Continuous fiber reinforced cryo-additive manufacturing forming method
Through the continuous fiber-reinforced frozen additive manufacturing forming method, the problem of difficult to form composite materials with high fiber content is solved. The efficient forming of fibers is achieved through the wetting and freezing and compacting steps, and the fiber content is increased through the weaving technology of implanted holes and the improvement of fiber content is improved. The comprehensive properties of composite materials.
Patent Information
- Application Number
- CN202410883019.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- Filing Date
- 2024-07-02
- Publication Date
- 2024-12-13
- Estimated Expiration
- 2044-07-02
AI Technical Summary
The existing continuous fiber reinforced composite materials with high fiber content are difficult to form through additive manufacturing technology, resulting in a low fiber content of composite components and it is difficult to further improve the overall performance.
Using continuous fiber reinforced frozen additive manufacturing forming method, the additive manufacturing of continuous fibers is achieved through layering, path planning, wetting, printing and freezing compaction steps, and implanted holes are reserved during the printing process to weave Z-direction Fiber, improves fiber content and interlayer bonding performance.
The fiber content and comprehensive performance of composite material components are improved, and the efficient forming and customized structure manufacturing of continuous fibers is achieved, with a simple and reliable method.
Smart Images
Figure CN118636463B_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of composite material forming methods, and in particular to a continuous fiber reinforced cryogenic additive manufacturing forming method. Background Art
[0002] Continuous fiber reinforced composite materials are increasingly being used in aerospace, marine engineering and ships, advanced rail transportation, new energy vehicles, biomedicine, electronic appliances and many other fields due to their superior mechanical properties, designability, corrosion resistance, fatigue resistance and many other advantages. The combination of additive manufacturing and continuous fiber reinforced composite materials can give full play to the manufacturing advantages of additive manufacturing and the performance advantages of composite materials, realize the effective manufacturing of high-performance, high-value-added, customized composite materials structures, and further expand the application scope of continuous fiber reinforced composite materials.
[0003] At present, in the additive manufacturing technology of continuous fiber reinforced composite materials, continuous fibers and resins are usually synthesized together, and the printing nozzle is moved under path control to form composite components. The content of continuous fibers in composite components directly affects the mechanical properties of the components, but in the current additive manufacturing technology of continuous fiber reinforced composite materials, the formation of composite components depends on the bonding effect of resin, and continuous fibers with high fiber content are difficult to form through additive manufacturing processes, which makes the fiber content of composite components low, and it is difficult to further improve the comprehensive performance of composite components. Summary of the invention
[0004] In view of this, the present invention provides a continuous fiber reinforced cryo-additive manufacturing forming method to solve the problem that existing high-fiber-content continuous fiber reinforced composite materials are difficult to obtain through additive manufacturing technology, and thus it is difficult to further improve the comprehensive performance of the corresponding composite material components.
[0005] The present invention provides a continuous fiber reinforced frozen additive manufacturing forming method, comprising the following steps: layering: constructing a three-dimensional model of a preformed component and layering the three-dimensional model; path planning: setting an additive manufacturing path for each layer of the preformed component according to cross-sectional profile information of each layer of the three-dimensional model; soaking: soaking the continuous fiber with water; printing: printing on a printing platform using the continuous fiber according to the additive manufacturing path of the corresponding layer to obtain a printed layer; freezing compaction: during the printing process, freezing and compacting the printed layer; repeating the soaking step, the printing step and the freezing and compaction step until a predetermined number of printed layers is reached.
[0006] In an alternative embodiment, the soaking step is performed before the continuous fiber is printed onto the printing platform.
[0007] In an alternative embodiment, the soaking step is performed after the continuous fiber is printed onto the printing platform.
[0008] In an optional embodiment, in the soaking step, the water is purified water or deionized water.
[0009] In an optional embodiment, in the freeze compaction step, a cooling roller is used to contact-compact and cool the printed layer to make the printed layer flat.
[0010] In an optional embodiment, a heat insulation structure is provided on the printing platform.
[0011] In an optional embodiment, in the printing step, an implantation hole is reserved in a direction perpendicular to the printing layer; and after repeating the soaking step, the printing step and the freezing compaction step until a predetermined number of printing layers is reached, the step further includes: implanting fibers: implanting continuous fibers in the implantation hole to form a preformed component.
[0012] In an optional embodiment, in the fiber implanting step, continuous fibers are woven into implantation holes of multiple printed layers in a direction perpendicular to the printed layers.
[0013] In an optional embodiment, after the fiber implanting step, the method further includes the following steps: post-processing: drying the preformed component and impregnating the preformed component.
[0014] In an optional embodiment, the continuous fiber is one or more of carbon fiber, aramid fiber, glass fiber, silicon carbide fiber, alumina fiber, and ultra-high molecular weight polyethylene fiber.
[0015] The technical solution of the present invention has at least the following advantages:
[0016] 1. The additive manufacturing of continuous fibers is realized alone without the use of other matrix materials, thereby increasing the fiber content in the composite material components of the continuous fiber reinforced composite materials, thereby improving the comprehensive performance of the corresponding composite material components.
[0017] 2. The method of immersion and freezing compaction is used to achieve pre-fixation in the continuous fiber additive manufacturing process, which ensures the forming effect of the continuous fiber, and the implementation method is simple and reliable.
[0018] 3. During the printing process, implantation holes are reserved, and fibers in a direction perpendicular to the printing layer, i.e., Z-direction fibers, are implanted in the printing layer by weaving, so as to further increase the fiber content in the composite material components of the continuous fiber reinforced composite material, thereby further improving the performance of the corresponding composite material components. BRIEF DESCRIPTION OF THE DRAWINGS
[0019] In order to more clearly illustrate the specific implementation methods of the present invention or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.
[0020] Figure 1 It is a flow chart of a continuous fiber reinforced cryo-additive manufacturing forming method according to an embodiment of the present invention;
[0021] Figure 2 A schematic structural diagram of a device for implementing a continuous fiber reinforced cryo-additive manufacturing forming method according to an embodiment of the present invention;
[0022] Figure 3 A top view of a printing layer in a continuous fiber reinforced cryogenic additive manufacturing forming method according to an embodiment of the present invention;
[0023] Figure 4 A top view of a preformed component in a continuous fiber reinforced cryogenic additive manufacturing forming method according to an embodiment of the present invention;
[0024] Figure 5 It is a front view of a preformed component in a continuous fiber reinforced cryo-additive manufacturing forming method according to an embodiment of the present invention;
[0025] Figure 6 It is a cross-sectional view of a preformed component in a continuous fiber reinforced cryogenic additive manufacturing forming method according to an embodiment of the present invention.
[0026] Description of reference numerals:
[0027] 1. Continuous fiber; 2. Printing platform; 3. Printing layer; 31. X-direction printing layer; 32. Y-direction printing layer; 33. Z-direction woven layer; 4. Printing nozzle; 41. Water injection pipe; 42. Insulation part; 43. Heating part; 5. Cooling roller. DETAILED DESCRIPTION
[0028] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present invention.
[0029] Combine the following Figures 1 to 6 , describing an embodiment of the present invention.
[0030] According to an embodiment of the present invention, on the one hand, a continuous fiber reinforced cryo-additive manufacturing method is provided, which specifically comprises the following steps:
[0031] S10: Layering, specifically, constructing a three-dimensional model of the preformed component by computer, and layering the three-dimensional model. More specifically, the three-dimensional model has mutually perpendicular X, Y, and Z directions, and the three-dimensional model is divided into layers in the Z direction to obtain the cross-sectional profile information of each layer of the preformed component on the XY plane. In this step, the present application does not specifically limit the thickness of each layer (i.e., the dimension in the Z direction), and the thickness of each layer can be adaptively adjusted according to the material, size, etc. of the continuous fiber 1. In the description of the present application, it should be understood that the X, Y, Z directions, and the XY plane are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the three-dimensional model of the preformed component must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present application.
[0032] S20: Path planning, specifically, setting an additive manufacturing path for each layer of the preformed component according to the cross-sectional profile information of each layer of the three-dimensional model.
[0033] S30: soaking, specifically soaking the continuous fiber 1 with water. The water may be pure water or deionized water. Pure water or deionized water does not contain impurities such as minerals and is not easy to introduce impurities.
[0034] S40: Printing, specifically, printing the continuous fiber 1 on the printing platform 2 according to the additive manufacturing path of the corresponding layer to obtain the printed layer 3. It can be understood that the printing platform 2 is on the XY plane, and the continuous fiber 1 is printed layer by layer on the printing platform 2 by repeating the printing steps. The present application does not specifically limit the printing parameters such as the printing speed, printing spacing, and printing angle, as long as the printing of the continuous fiber 1 of the corresponding material can be achieved. For example, Figure 3 As shown, the printing layer 3 may include an X-direction printing layer 31 and a Y-direction printing layer 32 stacked in sequence in the Z direction, and the printing angles of the X-direction printing layer 31 and the Y-direction printing layer 32 may be any angle of 0-360°, and illustratively, may be 0°, 30°, 45°, 60°, 90°, 120°, 135°, and the like.
[0035] S50: freezing and compacting, specifically, freezing and compacting the printed layer 3 during the printing process. Specifically, due to the above-mentioned soaking and printing steps, the printed layer 3 is soaked with water, and through the freezing and compacting step, the water in the printed layer 3 is condensed and the printed layer 3 is flattened, so that the current printed layer 3 is flatly fixed on the printing platform 2 or on the printed layer 3 that has been printed.
[0036] S60: Repeat the soaking step, the printing step and the freezing and compacting step until the predetermined number of printing layers is reached. Specifically, in this step, by repeatedly implementing the soaking step, the printing step and the freezing and compacting step, the stacking of multiple printing layers 3 is achieved, and the adjacent printing layers 3 are frozen into an integral structure by solidification of water. Thus, after reaching the predetermined number of printing layers, the predetermined number of printing layers 3 together form an integrated composite material preformed component. In this application, the number of printing layers 3 in this step is not specifically limited, and the number of printing layers depends on the size of the preformed component and the thickness of each layer in the layering step.
[0037] The present application does not specifically limit the size and shape of the preformed components. The continuous fiber reinforced cryo-additive manufacturing forming method of the present application is based on the additive manufacturing forming process and can realize the production of various complex components.
[0038] By utilizing the technical solution of the present invention, by printing the continuous fiber 1 which is not doped with a matrix such as resin, and utilizing the solidification of water to achieve bonding of each printed layer 3, a composite preform component with pure fiber content can be obtained. Of course, according to actual needs, a small amount of resin or other matrix material can also be added to the continuous fiber 1 during the printing process or before the printing step, and the present application does not limit this. The purpose of the continuous fiber 1 reinforced frozen additive manufacturing forming method of the present application is to realize the additive manufacturing of continuous fibers or continuous fiber reinforced composite materials with high fiber content through the process of soaking, printing and freezing and compacting the continuous fiber 1, thereby further improving the performance of the corresponding composite component.
[0039] The soaking step, printing step and freezing compaction step may be performed simultaneously or separately, and the sequence numbers S30, S40, S50, etc. do not represent the order in which the steps are performed.
[0040] Specifically, the continuous fiber 1 is one or more of carbon fiber, aramid fiber, glass fiber, silicon carbide fiber, alumina fiber, ultra-high molecular weight polyethylene fiber, etc. The present application does not specifically limit the material of the continuous fiber 1, as long as it meets the performance requirements of the composite material.
[0041] Specifically, in some embodiments, Figure 2 As shown, the soaking step, printing step and freezing compaction step are performed simultaneously. The soaking step and printing step are both performed on the printing platform 2 using a printing nozzle 4, and the printing nozzle 4 has a connected printing channel and a water injection pipe 41. Pure water or deionized water is passed into the water injection pipe 41 and flows into the printing channel along the water injection pipe 41 to soak the continuous fiber 1. That is, in this embodiment, the soaking step is performed before the continuous fiber 1 is printed on the printing platform 2, so that the continuous fiber 1 can be fully soaked to ensure the molding effect after freezing.
[0042] Furthermore, in the freezing and compacting step, a local low temperature environment can be provided near the nozzle of the print head 4, so that the printed continuous fiber 1 can be frozen, compacted and fixed as the printing process progresses. Exemplarily, the freezing and compacting step can be implemented by using a cooling roller 5, which is arranged on one side of the nozzle. During the printing process of the print head 4, the current printing layer 3 is contact-compacted and cooled to freeze the water in the printed continuous fiber 1 and roll it flat, so that the printed continuous fiber 1 is fixed on the printing platform 2 or the surface of the previous printing layer 3. Among them, a cooling medium is passed into the cooling roller 5, and the cooling medium can be cold air, which has low cost; or, the cooling medium can be liquid nitrogen, which has good freezing effect. It can be understood that the freezing and compacting step can also be implemented in other ways, as long as the instant freezing and fixation of the printing layer 3 can be achieved and the flatness of the printing layer 3 can be ensured.
[0043] For example, Figure 2 As shown, the cooling roller 5 is cylindrical and can roll around its own axis. The cooling roller 5 is used to roll on the current printing layer 3 to achieve contact cooling, freezing, compaction and flattening of the printing layer 3. The present application does not specifically limit the freezing temperature, pressing force, rotation speed, etc. of the cooling roller 5, as long as the function of freezing and compacting the printing layer 3 can be achieved.
[0044] For example, Figure 2 As shown, the print head 4 also includes a heat preservation part 42 and a heating part 43. The heat preservation part 42 is formed by a heat insulation structure, and the heating part 43 is provided with a heating element. The arrangement of the heat preservation part 42 and the heating part 43 can ensure the fluidity of water in the print head 4 and prevent the water from freezing due to the influence of the cooling roller 5.
[0045] Exemplarily, a heat insulating structure or a cooling element is also provided on the printing platform 2 to keep the printed layer 3 on the printing platform 2 warm or cool it, so that the printed layer 3 is always in a low-temperature environment to prevent the water in the printed layer 3 from melting.
[0046] Further, in some embodiments not shown in the figures, the soaking step can also be implemented after the continuous fiber 1 is printed on the printing platform 2. Exemplarily, a water sprayer is used to spray water on the printed continuous fiber 1 to soak the continuous fiber 1. Exemplarily, the water sprayer can be located upstream of the cooling roller 5 to soak the printed continuous fiber before cooling and compacting. Alternatively, in some necessary cases, the soaking step can be implemented both before and after the continuous fiber 1 is printed on the printing platform 2.
[0047] For example, in the soaking step, the amount of water soaking can be controlled by a flow control structure, and the control structure can be a supply pump with adjustable flow. Alternatively, a regulating valve, a flow meter, etc. can be set on the water supply pipeline. For example, in the soaking step, the amount of water soaking can also be controlled by adjusting the diameter of the continuous fiber 1, the printing interval, etc.
[0048] Furthermore, in some embodiments, in the printing step, in a direction perpendicular to the printed layer 3, that is, in the Z direction, an implantation hole is reserved in the printed layer 3. Figure 3 As shown, the printing layer 3 includes an X-direction printing layer 31 and a Y-direction printing layer 32, and the X-direction printing layer 31 and the Y-direction printing layer 32 together constitute a grid structure to form an implantation hole. It can be understood that there are multiple implantation holes, and preferably, multiple implantation holes are evenly arranged. The present application does not specifically limit the shape of the implantation hole, and the implantation hole can be configured as a circle, a rectangle, a polygon, etc. Specifically, the shape of the implantation hole depends on the printing angle and printing path of the X-direction printing layer 31 and the Y-direction printing layer 32.
[0049] Specifically, after repeatedly implementing the soaking step, the printing step, and the freezing and compacting step until a predetermined number of printing layers is reached, the method further includes the following steps:
[0050] S70: implanting fibers, specifically implanting continuous fibers 1 in the implantation holes to form a preformed component. This step can introduce Z-direction fibers into a preformed component with a high fiber content to further increase the fiber content and interlayer bonding performance of the preformed component, thereby improving the comprehensive performance of the composite component. The continuous fibers 1 in the implantation step may or may not undergo a soaking step.
[0051] Specifically, in the fiber implantation step, the continuous fiber 1 is woven into the implantation holes of the plurality of printed layers 3 in a direction perpendicular to the printed layer 3. The combination of printing and weaving makes the implantation process simple and easy to control, and the implantation efficiency is high. Figure 4-6 As shown, the X-direction printing layer 31, the Y-direction printing layer 32 and the Z-direction braiding layer 33 together form a prefabricated molding component. Figure 6 As shown, in the fiber implanting step, the continuous fiber 1 is woven in an S-shaped manner, and penetrates the multiple implantation holes between the multiple printing layers 3 from head to tail, thereby improving the integrity of the X-direction printing layer 31, the Y-direction printing layer 32 and the Z-direction braided layer 33.
[0052] Furthermore, in some embodiments, after the fiber implanting step, the method further comprises the steps of:
[0053] S80: Post-processing, specifically drying the preformed component and impregnating the preformed component. In this step, the preformed component of the composite material obtained after the above-mentioned fiber implantation step is dried to remove water in the preformed component. Exemplarily, this step can dry the preformed component in a drying oven. Then, the dried preformed component is impregnated as a whole according to the matrix requirements to prepare a composite material component. The present application does not specifically limit the matrix material used in the impregnation treatment, which is based on the actual requirements of the composite material component.
[0054] The technical solution of the present invention has at least the following advantages:
[0055] 1. The continuous fiber 1 is additively manufactured alone without using other matrix materials, thereby increasing the fiber content in the composite material component of the continuous fiber 1 reinforced composite material, thereby improving the comprehensive performance of the corresponding composite material component.
[0056] 2. The method of immersion and freezing compaction is used to achieve pre-fixation of the continuous fiber 1 during the additive manufacturing process, thereby ensuring the forming effect of the continuous fiber 1, and the implementation method is simple and reliable.
[0057] 3. During the printing process, implantation holes are reserved, and fibers in a direction perpendicular to the print layer 3, i.e., Z-direction fibers, are implanted in the print layer 3 by weaving, so as to further increase the fiber content in the composite material component of the continuous fiber 1 reinforced composite material, thereby further improving the performance of the corresponding composite material component.
[0058] Although the embodiments of the present invention have been described in conjunction with the accompanying drawings, those skilled in the art may make various modifications and variations without departing from the spirit and scope of the present invention, and such modifications and variations are all within the scope defined by the appended claims.
Claims
1. A continuous fiber reinforced cryo-additive manufacturing method, characterized in that: Includes steps: Layering: constructing a three-dimensional model of the preformed component and layering the three-dimensional model; Path planning: setting an additive manufacturing path for each layer of the preformed component according to the cross-sectional profile information of each layer of the three-dimensional model; Wetting: Wetting the continuous fibers with water (1); Printing: Printing on a printing platform (2) using the continuous fiber (1) according to the additive manufacturing path of the corresponding layer to obtain a printed layer (3); Freeze compaction: During the printing process, the printed layer (3) is freeze compacted; The soaking step, the printing step and the freezing and compacting step are repeatedly performed until a predetermined number of printing layers is reached.
2. The continuous fiber reinforced cryo-additive manufacturing method according to claim 1, characterized in that: The soaking step is performed before the continuous fiber (1) is printed onto the printing platform (2).
3. The continuous fiber reinforced cryo-additive manufacturing method according to claim 1, characterized in that: The soaking step is performed after the continuous fiber (1) is printed onto the printing platform (2).
4. The continuous fiber reinforced cryo-additive manufacturing method according to claim 1, characterized in that: In the soaking step, the water is pure water or deionized water.
5. The continuous fiber reinforced cryo-additive manufacturing method according to claim 1, characterized in that: In the freezing compaction step, a cooling roller (5) is used to perform contact compaction and cooling on the printed layer (3) so as to make the printed layer (3) flat.
6. The continuous fiber reinforced cryo-additive manufacturing method according to claim 5, characterized in that: A heat insulation structure is provided on the printing platform (2).
7. The continuous fiber reinforced cryo-additive manufacturing method according to claim 1, characterized in that: In the printing step, an implantation hole is reserved in a direction perpendicular to the printed layer (3); After the step of repeatedly implementing the soaking step, the printing step and the freezing and compacting step until a predetermined number of printing layers is reached, the method further includes: Implanting fibers: Implanting the continuous fibers (1) in the implanting holes to form a preformed component.
8. The continuous fiber reinforced cryo-additive manufacturing method according to claim 7, characterized in that: In the fiber implanting step, the continuous fibers (1) are woven into the implanting holes of the plurality of printed layers (3) in a direction perpendicular to the printed layers (3).
9. The continuous fiber reinforced cryo-additive manufacturing method according to claim 7, characterized in that: After the fiber implantation step, the method further comprises the steps of: Post-processing: drying the preformed component and impregnating the preformed component.
10. The continuous fiber reinforced cryo-additive manufacturing method according to any one of claims 1 to 9, characterized in that: The continuous fiber (1) is one or more of carbon fiber, aramid fiber, glass fiber, silicon carbide fiber, alumina fiber, and ultra-high molecular weight polyethylene fiber.