3D Screen-Printed Green Parts With Wavy Walls to Prevent Cracking
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Solution Overview
Problem
Existing screen printing processes for producing green parts with vertical wall structures, such as honeycombs, are prone to cracking and material deformation due to curvature, leading to stress and undesirable defects.
Innovation Solution
A three-dimensional screen printing process using a screen printing mask with wavy openings to create green parts with wavy structures, allowing for deformation without significant cracking by utilizing the 'accordion effect' to absorb stretching and compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If green parts with vertical wall structures (e.g., honeycombs) are produced using conventional screen printing, then the manufacturing process is simple and efficient, but cracks and defects occur during deformation due to tension on the outer radius and compression on the inner radius
Solution Approach 1:
The patent applies curvature principle by transitioning from straight vertical walls to wavy/corrugated vertical walls in the green part structure. The wavy structure with defined wavelength and amplitude allows the component to deform along the curvature of the waves during bending, distributing stress evenly and preventing crack formation at the outer radius while accommodating compression at the inner radius.
2Adaptability or versatility
If the green part is deformed to create complex shapes, then the component can be adapted to various applications, but tension cracks occur on the outer radius of curvature
Solution Approach 1:
The wavy structure预先 incorporates curvature geometry that matches the intended deformation path. When the green part is bent to create complex shapes, the waves naturally follow the curvature, allowing the material to stretch and compress along the wave contours rather than creating stress concentrations that would cause cracks.
3Adaptability or versatility
If material is compressed on the inner radius of curvature, then the green part can be deformed into complex shapes, but material deformation and defects occur
Solution Approach 1:
The corrugated structure with optimized wavelength and amplitude provides geometric compliance that accommodates compression on the inner radius of curvature. The waves can fold and compress without causing material failure, maintaining structural integrity while enabling complex shape formation.
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 wavy structures in the green parts effectively prevent or minimize cracks and material deformation during manufacturing and operation, enabling the production of complex-shaped components suitable for turbomachinery applications.
Implementation Method 1
deformation can cause stretching and/or compression in the green part, which is compensated for, at least in part, by the adjustment of the wavelength of the corrugated structure of the green part
Implementation Method 2
A screen printing mask with a screen printing structure is used, whereby the screen printing mask has openings for the printing material to be pressed through
Implementation Method 3
The printing material contains or consists of a proportion of powder, in particular ceramic or metal powder, and a binder
Data Source
Figure 1
Figure 1A~1C
Figure 2~3
AI summary
The invention relates in particular to a three-dimensional screen printing method for producing a green part (20) from printing material (11) for a powder metallurgical component (30), wherein the printing material (11) contains powder, more particularly metal powder or ceramic powder, and binder or consists of these materials, characterized in that a screen printing mask (10) has a screen printing structure (1) having openings (1', 1", 13) for pressing the printing material (11) through, the openings (1', 1") being partly undulate so that the green part (20) at least partly has a three-dimensional undulate structure (21) and/or undulate edges (22).