Reinforced 3D-Printed Deflection Members for Higher Durability
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Solution Overview
Problem
Existing deflection members made via additive manufacturing lack durability and strength due to the absence of a separate reinforcing member, which is crucial for withstanding extreme conditions in papermaking and nonwoven processes.
Innovation Solution
Utilize three-dimensional printing technology to create deflection members with a non-unitary reinforcing member, integrating a resinous framework onto a separately manufactured reinforcing member using cross-linkable polymers and filler materials, forming a durable structure with unique topography.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If additive manufacturing is used to make deflection members, then manufacturing complexity is reduced and productivity is improved, but durability and strength deteriorate due to the absence of a separate reinforcing member
Solution Approach 1:
The patent combines the reinforcing member and resinous framework into a single integrated deflection member structure. The reinforcing member is embedded within the resinous framework, creating a composite structure that merges the strength benefits of the reinforcing member with the成形 capabilities of the resinous framework, thereby maintaining both durability and manufacturing efficiency
Solution Approach 2:
The patent uses composite materials by combining a reinforcing member (such as woven or non-woven fabric) with a resinous framework material. This composite structure provides both the mechanical strength needed for durability and the成形 properties required for deflection member functionality, resolving the contradiction between strength and manufacturing ease
2Strength
If a separate reinforcing member is added to enhance durability, then strength is improved, but device complexity increases
Solution Approach 1:
The reinforcing member and resinous framework are merged into a single integrated structure where the reinforcing member is embedded within the resinous framework. This merging eliminates the need for separate assembly steps and reduces structural complexity while maintaining the strength benefits of the reinforcing member
Solution Approach 2:
The resinous framework is designed with a porous structure that accommodates the reinforcing member within its matrix. This porous design allows the reinforcing member to be integrated without significantly increasing overall structural complexity, as the reinforcing member fits within the existing framework architecture
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 resulting deflection members exhibit enhanced durability and longevity, capable of enduring the evolving processing environments of fibrous web making machines, while maintaining the ability to form complex three-dimensional structures.
Implementation Method 1
radiation is created by at least one radiation source and directed from the at least one radiation source towards the reinforcing member such that the radiation passes through the reinforcing member to at least partially cure the photopolymer resin in contact with the reinforcing member
Data Source
AI summary
A method for manufacturing a deflection member is disclosed. The method may include the steps of providing an additive manufacturing apparatus that includes at least two radiation sources and photopolymer resin, providing a reinforcing member, contacting a surface of the reinforcing member with the photopolymer resin, and directing radiation from the radiation source(s) towards a surface(s) of the reinforcing member to at least partially cure photopolymer resin in contact with the surface of the reinforcing member.