UV Light Diffusion Window for Smoother 3D Resin Printing
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Solution Overview
Problem
Existing methods for additive manufacturing of 3D components such as dental restorations and dental appliances fail to efficiently remove elemental mercury (Hg0) from flue gas and oxidized mercury (Hg2+) from waste liquid, with activated carbon injection technology being costly and its mercury removal efficiency affected by NOx and SO2.
Innovation Solution
Utilization of metal sulfides (e.g., FeS2, CuS, CuFeS2) as mercury removal adsorbents, which contact with flue gas and waste liquid, adsorbing and converting Hg0 from flue gas and Hg2+ from waste liquid into stable mercury sulfide compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical surface treatment (polishing, grinding) is applied to printed 3D components, then surface smoothness is improved, but additional staff, working hours, and consumables are required increasing costs
Solution Approach 1:
The optical diffuser is integrated into the UV-transparent window before the printing process, pre-conditioning the UV light to create smooth surface features during curing. This preliminary action eliminates the need for post-printing mechanical surface treatment operations.
Solution Approach 2:
The patent replaces mechanical surface treatment operations (polishing, grinding) with an optical solution. The optical diffuser scatters UV light to create smooth surfaces during printing, substituting the need for mechanical post-processing operations.
2Manufacturing precision
If mechanical surface treatment is applied to transparent photocurable resin components, then transparency is improved by removing opacity, but production time and costs increase
Solution Approach 1:
The optical diffuser is positioned in the UV light path before the resin is exposed, pre-conditioning the light to create transparent, opaque-free surfaces during the printing process itself, eliminating the need for separate post-processing transparency treatments.
Solution Approach 2:
The patent replaces mechanical surface treatment operations with an optical field-based solution. The diffused UV light creates smooth, transparent surfaces during curing, substituting the need for mechanical polishing and grinding operations that would otherwise be required.
3Manufacturing precision
If anti-aliasing software is used to improve edge-smoothness, then computational costs increase and physical limitations reduce practical effects
Solution Approach 1:
The patent replaces software-based anti-aliasing algorithms with a physical optical solution. The optical diffuser physically scatters UV light to create smooth edges during printing, eliminating the need for computationally intensive software processing and its associated limitations.
Solution Approach 2:
The optical diffuser acts as an intermediary element between the UV light source and the photocurable resin. It mediates the light interaction by scattering and diffusing the UV radiation, creating smooth edges without requiring complex computational algorithms.
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
Achieves efficient, cost-effective, and environmentally friendly simultaneous removal of Hg0 from flue gas and Hg2+ from waste liquid, avoiding secondary pollution and reducing operational costs.
Implementation Method 1
an optical means (6-5) which is adapted to diffuse the projected UV light (8) towards the building platform (9) into the region (R) where the UV light photocurable resin (5) is to be layerwise cured
Implementation Method 2
a UV-transparent window (6-4) at the bottom of the reservoir (4), wherein said UV-transparent window (6-4) includes a UV-transparent plate (6-4a) and a UV-transparent anti-adhesive flexible foil (6-4b)
Implementation Method 3
a 3D (three-dimensional) component is printed layer-by-layer through light-based curing of a liquid printing medium i.e., a photocurable resin, which is selectively cured under the influence of UV radiation
Data Source
AI summary
The present invention relates to an additive manufacturing apparatus for additively manufacturing a component, including: a resin vat unit which includes: a reservoir for storing UV light photocurable resin; and a UV-transparent window at the bottom of the reservoir, the UV-transparent window includes a UV-transparent plate and a UV-transparent anti-adhesive flexible foil; a projection unit for projecting UV light through the UV-transparent window into the reservoir; a movable building platform having a surface onto which the component can be formed through layerwise curing of said resin. The UV-transparent window further includes: an optical means which is adapted to diffuse the projected UV light towards the building platform into a region (R) where the UV light photocurable resin is to be layerwise cured, the optical means is arranged in the light path of the projected UV light.