:
The patent uses periodic action by implementing multiple scanning passes of the laser beam over the powder layer. The laser scans the powder layer multiple times at different positions and orientations, ensuring uniform heating and sintering of all powder particles, including those in overlapping layers, thereby achieving uniform fusion and consistent material composition
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 reduces preparation time, enhances precision and versatility, and achieves uniform, solid, and resistant treating profiles with improved production flexibility and cost-effectiveness.
Implementation Method 1
premelting the deposited layer of powder of polymeric material by means of at least one laser apparatus, which is operated to scan the cross-sections on each layer
Implementation Method 2
selectively raising the temperature value of the deposited layer of powder of polymeric material and sintering the deposited layer of powder of polymeric material by means of said laser apparatus
Data Source
AI summary
A method for preparing plates (22, 32) for cylinders (20, 30) to treat items of the paper processing industry (40), wherein the plates (22, 32) comprise a base (22a, 32a) having a support surface (21) and treating profile elements (25, 35) on said support surface (21) of said base (22a, 32a), the method comprising an additive manufacturing process, and comprising the following steps: a) acquiring a treating pattern (50) to be produced on the item of the paper processing industry (40) or acquiring the shape of said base (22a, 32a) of the plates (22, 32) and said treating pattern (50); b) creating a 3D reference model of at least the treating profile elements (25, 35) according to the treating pattern (50) or a 3D reference model of said base (22a, 32a) and of said treating profile elements (25, 35); c) distributing at least one layer (70) of a powder of polymeric material, preferably a powder of thermoplastic polymeric material, on said support surface (21) of said base (22a, 32a) or on a platform (203); d) premelting the deposited layer (70) of powder of polymeric material by means of at least one laser apparatus (80), which is operated to scan the cross-sections on each layer (70) with at least one first scan, in accordance with the 3D reference model of said treating profile elements (25, 35) or of both said base (22a, 23aand said treating profile elements (25, 35) 20 e) selectively raising the temperature value of the deposited layer (70) of powder of polymeric material and sintering the deposited layer (70) of powder of polymeric material by means of said laser apparatus (80), which is operated to scan the premelted cross-sections on each layer (70) with at least one second scan, in accordance with said 3D reference model of said treating profile elements (25, 35) or of both said base (22a, 23a) and said treating profile elements (25, 35), wherein a new layer (70) of said powder of polymeric material is deposited after the scanning operation of at least one cross-section by the laser apparatus (80) is completed. It is also disclosed a method for preparing plates (22,32) for cylinders (20,30) to treat items of the paper processing industry (40), wherein the support surface (21) of said base (22a, 32a), or said platform (203), is formed or pretreated to receive and retain the powder of polymeric material.