UV Resin Layer Flattening for Raised Portion Control
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Solution Overview
Problem
The formation of locally raised portions due to surface tension in semi-cured layers of ultraviolet curing resin affects the shape of upper layers and finished products, particularly in narrow sections, leading to inconsistencies in thickness and conductivity.
Innovation Solution
A multi-step process involving discharge, flattening, semi-curing, and curing of curable viscous fluids, with adjusted flattening member height and increased scans to address raised portions, ensuring smooth layer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the ultraviolet curing resin is discharged and semi-cured, then the shaped object is formed, but locally raised portions are formed due to surface tension affecting the shape of upper layers
Solution Approach 1:
The patent applies preliminary flattening action before the resin is fully cured. The flattening roller performs flattening on the semi-cured layer while the resin is still in a semi-cured state, preventing the surface tension from causing raised portions in the final cured product. This preliminary intervention eliminates the harmful effect before it can affect upper layers.
Solution Approach 2:
The patent changes the curing parameter by using semi-curing instead of full curing during the flattening process. By controlling the curing degree to be partial (semi-cured state), the resin maintains sufficient plasticity to be flattened while preventing the surface tension from causing raised portions. This parameter change allows the flattening operation to be effective.
2Shape
If the flattening member height is adjusted to address raised portions, then the surface flatness is improved, but the contact time between flattening member and resin must be increased
Solution Approach 1:
The patent changes the curing parameter to semi-cured state, which significantly reduces the contact time required for flattening. The semi-cured resin has optimal plasticity that allows rapid flattening without requiring extended contact time, thus resolving the time consumption issue while achieving surface flatness.
3Strength
If the resin is fully cured before flattening, then the structural strength is maintained, but the raised portions cannot be effectively flattened
Solution Approach 1:
The patent changes the curing parameter from full curing to semi-curing before the flattening operation. This parameter change allows the resin to maintain sufficient structural integrity while remaining plastic enough to be flattened effectively. The semi-cured state provides the optimal balance between strength and formability.
Solution Approach 2:
The patent performs flattening as a preliminary action before the resin is fully cured. By flattening the semi-cured layer, the raised portions are eliminated before they can affect the shape accuracy of upper layers, while the resin maintains sufficient strength through the semi-cured state.
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
The method reduces the influence of raised portions by increasing contact time and removing excess fluid, resulting in uniform thickness and improved conductivity of the final product.
Implementation Method 1
a locally raised portion may be formed by a surface tension of the ultraviolet curing resin
Implementation Method 2
the discharged curable viscous fluid is cured by irradiation with ultraviolet rays
Data Source
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AI summary
Provided are a shaping method and a shaping device capable of reducing an influence of a raised portion of a semi-cured layer on an upper layer. The shaping method repeatedly executes a first discharging step, a first flattening step, and a first curing step to form a first flattening layer on a stage. In the shaping method, the second discharging step and the semi-curing step are repeatedly executed to form a semi-cured layer on the stage. In the shaping method, the flattened semi-cured layer is cured to form a smooth layer. The shaping method includes a third discharging step of discharging the first curable viscous fluid onto the smooth layer, a third flattening step of providing the flattening member at a height corresponding to a height of a raised portion formed on the smooth layer and flattening the first curable viscous fluid discharged in the third discharging step, by the flattening member, by increasing the number of scans of flattening by the flattening member to be larger than that in the first flattening step, and a third curing step of curing the first curable viscous fluid flattened in the third flattening step.