Watch Component Manufacturing via Cold Aerosol Deposition
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Solution Overview
Problem
Existing manufacturing processes for watch components fail to achieve tight control of functional dimensional tolerances, leading to inconsistencies and increased costs.
Innovation Solution
The method involves using the Aerosol Deposition Method (ADM) at room temperature to deposit materials onto a substrate with precise structuring means such as molds or masks, allowing for selective and three-dimensional deposition without heat treatment, resulting in deposits with thicknesses of at least 100 µm, and up to 1000 µm, enabling tight control of dimensional tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional thermal deposition methods are used, then materials can be deposited onto substrates, but heat treatment causes distortion and loss of dimensional tolerance control
Solution Approach 1:
The invention changes the temperature parameter from conventional thermal deposition (requiring heat treatment) to cold aerosol deposition (room temperature), thereby achieving dimensional tolerance control while still depositing thick material layers
Solution Approach 2:
The invention replaces the thermal field (heat treatment) with a mechanical field (aerosol projection with kinetic energy), where particles are accelerated and deposited without thermal processing, eliminating heat-induced distortion
2Manufacturing precision
If UV photolithography and galvanic deposition are used, then high-precision metal microstructures can be manufactured, but functional dimensional tolerances cannot be tightly controlled
Solution Approach 1:
The invention transitions from planar photolithography patterning to three-dimensional aerosol deposition with structuring means, enabling precise dimensional control in all spatial dimensions while achieving thick deposits
Solution Approach 2:
The invention applies structuring means (molds or masks) before deposition to predefine the geometric constraints, ensuring that the deposited material adheres to precise dimensional specifications from the outset
3Adaptability or versatility
If injection molding is used for powder molding, then iron parts can be produced, but composite materials incompatible with thermal processes cannot be deposited
Solution Approach 1:
The invention changes the fundamental parameter from thermal processing to cold aerosol deposition, enabling the use of composite materials (metals, ceramics, polymers) that would decompose or react under thermal processing conditions
Solution Approach 2:
The invention explicitly enables the deposition of composite materials by avoiding heat treatment, allowing combinations of metals, ceramics, and polymers to be deposited as functional coatings or structures
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 approach provides precise control over functional dimensional tolerances, reduces manufacturing costs, and allows for the use of composite materials that are incompatible with conventional thermal deposition methods, enhancing properties like impact resistance and wear resistance.
Implementation Method 1
The projecting step is carried out by the cold aerosol projection method of particles 'Aerosol Deposition Method (ADM)' carried out at room temperature
Data Source
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AI summary
A method for manufacturing a watch component (3) comprising the steps of providing a substrate (2), a deposition device (1) for depositing at least one material (9) on the substrate (2), and structuring means (4, 5) for selectively depositing said at least one material (9) on the substrate (2); using the deposition device (1) and the structuring means (4, 5), projecting said at least one material to form a structured deposit (3) on the substrate (2); and separating the structured deposit (3) from the substrate (2) so as to obtain the watch component (20); wherein the projecting step is carried out by an aerosol projection process of particles of said at least one material (9); and wherein the deposit has a thickness of at least 200 µm.