3D-Printed Pervious Tray Surface for Durable Non-Stick Release
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Solution Overview
Problem
Existing anti-adhesion or non-stick coatings on trays used in the food industry wear out due to abrasion, requiring regular re-coating and posing a challenge for maintaining a non-stick surface.
Innovation Solution
A method for producing an element with both pervious and non-pervious parts using a three-dimensional printing process, where the pervious part is formed by partially fusing granular material to maintain inter-particle voids, creating a non-stick surface, and the impervious part is formed by fully fusing the material to remove voids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional non-stick coatings are applied to trays, then the non-stick property is improved, but the coating wears out due to abrasion requiring regular re-coating
Solution Approach 1:
The patent applies porous materials by creating a pervious part in the tray body through selective laser sintering, where particles are partially fused to maintain inter-particle voids. This porous structure provides inherent non-stick properties without requiring traditional coatings, eliminating wear and re-coating needs while maintaining the non-stick function throughout the tray's service life.
Solution Approach 2:
The patent utilizes parameter changes by varying laser printing parameters (energy input, scanning speed, hatching distance) to create different density regions within the same tray body. The pervious part uses parameters that maintain porosity for non-stick properties, while the impervious part uses parameters that create dense structures for structural support, all from a single material without coatings.
2Strength
If particles are fully fused to create impervious parts, then structural strength is improved, but the non-stick surface property is lost
Solution Approach 1:
The patent applies local quality by creating distinct regions within the tray body with different properties: a pervious part with interconnected pores for non-stick surface properties and an impervious part with dense structure for structural strength. Each region is optimized for its specific function while being integrally formed from the same material.
Solution Approach 2:
The patent segments the tray body into functionally distinct parts - the pervious part containing interconnected pores for non-stick properties and the impervious part for structural support. This segmentation allows each part to perform its specific function optimally while being manufactured as a single integral component.
3Ease of manufacture
If pervious and impervious parts are manufactured separately, then manufacturing flexibility is improved, but assembly complexity and potential leakage paths increase
Solution Approach 1:
The patent merges the pervious part and impervious part into a single integrally formed component manufactured in one selective laser sintering process. This eliminates assembly complexity, potential leakage paths at interfaces, and sealing requirements while maintaining the manufacturing flexibility to create complex geometries with varying density distributions.
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
The method allows for the integration of pervious and impervious parts within a single element, providing a durable non-stick surface that can be easily cleaned and maintained, reducing the need for frequent re-coating.
Implementation Method 1
directing a laser beam at printing positions on or in said layer of granular material using first or second set of printer settings
Implementation Method 2
particles of said granular material are partially fused together to form a material wherein a space between the particles is at least partially maintained
Implementation Method 3
directing a laser beam at printing positions on or in said layer of granular material using first or second set of printer settings
Implementation Method 4
particles of said granular material are fused together to form a material wherein a space between the particles of the granular material is substantially removed
Data Source
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AI summary
An element comprising a non-stick surface for substantially cleanly removing a product which is arranged against said non-stick surface. The element comprises a first layer of an pervious material, which is configured to allow a fluid to flow there through. An outer surface of said first layer provides the non-stick surface. The element comprises a second layer of an impervious material, which is configured to substantially block a flow of fluid there through. The second layer is arranged at a side of said first layer opposite to the outer surface. The element comprises ducts or chambers which are arranged in said first layer or in between said first and second layer. Said ducts or chambers are arranged in fluid connection with said pervious material and are configured for feeding a pressurized fluid to the pervious material. At least the first layer is formed using a three-dimensional printing tool.