Additive Manufacturing Polymer Smoothing via Liquid Thermal Treatment
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Solution Overview
Problem
Additive manufacturing processes often result in polymer elements with undesirable rough surfaces, posing challenges for further processing and application.
Innovation Solution
A method involving a treating liquid, preferably a water-alcohol mixture, is applied to polymer elements obtained through additive manufacturing. The method includes an optional heating step to condition the treating liquid, a smoothing step where the polymer elements come into contact with the treating liquid at controlled temperatures, and an optional cooling step to finalize the treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing processes are used to produce polymer elements, then manufacturing flexibility and complexity are improved, but surface smoothness deteriorates with roughness heights up to 20 μm and more
Solution Approach 1:
The patent applies parameter changes by heating the treating liquid to a temperature between 40°C and 200°C, preferably between 80°C and 170°C. This temperature parameter change causes the polymer elements to soften and become plastic, enabling the treating liquid to smooth the rough surfaces effectively while maintaining manufacturing flexibility
Solution Approach 2:
The patent introduces a treating liquid as an intermediary substance between the rough polymer elements and the desired smooth surface. The treating liquid, when heated to appropriate temperatures, acts as a mediator that softens and smooths the polymer surfaces without requiring direct mechanical intervention, thus preserving the additive manufacturing advantages
2Manufacturing precision
If the treating liquid is heated to high temperatures to improve smoothing effectiveness, then surface smoothness is improved, but energy consumption and risk of polymer deformation increase
Solution Approach 1:
The patent optimizes the temperature parameter of the treating liquid to a specific range (40°C-200°C, preferably 80°C-170°C) that is high enough to effectively smooth the polymer surfaces but low enough to prevent polymer degradation and minimize energy consumption. This parameter optimization resolves the contradiction between smoothing effectiveness and energy efficiency
Solution Approach 2:
The patent employs a circulation device to continuously circulate the heated treating liquid through the polymer elements. This continuous circulation maintains consistent temperature and smoothing action throughout the treatment process, improving surface smoothness uniformly while avoiding the need for excessive heating that would increase energy consumption
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 effectively increases the surface smoothness of polymer elements, reducing roughness heights and improving the elements' mechanical and aesthetic properties.
Implementation Method 1
a treatment step, preferably a smoothing step, in which the polymer elements are in, or come into, contact with the treating liquid, preferably at a temperature above a lower threshold temperature and/or preferably below the upper threshold temperature
Implementation Method 2
an optional heating step for heating a treating liquid, preferably to a temperature below an upper threshold temperature, wherein the upper threshold temperature is preferably in a range of 1° C. to 150° C. below the melting temperature of the polymer
Implementation Method 3
The apparatus further preferably comprises at least one of the following devices: a circulation device, a heating device and/or a coolant tank with a cooling fluid
Implementation Method 4
The apparatus further preferably comprises at least one of the following devices: a circulation device, a heating device and/or a coolant tank with a cooling fluid
Implementation Method 5
an optional cooling step for cooling the polymer elements
Data Source
AI summary
The present invention relates to a method for treating polymer elements obtained by an additive manufacturing process. The method encompasses providing a treating liquid in a chamber of an apparatus and providing the polymer elements to be treated. Further, the method optionally encompasses a heating step of heating a treating liquid to a temperature below an upper threshold temperature, wherein the upper threshold temperature is in a range of 1° C. to 80° C. below the melting temperature of the polymer from which the polymer elements are formed. The method further encompasses a treatment, preferably smoothing, step, wherein the polymer elements are in, or come into, contact with the treating liquid at a temperature above a lower threshold temperature and below the upper threshold temperature for a predetermined period. This is carried out under conditions in which the treating liquid is in liquid state. Furthermore, the method optionally encompasses a cooling step for cooling the polymer elements. The present invention also relates to an apparatus for treating polymer elements.