Structure Forming Apparatus for High-Accuracy Sheet Manufacturing
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Solution Overview
Problem
Existing film manufacturing methods using forming rolls are limited in the fineness and accuracy of the shape transferred onto the film.
Innovation Solution
A structure forming apparatus comprising a rotatable roller, a retaining member, and an irradiation unit that selectively radiates an energy beam to cure a material in a slit region, allowing for the formation of a sheet-like structure with high accuracy and complexity, using techniques like stereolithography and rapid prototyping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a forming roll with engraved pattern is used to transfer shape onto film, then the manufacturing process is simple and continuous, but the fineness and accuracy of the transferred shape is limited
Solution Approach 1:
The patent replaces the mechanical contact-based forming roll system with a non-contact energy beam irradiation system. The roller transmits energy beams (such as laser) to selectively cure the material, eliminating the need for physical engraved patterns on forming rolls while achieving higher shape accuracy and fineness through precise beam control and digital modeling techniques.
Solution Approach 2:
The patent changes the fundamental parameter of shape transfer from mechanical contact (engraved pattern) to energy beam irradiation. By controlling the energy beam parameters (intensity, duration, scanning pattern) and using photo-curable materials, the system achieves variable shape accuracy and fineness that is not constrained by the physical limitations of engraved rolls.
2Shape
If traditional forming roll method is used, then the device structure is simple, but the complexity and fineness of the formed shape is limited
Solution Approach 1:
The patent substitutes the mechanical pattern transfer method with a digital modeling approach using energy beam irradiation. This enables the formation of complex three-dimensional shapes with high precision by controlling the curing of photo-curable materials layer by layer or selectively in specific regions, achieving both shape complexity and manufacturing precision simultaneously.
Solution Approach 2:
The patent transitions from two-dimensional pattern transfer on the film surface to three-dimensional shape formation by controlling the depth and distribution of material curing. The energy beam can selectively cure material at different depths and positions, enabling complex 3D structures while maintaining high shape accuracy.
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
Enables the creation of sheet-like structures with minute and highly accurate shapes, improving the precision and complexity of formed patterns, and allowing for efficient production with post-curing treatments.
Implementation Method 1
an irradiation unit configured to selectively radiate the energy beam to the slit region through the roller to cure the material so that a sheet-like structure is formed
Data Source
AI summary
Provided is a structure forming apparatus, including: a roller provided to be rotatable, having a length in an axial direction of the rotation, and capable of transmitting an energy beam; a retaining member arranged to face the roller such that a slit region having a length in the axial direction is formed between the retaining member and the roller, and capable of retaining a material to be cured by energy of the energy beam at least in the slit region; an irradiation unit configured to selectively radiate the energy beam to the slit region through the roller to cure the material so that a sheet-like structure is formed; and a take-up reel configured to take up the sheet-like structure thus formed.