Transfer Plate Raised Portions for High-Density Particle Patterning
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Solution Overview
Problem
Existing additive manufacturing methods struggle to efficiently form high-density patterns using multiple kinds of materials, particularly in forming electrodes for secondary batteries, as they lack effective techniques for transferring and distributing solid particles with high precision and density.
Innovation Solution
A transfer plate with raised portions and recessed regions is used to hold and transfer solid particles, where regions with higher holding power are interposed between those with lower holding power, and the raised portions have an elastic modulus lower than the particles, allowing for increased particle density by deformation during pressing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a transfer plate with uniform holding power is used to transfer solid particles, then the transfer process is simple, but the particle density and distribution quality are insufficient
Solution Approach 1:
The transfer plate is designed with regions of different holding powers (high holding power regions and low holding power regions) instead of uniform holding power. This local differentiation allows particles to be densely packed in high holding power regions while maintaining controlled distribution, resolving the contradiction between particle density and structural simplicity.
Solution Approach 2:
The transfer plate surface is segmented into distinct functional regions: high holding power regions for dense particle accumulation and low holding power regions for particle release and spacing. This segmentation enables precise control over particle distribution and density without requiring complex external control systems.
2Manufacturing precision
If the raised portion has high elastic modulus to maintain shape, then structural stability is good, but particle density during pressing is reduced
Solution Approach 1:
The elastic modulus of the raised portion is specifically controlled to be lower than that of the solid particles. This parameter change allows the raised portion to deform during pressing, enabling particles to be densely packed within the raised portion volume, while still maintaining sufficient structural stability for the transfer process.
Solution Approach 2:
The raised portion is designed to be dynamically deformable during the pressing process rather than rigidly fixed. This dynamic behavior allows the raised portion to compress and increase particle density under pressure, then recover its shape after pressing, balancing structural stability with particle densification.
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 enhances the density and distribution of solid particles on a base material, enabling the formation of high-density patterns and composite electrodes with improved properties.
Implementation Method 1
the raised portion has an elastic modulus lower than an elastic modulus of the solid particles
Data Source
AI summary
A forming method of a linear pattern, includes bringing a transfer plate including a raised portion extending in a predetermined direction and a material to be transferred containing solid particles into contact with each other and causing the raised portion to hold the solid particles, pressing the raised portion against a base material, and separating the raised portion from the base material, wherein the raised portion has distribution of holding power to hold the material to be transferred in a width direction orthogonal to the predetermined direction in a manner that a region with higher holding power is interposed between regions with lower holding power, and has a portion with an elastic modulus that is lower than an elastic modulus of the solid particles.