Substrate Surface Smoothing via Inkjet Filler Deposition
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Solution Overview
Problem
Surface defects such as cutter marks, scratches, and pits in substrates during manufacturing lead to uneven mating surfaces, affecting the cosmetic appearance, sealing, and functionality of parts, and can cause processing problems in later stages.
Innovation Solution
Non-contact additive processes like inkjet printing and robot-controlled needle dispensing are used to precisely deposit filler material around or in surface defects, ensuring smooth mating surfaces by comparing the substrate's surface to a reference contour and adjusting it to achieve conformance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machining processes are used to create parts, then manufacturing productivity is maintained, but surface defects such as cutter marks, scratches, and pits occur, leading to uneven mating surfaces and poor cosmetic appearance
Solution Approach 1:
The patent applies preliminary action by depositing filler material on the substrate surface before the mating component is manufactured. This pre-filling of surface defects allows the mating part to be manufactured normally without requiring rework, thereby maintaining productivity while achieving smooth mating surfaces. The filler material is applied in advance to correct surface irregularities that would otherwise cause cosmetic and functional issues.
2Manufacturing precision
If filler material is deposited to repair surface defects, then mating surface smoothness is improved, but additional manufacturing steps are required, increasing process complexity
Solution Approach 1:
The patent replaces traditional mechanical machining processes with a non-contact additive process for surface repair. Instead of using mechanical tools to remove material or reshape surfaces, the invention uses depositing technology to add filler material that conforms to the substrate surface. This substitution eliminates the need for complex mechanical repair operations while achieving smooth mating surfaces, thereby reducing process complexity.
3Reliability
If surface defects are left unrepaired, then manufacturing time is reduced, but sealing and adhesion performance deteriorate, affecting product reliability
Solution Approach 1:
The patent changes the physical and chemical parameters of the substrate surface by depositing filler material with specific properties. The filler material is formulated to match the substrate in terms of thermal expansion, adhesion characteristics, and surface energy. This parameter matching ensures that the repaired surface provides reliable sealing and adhesion performance equivalent to defect-free surfaces, without requiring extended manufacturing time for complex repair procedures.
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 method effectively creates smooth, cosmetically appealing, and functionally reliable mating surfaces by eliminating defects, enhancing adhesion and sealing, and improving the structural integrity of parts.
Implementation Method 1
non-contact additive processes, such as printing techniques or robot-controlled needle dispensing techniques, are used to precisely deposit material
Implementation Method 2
depositing material in and/or around surface defects so as to form consistently smooth surfaces
Data Source
AI summary
Methods for modifying contours of substrate surfaces are disclosed. Methods include depositing filler material on a critical mating surface of a substrate so as to render the mating surface more mateable with a matching substrate. The filler material can be deposited within or around features or defects on the mating surface such that a final desired surface contour is achieved. In some cases, the final surface contour of the mating surface is planar. This can prevent gaps associated with the features or defects from forming between the substrate and the matching substrate when they are joined together. The final surface contour of the mating surface can be determined by comparing dimensions of the mating surface to dimensions of a reference surface. In some cases, ink jet printing techniques are used to deposit the filler material accurately in prescribed locations and with precise thickness control.