A device and method for electrofluid printing of complex curved surface multi-layer interconnected structure

Abstract

The present invention belongs to the field of advanced manufacturing technology, and discloses a device and method for printing an electric fluid with a complex curved multi-layer interconnected structure. The device includes a bed module that meets the motion requirements of the printing process; a printing module for printing processing, distance compensation, laser curing, and monitoring; and a parameter control module for graphic overlay, path planning, equipment driving, and process parameter regulation. The control method includes first preparing a conformal functional structure on the surface of a complex curved workpiece as a bottom functional structure layer; the material printed on the bottom functional structure is cured and sintered in situ by laser to achieve the preparation of a spatial interconnected structure; printing a functional layer between the spatial interconnected structures; printing a top functional structure; and repeating the above until the preparation of a multi-layer functional circuit structure is completed. The device of the present invention solves the problem of multi-material, high-efficiency, damage-free, high-precision, and integrated preparation of a conformal multi-layer interconnected structure with complex curved surfaces.

Description

Technical Field

[0001] The present invention belongs to the field of advanced manufacturing technology and relates to an electro-fluid printing device and method for a complex curved surface multi-layer interconnected structure. Background Art

[0002] Multilayer interconnect structures, such as packaged antennas, multilayer interconnected 3D circuits, and multifunctional skins, feature heterogeneous layers and interconnected layers. They offer advantages such as high integration, mechanical strength, flexibility, and design freedom, making them widely used in modern technology and industry. To meet the growing demand for miniaturization and integration in the next generation of electronic products, high-precision and high-efficiency manufacturing of complex curved multilayer interconnect structures is a key area of ​​focus and a growth driver for related industries.

[0003] The traditional preparation process of multi-layer interconnect structures is mainly based on the simple stacking of printed circuit board (PCB) technology. The process requires multiple steps of photolithography, lamination bonding, electroplating, etc. The entire process is complex, inefficient, and wastes a lot of materials. It also produces a large amount of toxic substances, which seriously damages the environment. In addition, traditional technology can only use flexible finished product cladding to manufacture multi-layer interconnect structures with curved surface features. Its poor conformal accuracy seriously restricts the further development of multi-layer interconnect structures. Therefore, it is urgent to develop new processes and manufacturing methods to replace traditional PCB processes to solve the defects in the manufacturing of existing complex curved multi-layer interconnect structures.

[0004] Jet printing technology has the characteristics of spatial freedom and can easily achieve conformal manufacturing of curved surfaces. Therefore, it has great potential in the manufacture of complex curved multi-layer interconnected structures. However, the manufacturing accuracy of traditional inkjet printing, 3D printing and aerosol printing technologies is limited by the size of the nozzle, making it difficult to achieve high-precision manufacturing of fine structures in complex curved multi-layer interconnected structures. Electrofluidic printing technology is a new inkjet printing method that uses electric field force to "pull" ink onto the substrate. Compared with "extrusion" printing, its manufacturing resolution and accuracy are significantly improved. For complex curved multi-layer interconnected structures, electrofluidic printing technology can not only use electric jets to manufacture fine structures on demand, but also achieve large-area deposition of dielectric layers through electrospraying. It is an ideal manufacturing method for complex curved multi-layer interconnected structures. Summary of the Invention

[0005] The purpose of this application is to overcome the shortcomings of the prior art and propose an improved printing device and method to achieve high-precision, high-efficiency, high-performance, and multi-material integrated manufacturing of complex curved multi-layer interconnected structures.

[0006] In order to achieve the above-mentioned purpose, some embodiments of the present invention propose an electro-fluid printing device with a complex curved multi-layer interconnected structure, which includes a bed module, a printing module and a parameter control module; the bed module is formed based on a five-axis vertical machine tool to realize the motion requirements during the printing process; the printing module is used to realize printing processing, distance compensation, laser curing and monitoring; the parameter control module is used to realize graphic overlay, path planning, equipment driving, process parameter regulation, and provide an operating platform for human-computer interaction; wherein, the printing module includes an auxiliary X / Y displacement platform, a positioning camera, a laser curing device, a micro-displacement stage, a laser rangefinder, a material storage tube, an auxiliary Z axis, an electro-fluid printing valve, an observation camera, an auxiliary U axis spray Head replacement device; the auxiliary Z axis is fixed on the first adapter plate, and the first adapter plate is fixed on the support plate; the auxiliary X / Y displacement platform surface is fixed on the second adapter plate, and the second adapter plate is fixed to the auxiliary Z axis; the electrostatic printing valve is fixed to the third adapter plate through a first clamp; the laser rangefinder, the positioning camera, the laser curing device and the material storage tube are all fixed on the third adapter plate through the first clamp, and the material storage tube is also connected to the electrostatic printing valve; the observation camera is fixed to the third adapter plate through the micro-displacement stage; the auxiliary U axis is fixed to the support plate through a fourth adapter plate; the head replacement device is fixed to the auxiliary U axis through a second clamp.

[0007] In some embodiments, the bed module includes a Z-axis, an X-axis, a saddle, a Y-axis, a slide, a column, a B / C rotating axis, a support seat, a bed and a turntable workbench; the bed serves as a bearing base, and the support seat and the column are respectively installed on the bed; the column and the support seat serve as mounting supports for the B / C rotating axis; the X-axis is fixed on the upper surface of the column; the Y-axis is fixed on the lower surface of the saddle, and the saddle plays a role of stability and sliding; the Z-axis is fixed on the back of the pallet of the printing module; the turntable workbench is fixed on the upper surface of the B / C rotating axis, and the turntable workbench is used to fix the workpiece on the B / C rotating axis; the slide is installed on the upper surface of the column, and the slide is used to realize the sliding of the X-axis and / or the Y-axis, and at the same time carry the saddle and the Z-axis.

[0008] In some embodiments, the parameter control module includes an operation panel, an electric field controller, a flow field controller, an industrial computer, a printing module drive box, a machine tool drive box and a chassis; the machine tool drive box controls the movement of the X-axis, Y-axis, Z-axis and B / C-axis, and communicates with the industrial computer; the industrial computer realizes the movement control of the auxiliary X / Y displacement platform, the auxiliary Z-axis and the auxiliary U-axis through the printing module drive box; the output end of the flow field control is connected to the electro-jet printing valve reservoir to realize the supply of printing materials, and the input end of the flow field control communicates with the industrial computer to realize the regulation of liquid supply parameters; the output end of the electric field controller is connected to the electro-jet printing valve to realize the establishment of an electric field between the nozzle and the substrate, and the input end of the electric field controller communicates with the industrial control to realize the adjustment of electrical parameters; the operation surface is connected to the industrial computer to provide a visual operation interface; the machine tool drive box, the printing module drive box, the industrial computer, the flow field controller, the electric field controller and the operation panel are all installed in the chassis.

[0009] In some embodiments, the observation phase is communicatively connected to the industrial computer, and the industrial computer directly displays the collected image on the operating surface to realize real-time monitoring of the printing process; the laser curing device is communicated with the industrial computer, and the operating surface adjusts the laser parameters through the industrial computer to assist the curing and sintering of the electrostatic printing valve spray material; the laser rangefinder is communicatively connected to the industrial computer, and the collected height information is transmitted to the operating panel through the industrial computer for display; the positioning camera is communicatively connected to the industrial computer, and the operating panel analyzes and marks the positioning information through the industrial computer.

[0010] In some embodiments, the auxiliary X / Y displacement platform, the auxiliary Z axis, and the auxiliary U axis are controlled by the industrial computer, and the nozzle replacement device and the second fixture are used to complete the replacement of the nozzle.

[0011] Other embodiments of the present application provide a method for electrofluidic printing of a complex curved multi-layer interconnected structure, which is implemented based on any one of the printing devices described above; wherein, the multi-layer interconnected structure is manufactured based on electrofluidic printing technology.

[0012] In some embodiments, the entire multi-layer interconnect structure preparation process is performed in situ on the printing device.

[0013] In some embodiments, the electro-fluid printing method for a complex curved multi-layer interconnected structure includes the following steps: Step 1: Fix the workpiece on a turntable workpiece to determine the starting point, manufacturing size range, and functional structure type of the workpiece printing; Step 2: Import the workpiece model into a dedicated paving and path planning software, pave the first functional knot onto the workpiece surface, complete the preliminary path planning, and generate a CNC G code path trajectory program based on the first functional knot after completion of the post-processing by an industrial computer; Step 3: Install the functional material storage tube containing the first functional structure material into the electro-fluid printing valve, connect the flow field controller output port to the storage tube, and connect the electric field control output port to the electro-fluid printing valve; turn on the observation camera, positioning camera, laser curing, and laser ranging; Step 3: Install the functional material storage tube containing the first functional structure material into the electro-fluid printing valve, connect the flow field controller output port to the storage tube, and connect the electric field control output port to the electro-fluid printing valve; turn on the observation camera, positioning camera, laser curing, and laser ranging; Step 4: Step 4: According to the type of functional structure, with the help of auxiliary X / Y displacement platform, auxiliary Z axis, auxiliary U axis, and nozzle replacement device, complete the selection and replacement of nozzles suitable for the functional structure, and conduct trial printing; Step 5: Start the CNC G code trajectory program of the first functional knot, and the laser distance measurement will perform multi-point distance measurement on the printing path, and perform real-time compensation of the printing height according to the distance measurement value, and execute the printing program in sequence according to the trajectory program; Step 6: The operation surface displays the current printing status in real time and records the position of the functional structure defects according to the real-time printing effect. After the printing is completed, repair the defective position according to the recorded defective position; Step 7: Import the model of the workpiece that has completed the printing of the first functional structure into the structural paving and path planning software, and the second functional structure Lay it on the surface of the first functional structure, complete the preliminary path planning, and generate a CNC G code path trajectory program based on the second functional structure after completion processing by the industrial computer; Step 8: Replace the nozzle suitable for the second functional structure, connect the replacement material storage with the second functional structure to the electro-printing valve, adjust the flow field parameters, electric field parameters, and laser curing parameters through the operating surface, and perform trial printing; Step 9: Start the CNC G code trajectory program of the second functional structure, the operating surface displays the current printing status in real time and records the defective position of the functional structure according to the printing effect. After the printing is completed, repair the defective position according to the recorded defective position; Step 10: Complete the model of the workpiece with the first functional structure and the second functional structure printed Import the structural draping and path planning software, split the functional layer into linear structures and superimpose them on the workpiece surface to complete the preliminary path planning. After the industrial computer completes the post-processing, a CNC G-code path trajectory program based on the functional layer is generated; Step 11: Replace the nozzle suitable for the functional layer, connect the replacement material storage tube containing the functional layer material to the electrospray printing valve, adjust the flow field parameters and electric field parameters through the operation panel to form the electrospray printing state, adjust the laser curing parameters, and perform a test print; Step 12: Start the CNC G-code trajectory program for the functional layer. The operation panel displays the current printing status in real time and records the defective locations of the functional structure based on the printing effect. After the printing is completed, repair printing is performed according to the recorded defect locations;Step 13: Import the workpiece model with the first functional structure, the second functional structure, and the functional layer printed into the structure paving and path planning software, paving the third functional structure on the surface of the functional layer, completing preliminary path planning. The industrial computer then performs post-processing to generate a CNC G-code path trajectory program based on the third functional structure. Step 14: Replace the nozzle suitable for the third functional structure, insert the material storage tube containing the third functional structure into the electro-jet printing valve, and use the operation panel to rectify the flow field parameters and electric field parameters to form a suitable conical jet for trial printing. Step 15: Start the CNC G-code trajectory program for the third functional structure. The operation panel displays the current printing status in real time and records the defect locations of the functional structure based on the printing effect. After printing is completed, repair printing is performed based on the recorded defect locations. Step 16: Based on the new model, adjust the corresponding materials, printing parameters, and CNC G-code trajectory program. Repeat steps 7 and 15 above to achieve electro-jet printing of multi-layer interconnected structures with more layers.

[0014] In some embodiments, the first functional structure includes conductive metal ink, conductive polymer, and dielectric ink; the second functional structure includes conductive metal ink, conductive polymer, and dielectric ink; the material of the functional layer includes conductive metal ink, conductive polymer, and dielectric ink; the third functional structure includes conductive metal ink, conductive polymer, and dielectric ink.

[0015] In some embodiments, during the printing of the first functional structure, a laser curing device is used to perform in-situ curing and sintering.

[0016] In some embodiments, the materials printed on the first functional structure and the second functional structure are prepared by laser in-situ solidification and sintering to achieve spatial interconnection structure; a functional layer is printed between the spatial interconnection structures, and the functional layer satisfies the exposure of the top of the spatial interconnection structure; in the process of printing the functional layer, a laser solidifier is used to achieve in-situ solidification and sintering of the functional layer.

[0017] The beneficial effects of the present invention include: the present invention provides a method and device for electrofluid printing manufacturing of complex curved multi-layer interconnected structures. The motion platform based on the five-axis motion machine tool can adjust the posture position of the workpiece during the printing process. Since it has five degrees of freedom, the posture of the workpiece with any curved surface shape can be adjusted. The electrofluid printing part moves the printing valve to the specified position on the basis of the five-axis motion platform to start printing. Since the functional structure has various sizes and shapes, a nozzle replacement device is designed, and the printing valve can automatically change the nozzle type according to the functional structure. In order to compensate for the morphological error of the workpiece surface to meet the requirements of conformal manufacturing, the path measurement of the workpiece surface is carried out before the printing starts, and the distance measurement data is compensated into the printing height during the printing process to achieve constant printing height and stable manufacturing of functional structures. In order to realize multi-material high-precision electrofluid printing manufacturing of spatial interconnected structures, fine functional structures and functional layers, a laser curing device is used to achieve real-time curing according to the printing path. During the printing process, professional CNC G code programs are generated by path planning software to ensure conformal printing manufacturing of complex surfaces. The electrojet printing valve utilizes a professionally developed flow field controller and electric field controller to adjust parameters, enabling on-demand printing of multiple materials with high precision and efficiency. The method and device described in this invention offer advantages such as reliable structure, rapid manufacturing efficiency, high printing accuracy, wide material applicability, and automated printing paths. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 Schematic diagram of an electrofluidic printing device for a complex curved multi-layer interconnected structure according to an embodiment of the present invention;

[0019] Figure 2 A schematic diagram of a printing module device structure according to an embodiment of the present invention;

[0020] Figure 3 Schematic diagram of electrofluidic printing of the bottom functional structure according to an embodiment of the present invention;

[0021] Figure 4 Schematic diagram of electrofluidic printing of a spatially interconnected functional structure according to an embodiment of the present invention;

[0022] Figure 5 A schematic diagram of electrofluidic printing of a functional layer according to an embodiment of the present invention;

[0023] Figure 6 Schematic diagram of electrofluidic printing of a top functional structure according to an embodiment of the present invention;

[0024] In the figure: 1 operation panel; 2 electric field controller; 3 flow field controller; 4 industrial computer; 5 printing module drive box; 6 machine tool drive box; 7 chassis; 8 Z axis; 200 printing module; 10 X axis; 11 saddle; 12 Y axis; 13 slide; 14 column; 15 B / C rotation axis; 16 support seat; 17 bed; 18 turntable; 19 workpiece; 20 functional structure; 21 functional structure; 22 functional layer; 23 functional structure; 91 pallet; 92 adapter plate; 93 adapter plate; 94 auxiliary X / Y displacement platform; 95 adapter plate; 96 positioning camera; 97 laser curing device; 98 adapter plate; 99 micro displacement stage; 910 fixture; 911 laser rangefinder; 912 auxiliary Z axis; 913 bolt; 914 material storage tube; 915 electrojet valve; 916 observation camera; 917 auxiliary U axis; 918 fixture; 919 nozzle replacement device. DETAILED DESCRIPTION

[0025] In order to make the objectives, technical solutions and advantages of the present invention more clearly understood, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0026] In this application, the X-axis, Y-axis, and Z-axis B / C rotation axes refer to motion mechanisms in corresponding directions, respectively, wherein the X, Y, Z, B, and C directions are the directions represented by the coordinate systems in the accompanying drawings, respectively. The X-axis may refer to an X-axis motion module, which may include an X-axis drive unit, an X-axis linear guide, and an X-axis slider, wherein the X-axis drive unit may, for example, include an X-axis servo motor, an X-axis lead screw, and an X-axis nut; the Y-axis may refer to a Y-axis motion module, which may include a Y-axis drive unit, a Y-axis linear guide, and a Y-axis slider, wherein the Y-axis drive unit may, for example, include a Y-axis servo motor, a Y-axis lead screw, and a Y-axis nut; the Z-axis may refer to a Z-axis motion module, which may include a Z-axis drive unit, a Z-axis linear guide, and a Z-axis slider, wherein the Z-axis drive unit may, for example, include a Z-axis servo motor, a Z-axis lead screw, and a Z-axis nut. The B / C rotating axis can be a composite structure of the B axis and the C axis, wherein the B axis motion module can include a B axis rotating worktable; a B axis servo motor, a B axis encoder, a B axis reducer, etc.; the C axis motion module can include a C axis rotating spindle; a C axis servo motor, a C axis encoder, a C axis reducer, etc.

[0027] Similarly, the auxiliary X / Y axis refers to a composite motion module in the X / Y direction, which also includes a drive unit, a guide rail, and a slider; the auxiliary Z axis is a motion module in the Z direction, which also includes a drive unit, a guide rail, and a slider; the auxiliary U axis is a motion module in the direction parallel to the X axis, which also includes a drive unit, a guide rail, and a slider.

[0028] like Figure 1As shown, a complex curved multi-layer interconnected structure electro-fluid printing device includes a bed module 100, a printing module 200 and a parameter control module 300. The bed module 100 is based on a five-axis vertical machine tool to meet the movement requirements during the printing process; the printing module 200 is used to realize printing processing, ranging compensation, laser curing, monitoring and other functions; the parameter control module 300 is used to realize graphic overlay, path planning, equipment driving, process parameter regulation and other functions, providing an operating platform for human-computer interaction of the printing device.

[0029] Likewise Figure 1 As shown, the bed module 100 includes a Z-axis 8, an X-axis 10, a saddle 11, a Y-axis 12, a slide 13, a column 14, a B / C rotating shaft 15, a support base 16, a bed 17, and a turntable table 18. The X-axis 10 is fixed to the upper surface of the column 14; the Y-axis 12 is fixed to the lower surface of the saddle 11; the Z-axis 8 is fixed to the back of the support plate 91; the B / C rotating shaft 15 is fixed to the column 14 and the support base 16; and the turntable table 18 is fixed to the upper surface of the B / C rotating shaft 15. The column 14 is mounted above the bed 17; the slide 13 is mounted on the upper surface of the column 14; and the support base 16 is mounted on the bed 17. The bed 17 is the load-bearing foundation of the machine tool, providing a base for the installation of various components above the machine tool; the column 14 and the support seat 16 are the mounting supports for the B / C rotating shaft 15, which serve to fix the B / C rotating shaft 15; the slide 13 is a load-bearing and sliding component that determines the sliding of the X-axis 10 and Y-axis 12, and at the same time bears the weight of the saddle 11 and Z-axis 8; the saddle 11 is the base for fixing the Z-axis 8, which serves to stabilize and slide; the turntable worktable 18 is responsible for fixing the workpiece on the B / C rotating shaft 15. The bed 17, column 14, slide 13, saddle 11, and support seat 16 are all components that are processed by casting and together form a complete bed module structure, providing installation support for other functional parts. The Z-axis 8 is located on the front surface of the saddle 11 and supports the printing module 200 through the pallet 91. The B / C rotating shaft 15 is installed on the column 14 and the support seat 16.

[0030] like Figure 2As shown, the printing module 200 includes an auxiliary X / Y displacement platform 94, a positioning camera 96, a laser curing device 97, a micro-displacement stage 99, a laser rangefinder 911, an auxiliary Z axis 912, a material storage tube 914, an electrostatic printing valve 915, an observation camera 916, an auxiliary U axis 917, and a nozzle replacement device 919. Among them, the auxiliary Z-axis 912 is fixed on the adapter plate 92, and the adapter plate 92 is fixed to the support plate 91 by bolts 913; the upper surface of the auxiliary X / Y displacement platform 94 is fixed on the adapter plate 93, and the adapter plate 93 is L-shaped and fixed to the auxiliary Z-axis 912; the electrostatic printing valve 915 is fixed to the adapter plate 95 by the clamp 910; the laser rangefinder 911 is fixed to the adapter plate 95 by the clamp 910; the positioning camera 96 ​​is fixed to the adapter plate 95 by the clamp 910; the adapter plate 95 is L-shaped and fixed to the lower surface of the auxiliary X / Y displacement platform 94; the observation camera 916 is fixed to the adapter plate 95 by the micro-displacement stage 99; the laser curing device 97 is fixed to the adapter plate 95 by the micro-displacement stage 99; the auxiliary U-axis 917 is fixed to the support plate 91 by the adapter plate 98; the nozzle replacement device 919 is fixed to the auxiliary U-axis 917 by the clamp 918. The material storage tube 914 is connected to the electro-jet printing valve 915 and fixed to the adapter plate 95 via a clamp 910. The above printing components coordinate with each other through the industrial computer 4 to complete the electro-jet printing of functional materials. For example, the auxiliary X / Y displacement platform 94, auxiliary Z axis 912, and auxiliary U axis 917 cooperate with the nozzle replacement device 919 to complete the selection of nozzle sizes corresponding to different functional structures and the test printing of the electro-jet printing valve 915. Before the printing work begins, the functional material storage tube 914 is installed on the electrostatic printing valve 915, and the flow field controller 3 and the electric field controller 2 are connected, which determine the parameter adjustment during the printing process. At the same time, the laser rangefinder 911, the positioning camera 96, the observation camera 916, and the laser curing device 97 are turned on. The laser rangefinder 911 can be used to compensate for the surface morphology error of the workpiece. The positioning camera 96 ​​can be used to quickly and accurately locate the starting point of the printing. The observation camera 916 can be used to monitor the printing quality and printing status in real time. The laser curing device 97 can be used to cure or sinter the functional structure in real time.

[0031] like Figure 1As shown, the parameter control module 300 includes an operation panel 1, an electric field controller 2, a flow field controller 3, an industrial computer 4, a printing module drive box 5, a machine tool drive box 6, and a chassis 7. The machine tool drive box 6 is connected to the X-axis 10, Y-axis 12, Z-axis 8, and B / C rotation axis 15, respectively, and communicates with the industrial computer 4 to realize power supply and motion control of the motor module. Through the linkage between the five axes, five-degree-of-freedom machining of the motion platform is achieved, solving the device problem of conformal manufacturing of complex curved multi-layer interconnected structures. The industrial computer 4 is connected to the operation panel 1, electric field controller 2, flow field controller 3, industrial computer 4, printing module drive box 5, and machine tool drive box 6. The industrial computer 4 controls the motion of the auxiliary X / Y displacement platform 94, auxiliary Z axis 912, and auxiliary U axis 917 through the printing module drive box 5. The output of the flow field controller 3 is connected to the electrostatic printing valve reservoir 914 to supply printing material, and the input communicates with the industrial computer 4 to control the liquid supply parameters. The output of the electric field controller 2 is connected to the electrostatic printing valve 121 to establish the electric field between the nozzle and the substrate, and the input communicates with the industrial computer 4 to adjust the electrical parameters. The operation panel 1 is connected to the industrial computer 4, providing a visual operation interface. The machine tool drive box 6, printing module drive box 5, industrial computer 4, flow field controller 3, electric field controller 2, and operation panel 1 are installed in the chassis 7. The above control modules work together to achieve on-demand printing manufacturing of multi-layer heterogeneous structures.

[0032] The industrial computer 4 controls the machine tool's motion using the post-processed G-code numerical control program for the functional structure. It also controls the flow field controller 3 to provide stable driving force for the material storage tube 914, enabling on-demand supply of functional materials. It also controls the electric field controller 2 to create a high-voltage electric field for the electrojet printing valve 915. Under appropriate flow rates and electric fields, various forms of electrojet printing can be achieved. Building on this foundation, the G-code program, coupled with the five-axis motion platform, enables the printing of complex curved, multi-layer interconnected structures.

[0033] The observation camera 916 communicates with the industrial computer 4, and displays the collected image directly on the operation panel 1 through the industrial computer 4, so as to realize real-time monitoring of the printing process; the laser curing device 97 communicates with the industrial computer 4, and the operation panel 1 adjusts the curing laser parameters through the industrial computer 4, and assists the electrostatic printing valve 915 in curing and sintering the sprayed material; the laser rangefinder 911 communicates with the industrial computer 4, and transmits the collected height information to the operation panel 1 through the industrial computer 4; the positioning camera 96 ​​communicates with the industrial computer 4, and the operation panel 1 analyzes and marks the positioning information through the industrial computer 4.

[0034] The auxiliary X / Y displacement platform 94, the auxiliary Z axis 912, and the auxiliary U axis 917 can be controlled by the industrial computer 4, and the nozzle replacement device 919 and the fixture 918 can be used to complete the replacement of the nozzle.

[0035] Some embodiments of the present application also disclose an electrofluidic printing method for a complex curved multi-layer interconnected structure, which is implemented based on the above-mentioned printing device. First, a conformal functional structure is prepared on the surface of a complex curved workpiece using electrofluidic printing technology as a bottom functional structure layer; second, the material printed on the bottom functional structure is laser in-situ solidified and sintered to achieve the preparation of a spatial interconnected structure; third, a functional layer is printed between the spatial interconnected structures, and the functional layer must ensure that the top of the spatial interconnected structure is exposed; fourth, the top functional structure is printed; finally, the second to fourth steps are repeated until the preparation of the multi-layer functional circuit structure is completed.

[0036] The above method may specifically include:

[0037] Step 1: Fix the complex curved surface workpiece 19 on the turntable workbench 18, and determine the starting point, manufacturing size range, and functional structure type of the workpiece 19 for printing.

[0038] Step 2: Import the workpiece 19 model into the dedicated paving and path planning software, pave the first functional structure 20 onto the surface of the workpiece 19, complete the preliminary path planning, and generate a CNC G code path trajectory program based on the first functional structure 20 after completion of post-processing by the industrial computer.

[0039] Step 3: Install the functional material storage tube 914 containing the material of the first functional structure 20 into the electroprinting valve 915. Connect the output port of the flow field controller 3 to the storage tube 914, and the output port of the electric field controller 2 to the electroprinting valve 915. Turn on the observation camera 916, positioning camera 96, laser curing device 97, and laser rangefinder 911.

[0040] Step 4: Start the electro-fluid printing control software, and use the auxiliary X / Y displacement platform 94, auxiliary Z axis 912, auxiliary U axis 917, and nozzle replacement device 919 to complete the selection and replacement of the nozzle suitable for the first functional structure 20 according to the functional structure type, and perform trial printing.

[0041] Step 5: Start the CNC G code trajectory program of the first functional structure 20. The laser rangefinder 911 will perform multi-point distance measurement on the printing path, perform real-time compensation of the printing height according to the distance measurement value, and then execute the printing program in sequence according to the trajectory program.

[0042] Step 6: The operation panel 1 displays the current printing status in real time and records the functional structure defect position according to the printing effect. After the printing is completed, repair printing is performed according to the recorded defect position.

[0043] Step 7: Import the model of the workpiece 19 with the first functional structure 20 printed into the structural paving and path planning software, pave the second functional structure 21 onto the surface of the functional mechanism 20, complete the preliminary path planning, and complete the post-processing by the industrial computer to generate a CNC G code path trajectory program based on the second functional structure 21.

[0044] Step 8: Replace the nozzle with one suitable for the structure 21, connect the material storage tube 914 containing the second functional structure 21 to the electro-printing valve 915, adjust the flow field parameters, electric field parameters, and laser curing parameters through the operation panel 1, and perform a trial print.

[0045] Step 9: Start the CNC G code trajectory program of the second functional structure 21. The operation panel 1 displays the current printing status in real time and records the defective position of the functional structure according to the printing effect. After the printing is completed, repair printing is performed according to the recorded defective position.

[0046] Step 10: Import the model of the workpiece 19 with the first functional structure 20 and the second functional structure 21 printed into the structural paving and path planning software, split the functional layer 22 into linear structures and overlay them on the surface of the workpiece 19 to complete the preliminary path planning. After the industrial computer completes the post-processing, a CNC G code path trajectory program based on the functional layer 20 is generated.

[0047] Step 11: Replace the nozzle suitable for the functional layer 22, connect the replaced material storage tube 914 containing the functional layer 22 to the electrospray printing valve 915, adjust the flow field parameters and electric field parameters through the operation panel 1 to form the electrospray printing state, adjust the laser curing parameters, and perform trial printing.

[0048] Step 12: Start the CNC G code trajectory program of the functional layer 22. The operation panel 1 displays the current printing status in real time and records the defective position of the functional structure according to the printing effect. After the printing is completed, repair printing is performed according to the recorded defective position.

[0049] Step 13: Import the model of the workpiece 19 with the first functional structure 20, the second functional structure 21 and the functional layer 22 printed into the structural paving and path planning software, pave the third functional structure 23 on the surface of the functional layer 22, complete the preliminary path planning, and generate a CNC G code path trajectory program based on the third functional structure 23 after post-processing by the industrial computer.

[0050] Step 14: Replace the nozzle suitable for the third functional structure 23, connect the replaced material storage tube 914 equipped with the third functional structure 23 to the electro-printing valve 915, adjust the flow field parameters and electric field parameters through the operation panel 1 to form a suitable conical jet for trial printing.

[0051] Step 15: Start the CNC G code trajectory program of the third functional structure 23. The operation panel 1 displays the current printing status in real time and records the defect position of the functional structure according to the printing effect. After the printing is completed, repair printing is performed according to the recorded defect position.

[0052] Step 16: After adjusting the corresponding materials, printing parameters and CNC G code trajectory program according to the new model, repeating the above steps 7 and 15 can realize the electrospray printing manufacturing of multi-layer interconnected structures with more layers.

[0053] The material of the first functional structure 20 includes conductive metal ink, conductive polymer, dielectric ink, etc.

[0054] The material of the second functional structure 21 includes conductive metal ink, conductive polymer, dielectric ink, etc.

[0055] The material of the functional layer 22 includes conductive metal ink, conductive polymer, dielectric ink, etc.

[0056] The material of the third functional structure 23 includes conductive metal ink, conductive polymer, dielectric ink, etc.

[0057] Before printing the first functional structure 20, the workpiece 19 is first securely mounted on the turntable 18 and leveled. The starting point for printing is then determined. The material reservoir 914 containing the first functional structure 20 is connected to the electrostatic printing valve 915. Using the auxiliary X / Y displacement platform 94, auxiliary Z-axis 912, and auxiliary U-axis 917, the nozzle replacement device 919 is used to replace the nozzle appropriate for the functional structure. The workpiece 19 model is imported into the industrial computer 4, and the first functional structure 20 is applied to the surface of the workpiece 19. After preliminary path planning, post-processing generates a CNC G-code trajectory program. A series of process parameters such as appropriate electric field parameters, flow field parameters, printing height parameters and laser curing parameters are set, and the G code of the first functional structure 20 is transmitted to the industrial computer 4. The industrial computer 4 moves the laser rangefinder 911 to the starting point of printing according to the position information fed back by the positioning camera 96. The industrial computer 4 collects the height information on the printing path through the laser rangefinder 911, and controls the auxiliary Z axis 912 through the height information to compensate for the height of the nozzle during the printing process.

[0058] like Figure 3 As shown, the industrial computer 4 will start printing and send the command to the machine tool drive box 6, the flow field controller 3, and the electric field controller 2. The material forms a conical jet under the action of the electric field, and uses the laser curing device 97 to achieve precise curing and sintering to prevent the flow of the material from affecting the dimensional accuracy of the structure. In conjunction with the movement of the five-axis motion platform, the first functional structure 20 is printed on the surface of the workpiece 19.

[0059] After printing the first functional structure 20, the material storage tube 914 containing the material for the spatially interconnected second functional structure 21 and the nozzle suitable for the structure 21 are replaced. The workpiece 19 model after printing the first functional structure 20 is imported into the industrial computer 4. The second functional structure 21 is then applied to the surface of the structure 20. After preliminary path planning, post-processing generates a CNC G-code trajectory program and sets the corresponding printing process parameters. Positioning and height measurement are performed using the positioning camera 96 ​​and the laser rangefinder 911.

[0060] like Figure 4 As shown, as the nozzle slowly rises, the material is deposited on the surface of the structure 20 in the form of a cone jet under the action of the electric field. Combined with the in-situ curing and sintering of the laser curing device 97, the printing manufacturing of the spatially interconnected second functional structure 21 is realized.

[0061] The material storage tube containing the functional layer 22 and the corresponding nozzle are replaced. Based on the structural dimensions of the functional layer 22, the stack of linear structures is simplified and applied to the surface of the workpiece 19 after the printed structures 20 and 22 have been completed. The linear structures are then used to perform preliminary path planning and generate a corresponding CNC G-code trajectory program. A series of process parameters are set, and positioning and height measurement are performed using a positioning camera 96 ​​and a laser rangefinder 911.

[0062] like Figure 5 As shown, by adjusting the process parameters, the liquid material is deposited on the surface of the workpiece 19 in the form of electrospray. Through reasonable path planning and laser curing, the density and uniformity of the printed structure are ensured, and the electrospray printing construction of the functional layer 22 is achieved while ensuring that the contact point at the top of the second functional structure 21 is not covered.

[0063] Replace the material storage tube 914 containing the material of the third functional structure 23 and the nozzle suitable for the structure 23, import the model of the workpiece 19 after printing the functional layer 22 into the industrial computer 4, lay the third functional structure 23 on the surface of the functional layer 22, generate the corresponding CNC G code trajectory program, add a series of process parameters, and use the positioning camera 96 ​​and the laser rangefinder 911 for positioning and height measurement.

[0064] like Figure 6 As shown, the slurry forms a conical jet under the action of the electric field, and the five-axis machine tool moves according to the instructions issued by the industrial computer 4, and prints the third functional structure 23 on the surface of the functional layer 22. The third functional structure 23 forms a good contact with the top of the second functional structure 21 in the space, ensuring that the first functional structure 20 and the third functional structure 23 have good interconnectivity. The laser curing device 97 realizes precise curing and sintering to prevent the flow of the material from affecting the dimensional accuracy of the structure.

[0065] According to different structural requirements, the model can be updated, and after generating the corresponding CNC G code trajectory program, the corresponding materials and E-jet printing parameters can be replaced and the above steps can be repeated to achieve E-jet printing manufacturing of multi-layer interconnected structures with more layers.

[0066] In summary, the present invention provides a method and device for electrofluidic printing of complex curved multi-layer interconnected structures, which solves the current problems of low resolution, low manufacturing efficiency, lack of conformality, and high cost in the manufacture of complex curved multi-layer interconnected structures. The proposed method and device for electrofluidic printing of complex curved multi-layer interconnected structures innovatively designs a special printing machine for complex curved substrates. Through the coordination of five-axis motion adjustment and a multifunctional printing module, it can achieve multi-material, high-precision, high-efficiency, and damage-free manufacturing of multi-layer interconnected structures. It has the characteristics of full-process automation of printing, fast forming, and high precision, and has good application prospects in the fields of precision machining, micro-nano machining, etc.

[0067] The above-described embodiments merely express the implementation methods of the present invention, but should not be understood as limiting the scope of the patent of the present invention. It should be pointed out that for those skilled in the art, several variations and improvements can be made without departing from the concept of the present invention, and these all fall within the scope of protection of the present invention.

Claims

1. A complex curved multi-layer interconnected structure electro-fluid printing device, characterized in that: It comprises a bed module (100), a printing module (200) and a parameter control module (300); the bed module (100) is formed based on a five-axis vertical machine tool to achieve the motion requirements during the printing process; the printing module (200) is used to achieve printing processing, distance measurement compensation, laser curing and monitoring; The parameter control module (300) is used to realize graphic overlay, path planning, equipment driving, process parameter regulation and control, and provide an operating platform for human-computer interaction; wherein, the printing module (200) includes an auxiliary X / Y displacement platform (94), a positioning camera (96), a laser curing device (97), a micro-displacement stage (99), a laser rangefinder (911), a material storage tube (914), an auxiliary Z-axis motion module (912), an electro-jet printing valve (915), an observation camera (916), an auxiliary U-axis motion module (917), and a nozzle replacement device (919); the auxiliary Z-axis motion module (912) is fixed on a first adapter plate (92), and the first adapter plate (92) is fixed on a support plate (91); the upper surface of the auxiliary X / Y displacement platform (94) is fixed on a second adapter plate (93), and the second adapter plate (93) is fixed on the auxiliary Z-axis motion module (917). module (912); the electrojet printing valve (915) is fixed to the third adapter plate (95) through the first clamp (910); the laser rangefinder (911), the positioning camera (96) and the material storage tube (914) are all fixed to the third adapter plate (95) through the first clamp (910); the laser curing device (97) is fixed to the third adapter plate (95) through the micro-displacement stage (99), wherein the material storage tube (914) is also connected to the electrojet printing valve (915); the observation camera (916) is fixed to the third adapter plate (95) through the micro-displacement stage (99); the auxiliary U-axis motion module (917) is fixed to the support plate (91) through the fourth adapter plate (98); the nozzle replacement device (919) is fixed to the auxiliary U-axis motion module (917) through the second clamp (918); The bed module (100) includes a Z-axis motion module (8), an X-axis motion module (10), a saddle (11), a Y-axis motion module (12), a slide (13), a column (14), a B / C rotation axis motion module (15), a support seat (16), a bed (17), and a turntable workbench (18); the bed (17) serves as a bearing base, and the support seat (16) and the column (14) are respectively mounted on the bed (17); the column (14) and the support seat (16) serve as mounting supports for the B / C rotation axis motion module (15); the X-axis motion module (10) is fixed on the upper surface of the column (14); the Y-axis motion module (12) is fixed on The lower surface of the saddle (11) plays a role of stabilization and sliding; the Z-axis motion module (8) is fixed to the back of the support plate (91) of the printing module; the turntable workbench (18) is fixed to the upper surface of the B / C rotary axis motion module (15), and the turntable workbench (18) is used to fix the workpiece (19) on the B / C rotary axis motion module (15); the slide (13) is installed on the upper surface of the column (14), and is a bearing and sliding component. The slide (13) is used to realize the sliding of the X-axis motion module (10) and the Y-axis motion module (12), and at the same time carries the saddle (11) and the Z-axis motion module (8); The parameter control module (300) includes an operation panel (1), an electric field controller (2), a flow field controller (3), an industrial computer (4), a printing module drive box (5), a machine tool drive box (6) and a machine box (7); the machine tool drive box (6) controls the movement of the X-axis motion module (10), the Y-axis motion module (12), the Z-axis motion module (8) and the B / C rotation axis motion module (15), and communicates with the industrial computer (4); the industrial computer (4) realizes the movement control of the auxiliary X / Y displacement platform (94), the auxiliary Z-axis motion module (912) and the auxiliary U-axis motion module (917) through the printing module drive box (5); the output end of the flow field controller (3) is connected to the The material storage tube (914) is connected to realize the supply of printing materials, and the input end of the flow field controller (3) communicates with the industrial control computer (4) to realize the regulation of liquid supply parameters; the output end of the electric field controller (2) is connected to the electro-jet printing valve (915) to realize the establishment of the electric field between the nozzle and the substrate, and the input end of the electric field controller (2) communicates with the industrial control computer (4) to realize the regulation of electrical parameters; the operation panel (1) is connected to the industrial control computer (4) to provide a visual operation interface; the machine tool drive box (6), the printing module drive box (5), the industrial control computer (4), the flow field controller (3), the electric field controller (2) and the operation panel (1) are all installed in the chassis (7).

2. The electro-fluid printing device for complex curved multi-layer interconnected structures according to claim 1, characterized in that: The observation camera (916) is connected to the industrial computer (4) for communication, and the industrial computer (4) directly displays the collected image on the operation panel (1) to realize real-time monitoring of the printing process; the laser curing device (97) is connected to the industrial computer (4), and the operation panel (1) adjusts the laser parameters through the industrial computer (4) to assist the electrostatic printing valve (915) in curing and sintering the sprayed material; the laser rangefinder (911) is connected to the industrial computer (4) for communication, and transmits the collected height information to the operation panel (1) through the industrial computer (4) for display; the positioning camera (96) is connected to the industrial computer (4), and the operation panel (1) analyzes and marks the positioning information through the industrial computer (4).

3. The electro-fluid printing device for complex curved multi-layer interconnected structures according to claim 1, characterized in that: The auxiliary X / Y displacement platform (94), the auxiliary Z-axis motion module (912), and the auxiliary U-axis motion module (917) are controlled by the industrial control computer (4), and the nozzle (920) is replaced by cooperating with the nozzle replacement device (919) through movement.

4. A method for electrofluid printing of complex curved multi-layer interconnected structures, characterized in that: The printing device according to any one of claims 1 to 3 is implemented; wherein the multi-layer interconnect structure is manufactured based on electrofluidic printing technology.

5. The electrofluid printing method for complex curved multi-layer interconnected structures according to claim 4, characterized in that: The entire preparation process of the multi-layer interconnected structure is carried out in situ on the printing device.

6. The electrofluid printing method for complex curved multi-layer interconnected structures according to claim 5, characterized in that: The following steps are involved: Step 1: Fix the workpiece (19) on the turntable workbench (18), and determine the starting point, manufacturing size range, and functional structure type of the workpiece (19); Step 2: Import the workpiece (19) model into the structure cladding and path planning software, clad the first functional structure (20) on the surface of the workpiece (19), complete the preliminary path planning, and complete the post-processing by the industrial computer to generate a CNC G code path trajectory program based on the first functional structure (20); Step 3: Install the material storage tube (914) containing the material of the first functional structure (20) into the electro-jet printing valve (915), connect the output port of the flow field controller (3) to the material storage tube (914), and connect the output port of the electric field controller (2) to the electro-jet printing valve (915); turn on the observation camera (916), the positioning camera (96), the laser curing device (97), and the laser rangefinder (911); Step 4: Based on the type of functional structure, the auxiliary X / Y displacement platform (94), the auxiliary Z-axis motion module (912), the auxiliary U-axis motion module (917), and the nozzle replacement device (919) are used to select and replace the nozzle suitable for the first functional structure (20), and a trial printing is performed; Step 5: Start the CNC G code path trajectory program of the first functional structure (20), the laser rangefinder (911) will perform multi-point distance measurement on the printing path, perform real-time compensation of the printing height according to the distance measurement value, and execute the printing program in sequence according to the trajectory program; Step 6: The operation panel (1) displays the current printing status in real time and records the position of the functional structure defect according to the real-time printing effect. After the printing is completed, repair printing is performed according to the recorded defect position; Step 7: Import the model of the workpiece (19) on which the first functional structure (20) is printed into the structure paving and path planning software, paving the second functional structure (21) on the surface of the first functional structure (20), completing the preliminary path planning, and generating a numerical control G code path trajectory program based on the second functional structure (21) after post-processing by the industrial control computer; Step 8: Replace the nozzle with one suitable for the second functional structure (21), connect the material storage tube (914) containing the material of the second functional structure (21) to the electro-jet printing valve (915), adjust the flow field parameters, electric field parameters, and laser curing parameters through the operation panel (1), and perform a trial printing; Step 9: Start the CNC G code path trajectory program of the second functional structure (21), the operation panel (1) displays the current printing status in real time and records the defective position of the functional structure according to the printing effect, and after the printing is completed, perform repair printing according to the recorded defective position; Step 10: Importing the model of the workpiece (19) on which the first functional structure (20) and the second functional structure (21) are printed into the structural paving and path planning software, splitting the functional layer (22) into linear structures and superimposing them on the surface of the workpiece (19), completing the preliminary path planning, and generating a numerical control G code path trajectory program based on the functional layer (22) after post-processing by the industrial control computer; Step 11: Replace the nozzle suitable for the functional layer (22), connect the material storage tube (914) containing the functional layer (22) material to the electrospray printing valve (915), adjust the flow field parameters and electric field parameters through the operation panel (1) to form an electrospray printing state, adjust the laser curing parameters, and perform a test print; Step 12: starting the CNC G code path trajectory program for the functional layer (22), the operation panel (1) displays the current printing status in real time and records the defective position of the functional structure according to the printing effect, and after the printing is completed, performing repair printing according to the recorded defective position; Step 13: importing the model of the workpiece (19) on which the first functional structure (20), the second functional structure (21) and the functional layer (22) are printed into the structure paving and path planning software, paving the third functional structure (23) on the surface of the functional layer (22), completing the preliminary path planning, and generating a numerical control G code path trajectory program based on the third functional structure (23) after post-processing by the industrial control computer; Step 14: Replace the nozzle with one suitable for the third functional structure (23), connect the material storage tube (914) containing the material of the third functional structure (23) to the electro-jet printing valve (915), adjust the flow field parameters and electric field parameters through the operation panel (1), and form a suitable conical jet to perform trial printing; Step 15: starting the CNC G code path trajectory program for the third functional structure (23), the operation panel (1) displays the current printing status in real time and records the defect position of the functional structure according to the printing effect, and after the printing is completed, performing repair printing according to the recorded defect position; Step 16: After adjusting the corresponding materials, printing parameters and CNC G code path trajectory program according to the new model, repeating the above steps 7 to 15 can achieve electrospray printing manufacturing of multi-layer interconnected structures with more layers.

7. The electrofluid printing method for complex curved multi-layer interconnected structures according to claim 6, characterized in that: The material of the first functional structure (20) includes conductive metal ink, conductive polymer, and dielectric ink; the material of the second functional structure (21) includes conductive metal ink, conductive polymer, or dielectric ink; the material of the functional layer (22) includes conductive metal ink, conductive polymer, or dielectric ink; and the material of the third functional structure (23) includes conductive metal ink, conductive polymer, or dielectric ink.

8. The electrofluid printing method for complex curved multi-layer interconnected structures according to claim 7, characterized in that: During the process of printing the first functional structure (20), a laser curing device (97) is used to perform in-situ curing and sintering.

9. The electrofluid printing method for complex curved multi-layer interconnected structures according to claim 8, characterized in that: The material printed on the first functional structure (20) is subjected to in-situ laser curing and sintering to realize the preparation of a spatial interconnected structure; a functional layer (22) is printed between the spatial interconnected structures, and the functional layer (22) satisfies the exposure of the top of the spatial interconnected structure; during the process of printing the functional layer (22), a laser curing device (97) is used to realize in-situ curing and sintering of the functional layer (22).

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