Roller Functional Layer Additive Manufacturing via Laser Sintering
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Solution Overview
Problem
Current methods for producing roller functional layers require multiple process steps, increasing processing time and costs, and are limited in the types of structures that can be introduced, as they rely on external machining techniques like drilling or milling, which restrict the creation of complex internal structures.
Innovation Solution
A method that applies a coating substrate to a roller blank, allowing for simultaneous application over a wide area and curing to form a solidified structure, enabling the creation of complex three-dimensional functional structures within the functional layer without additional post-processing steps, using techniques like laser sintering and electrostatic adhesion, allowing for the formation of channels and cavities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple process steps are used to apply functional layer and create structures, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
The patent combines the functional layer application and structure creation into a single additive manufacturing process step. The 3D printing technique simultaneously deposits material and forms complex internal structures (channels, cavities, grooves) without requiring separate machining operations, thereby merging multiple traditional process steps into one integrated operation that improves productivity while maintaining precision.
Solution Approach 2:
The additive manufacturing process performs preliminary structuring during the layer application itself rather than as a subsequent operation. Structures such as channels and cavities are built in-place as the functional layer is deposited, eliminating the need for post-manufacturing drilling or milling operations and reducing total processing time.
2Manufacturing precision
If external machining techniques are used to create structures, then manufacturing precision is improved, but device complexity deteriorates
Solution Approach 1:
The patent replaces traditional mechanical machining techniques (drilling, milling) with an additive manufacturing process that uses controlled material deposition and curing. This substitution eliminates the need for complex external machining equipment and multiple tooling operations, reducing device complexity while achieving the required structural precision through digital modeling and controlled layer-by-layer construction.
3Ease of manufacture
If traditional coating methods are used, then ease of manufacture is improved, but adaptability deteriorates
Solution Approach 1:
The additive manufacturing process enables local variation in structure creation within the functional layer. Different regions can be printed with different patterns, densities, and geometries (channels, cavities, grooves) according to specific functional requirements, allowing high adaptability while maintaining ease of manufacture through a single digital design file that controls the entire layer deposition process.
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 processing time and costs by integrating complex structures into the functional layer during the manufacturing process, enabling the creation of functional layers with intricate designs, such as channels and holes, without the need for external machining, resulting in a more efficient and versatile roller production method.
Implementation Method 1
The coating substrate is applied to the surface of the roller blank, in particular by immersing the roller blank in a storage volume for the coating substrate
Implementation Method 2
curing of the entire applied coating substrate or parts thereof to form a solidified structure
Implementation Method 3
using techniques like laser sintering
Data Source
Figure 1~2
Figure 3
AI summary
A method for producing or machining a roller (1) which is suitable to be used in a machine for producing or processing a fibrous web, wherein the roller comprises a roller core (2) and at least one functional layer (3), wherein the method comprises the application of at least one functional layer, wherein the application comprises at least the following process steps: a) applying a coating substrate (4) to the surface of the rolling blank, wherein the application takes place simultaneously over at least half the roller width, preferably over 75% of the roller width, particularly preferably over the entire roller width, b) hardening of the entire applied coating substrate (4) or parts thereof to form a solidified structure.