3D binding additive manufacturing structure and preparation method thereof

Abstract

According to the 3D binding additive manufacturing structure and the preparation method thereof, based on the principle that a stapler binds paper, binding anchors are installed in the thickness direction in the laying process of each layer of material layers, each binding anchor comprises a horizontal section and a vertical section, and the binding anchors and the material layers are alternately installed and laid, so that the binding anchors and the material layers are interwoven and consolidated; according to the 3D binding additive manufacturing structure and the preparation method thereof, the technical bottleneck that a three-dimensional continuous fiber structure cannot be prepared from an existing 3D printing material is broken through, and the interlayer performance of the 3D printing material is improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of three-dimensional weaving, and particularly relates to a 3D binding additive manufacturing structure and a preparation method thereof. Background Art

[0002] A preform is an integral structural material formed by fibers through certain processing. The fiber integral structure overcomes the problem that the interlayer properties of a laminate rely solely on the reinforcing matrix, resulting in low mechanical properties, and has become an important part of high-performance composite materials. Currently, there are many forming methods for preforms, such as weaving, knitting, needling, stitching, etc., but each process has certain limitations. For example, the weaving process has complex procedures and low efficiency; processes such as knitting and stitching are greatly affected by thickness, etc., which to a certain extent affects the further development of preforms.

[0003] 3D printing has become a research hotspot in current material manufacturing due to its unique additive manufacturing characteristics. Technical breakthroughs have been achieved in 3D printing technologies for various isotropic materials, enabling engineering applications and showing good development prospects. Continuous fiber reinforced 3D printing has also received key attention from the composite materials research community and shows good development momentum. However, due to the idea of layer-by-layer preparation, 3D printing can currently only achieve the printing of continuous planar fibers. Although some research institutions have proposed strategies for bending the trajectories of planar fibers in order to obtain a "non-planar" layout, it still belongs to the category of planar printing after all. The fact that planar continuous fiber 3D printing cannot manufacture three-dimensional continuous fiber structure materials has become a pain point in the development of this technology. The present invention breaks through the technical bottleneck that existing 3D printing materials cannot prepare three-dimensional continuous fiber structures and improves the interlayer properties of 3D printing materials. Summary of the Invention

[0004] The purpose of the present invention is to provide a 3D binding additive manufacturing structure and a preparation method thereof to solve the problem that existing 3D printing materials cannot prepare three-dimensional continuous fiber structures.

[0005] The technical solution for achieving the purpose of the present invention is as follows:

[0006] A preparation method of a 3D binding additive manufacturing structure includes the following steps:

[0007] Step 1: Install the first binding anchor: Place a plurality of first binding anchors in the first direction and the second direction respectively. The first binding anchor includes a first horizontal section and a first vertical section. One end of the first horizontal section is connected to the lower end of the first vertical section. The middle part of the first vertical section is flexible and can be bent into a second horizontal section. The first horizontal section and the second horizontal section are not parallel. In the first direction, there is a first spacing between the first horizontal sections of adjacent front and rear first binding anchors. In the second direction, there is a second spacing between the first horizontal sections of adjacent left and right first binding anchors;

[0008] Step Two: Laying Materials: Place raw materials in the 3D printer head, and lay multiple layers of materials alternately along the height direction in the first direction and the second direction;

[0009] Step Three: Placing the First Binding Anchors of the Second Cycle: Place multiple first binding anchors in the first and second directions on the surface layer of the materials. The 3D printer head continues to lay multiple layers of materials alternately along the height direction in the first direction and the second direction;

[0010] Step Four: Bending the First Binding Anchors: When the laid materials reach the middle part of the bottommost first binding anchor, bend the middle part of the bottommost first binding anchor to form a second horizontal section, and press the second horizontal section onto the surface of the topmost layer of materials;

[0011] Step Five: Repeat Steps One, Two, Three, and Four. When the laid materials reach the middle part of the corresponding layer of first binding anchors, bend the middle part of the corresponding layer of first binding anchors to form a second horizontal section and press it onto the surface of the topmost layer of materials until the materials reach the designed height. At this time, bend the middle part of the topmost first binding anchor to complete the preparation of the composite material. Among them, the first direction and the second direction are not parallel.

[0012] A preparation method for a 3D binding additive manufacturing structure, comprising the following steps:

[0013] Step One: Installing the Second Binding Anchors: Place multiple second binding anchors respectively along the first direction and the second direction. The second binding anchor includes a third horizontal section and a second vertical section. The third horizontal end is connected to the lower end of the first vertical section. Among them, the third horizontal sections of the multiple second binding anchors in the first direction are on the same straight line, the third horizontal sections of the multiple second binding anchors in the second direction are parallel to each other, and the second vertical sections in each direction are vertically upward;

[0014] Step Two: Laying Materials: Place raw materials in the 3D printer head, and the printer head lays materials between the second vertical sections of adjacent second binding anchors along the first direction and the second direction;

[0015] Step Three: Rotating the Second Binding Anchors: Rotate one of the second binding anchors in one of the directions where two layers of materials have been pressed, so that the second vertical section of one of the second binding anchors in one of the directions is pressed onto the surface of the topmost layer of materials. In this one of the directions, continue to install the second binding anchors in this direction in the manner of Step One, and then lay materials with the 3D printer head in this one of the directions. Then rotate the second binding anchors in the other direction so that the second vertical section of the second binding anchors in the other direction is pressed onto the surface of the topmost layer of materials, and then continue to install the second binding anchors in this other direction in the manner of Step One in this other direction;

[0016] Step 4: Alternately and circularly rotate the second binding anchor and the laying material in the manner of Step 3 until the material reaches the designed height, thereby completing the preparation of the composite material. The first direction and the second direction are not parallel.

[0017] A preparation method for a 3D binding additive manufacturing structure, comprising the following steps:

[0018] Step 1: Place raw materials in the 3D printer head. The printer head alternately lays multiple layers of materials along the height direction in the first direction and the second direction. There is a gap between the materials at the same height in each direction. The gaps formed by the alternately laid material layers in the first direction and the second direction form multiple channels in the height direction. The first direction and the second direction are not parallel;

[0019] Step 2: Install a third binding anchor in at least some of the channels. The third binding anchor includes a fourth horizontal section, a third vertical section, and a fourth vertical section. The fourth horizontal section is connected to the upper ends of the third vertical section and the fourth vertical section. The third vertical section and the fourth vertical section are inserted into the channels, and the fourth horizontal section is pressed against the upper surface of the uppermost material layer;

[0020] Step 3: Continue to alternately lay multiple layers of materials along the height direction in the first direction and the second direction. During this process, continuously install the third binding anchor in the channels in the manner of Step 2, ensuring that the uppermost material layer pressed by the fourth horizontal section of the third binding anchor includes the material layers in the first direction and the second direction, until all the material layers are laid to form a composite material product.

[0021] Further, the way to bend the middle part of the first binding anchor in Step 4 is: soften the middle part of the first binding anchor through a heating device above the material, and use a pressure roller to bend the middle part of the first binding anchor into a second horizontal section and press it against the surface material.

[0022] Further, the material is a composite polymer or a fiber raw material polymer.

[0023] Further, the first direction and the second direction are perpendicular.

[0024] Further, the first horizontal section and the second horizontal section are perpendicular.

[0025] Further, the channels are straight channels or inclined channels.

[0026] Further, the cross-section of each section of the first binding anchor and / or the second binding anchor and / or the third binding anchor is a polygon, a circle, or an ellipse.

[0027] Further, the material of the first binding anchor and / or the second binding anchor and / or the third binding anchor is a composite material.

[0028] A 3D binding additive manufacturing structure, which is prepared by the above-mentioned preparation method.

[0029] Compared with the prior art, its significant advantages are as follows:

[0030] The present invention weaves the fiber layer plane in a low-damage manner (3D printing), and uses binding anchors to realize the connection of fibers between layers, reducing fiber damage during the weaving process, which is beneficial to improving the service performance of the preform. Description of the Drawings

[0031] Figure 1 It is a schematic diagram of the laying process of Example 1.

[0032] Figure 2 It is a schematic diagram of the pressing roller of Example 1.

[0033] Figure 3 It is a schematic diagram of the upper heating device of Example 1.

[0034] Figure 4 It is a schematic diagram of the pressing roller bending out the second horizontal section after heating in Example 1.

[0035] Figure 5 It is a schematic diagram of the laying of the second binding anchor in Example 2.

[0036] Figure 6 It is a schematic diagram of the laying state of the first layer of material in Example 2.

[0037] Figure 7 It is a schematic diagram of the laying state of the second layer of material in Example 2.

[0038] Figure 8 It is a schematic diagram of the rotational crimping of the second binding anchor in Example 2.

[0039] Figure 9 It is a schematic diagram of the laying state of the third layer of material in Example 2.

[0040] Figure 10 It is a schematic diagram of the rotational crimping of the second binding anchor in Example 2.

[0041] Figure 11 It is a schematic diagram of a structure of the third binding anchor in Example 3.

[0042] Figure 12 It is another schematic diagram of the structure of the third binding anchor in Example 3.

[0043] Figure 13 It is a schematic diagram of installing the third binding anchor during the process of laying the fiber layer in Example 3.

[0044] Figure 14 It is a schematic diagram of the frame preform with the third binding anchor installed in Example 3. Detailed implementation manners

[0045] The present invention will be described in detail below in conjunction with the accompanying drawings and specific implementation manners.

[0046] Based on the principle of stapling paper by a "stapler", the present invention installs binding anchors along the thickness direction during the laying process of each layer of the material layer, thereby forming a 3D binding additive manufacturing structure and its preparation method, breaking through the technical bottleneck that existing 3D printing materials cannot prepare three-dimensional continuous fiber structures.

[0047] Example 1

[0048] First, in conjunction with Figure 1 , Figure 1 which shows a schematic diagram of the laying process, the structure of the first binding anchor in this embodiment will be described first. The first binding anchor includes a first horizontal section and a first vertical section. One end of the first horizontal section is connected to the lower end of the first vertical section (i.e., forming an "L" shape). At least the middle part of the first vertical section is flexible and can be bent into a second horizontal section (the second horizontal section is as shown in Figure 4 ). The first horizontal section and the second horizontal section are not parallel. In this embodiment, it is preferably that the first horizontal section is perpendicular to the second horizontal section. Of course, it can also be at other angles such as 30°, 60°, etc. When installing the first binding anchor, in the first direction, there is a first spacing between the first horizontal sections of adjacent front and rear first binding anchors, and in the second direction, there is a second spacing between the first horizontal sections of adjacent left and right first binding anchors.

[0049] After installing the first binding anchor, start laying the material: Place the raw material in the 3D printer head, and alternately lay multiple layers of material along the height direction in the first direction and the second direction. The laying state is as shown in Figure 1 ;

[0050] Place the first binding anchors in the second cycle: During the laying process, place multiple first binding anchors (not shown in the figure) on the surface layer of the material in the first and second directions. The 3D printer head continues to alternately lay multiple layers of material along the height direction in the first direction and the second direction;

[0051] Bend the first binding anchor: When the laid material reaches the middle part of the bottommost first binding anchor, bend the middle part of the bottommost first binding anchor to form a second horizontal section, and press the second horizontal section to the surface of the topmost material. Soften the middle part of the first binding anchor through a heating device above the material, and use a pressure roller to bend the middle part of the first binding anchor into a second horizontal section and press it to the surface material, as shown in Figures 2 - 4 ;

[0052] Repeat the above steps. When the laid material reaches the middle part of the first binding anchor of the corresponding layer, bend the middle part of the first binding anchor of the corresponding layer to form a second horizontal section and press it onto the surface of the topmost layer of material. The continuously bent second horizontal section can intertwine and consolidate the first binding anchor and the material layer together until the material reaches the designed height. At this time, the bending of the middle part of the first binding anchor of the topmost layer is completed, and thus the preparation of the composite material is completed. Among them, the first direction and the second direction are not parallel, preferably perpendicular.

[0053] Example 2

[0054] First, install the second binding anchor: As Figure 5 shown, place a plurality of second binding anchors respectively along the first direction and the second direction ( Figure 5 exemplarily shows two second binding anchors, and actually there can be multiple). The second binding anchor includes a third horizontal section and a second vertical section. The third horizontal end is connected to the lower end of the first vertical section (i.e., forms an "L" shape). Among them, the third horizontal sections of the plurality of second binding anchors in the first direction are on the same straight line, and the third horizontal sections of the plurality of second binding anchors in the second direction are parallel to each other. The second vertical sections in each direction are vertically upward. Figure 5 shows the state of one second binding anchor in one of the two directions, and actually there can be multiple;

[0055] Lay the material: Place the raw material in the 3D printer head, and the printer head lays the material between the second vertical sections of adjacent second binding anchors along the first direction and the second direction. Figure 5 shows a schematic diagram of laying the first layer of material in one of the directions, Figure 6 shows a schematic diagram of laying the second layer of material in the other direction;

[0056] Rotate the second binding anchor: As Figures 7 - 10 shown, rotate the second binding anchor in one of the directions where two layers of material have been pressed, so that the second vertical section of the second binding anchor in one of the directions is pressed onto the surface of the topmost layer of material. In this one direction, continue to install the second binding anchor in this direction in the manner of step one, then lay the material with the 3D printer head in this one direction, then rotate the second binding anchor in the other direction, so that the second vertical section of the second binding anchor in the other direction is pressed onto the surface of the topmost layer of material, and then continue to install the second binding anchor in this other direction in the manner of step one in this other direction;

[0057] Rotate the second binding anchor and the laying material alternately in a cycle as described above. After each rotation of the second binding anchor, lay a layer of material, and then install a layer of the second binding anchor after laying the material. By repeating this cycle, the material layers and the second binding anchor can be intertwined and consolidated together until the material reaches the designed height, thereby completing the preparation of the composite material. The first direction and the second direction are not parallel, preferably perpendicular.

[0058] Example 3

[0059] First, in combination with Figure 11 , 12 , illustrate the structure of the third binding anchor in this embodiment. The third binding anchor includes a fourth horizontal section, a third vertical section, and a fourth vertical section. The fourth horizontal section is connected to the upper ends of the third vertical section and the fourth vertical section. Figure 11 is an "orthogonal coordinate" type binding anchor, Figure 12 is a channel-shaped binding anchor. Of course, the number of vertical sections can also be more than two and are sequentially connected to the fourth horizontal section.

[0060] Place raw materials in the 3D printer head. The printer head alternately lays multiple layers of materials along the height direction in the first direction and the second direction. There is a gap between adjacent material layers at the same height in each direction. The gaps formed by the alternately laid multiple material layers in the first direction and the second direction form multiple channels in the height direction. In this embodiment, the first direction and the second direction are perpendicular to each other.

[0061] As Figure 13 , install the third binding anchor in some or all of the channels. The third vertical section and the fourth vertical section are inserted into the channels, and the fourth horizontal section is pressed against the upper surface of the topmost material layer;

[0062] Continue to alternately lay multiple material layers along the height direction in the first direction and the second direction. During this process, continuously install the third binding anchor in the channels in the above-mentioned manner to ensure that the topmost material layer pressed by the fourth horizontal section of the third binding anchor includes the material layers in the first direction and the second direction until all the material layers are laid to form a composite material product, as Figure 14 shown.

[0063] Preferably, the channels are straight channels or inclined channels.

[0064] Preferably, the cross-sections of each section of the first binding anchor and / or the second binding anchor and / or the third binding anchor are polygonal, circular, or elliptical.

[0065] Preferably, the material of the first binding anchor and / or the second binding anchor and / or the third binding anchor is a composite material. The binding anchor is prepared by 3D printing using a composite material substrate or machined into various shapes after fiber preform composite. It is consistent with the material of the composite material and does not affect the performance of the composite material.

[0066] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A preparation method for a 3D binding additive manufacturing structure, characterized in that, It includes the following steps: Step 1: Install the first binding anchor: Place a plurality of first binding anchors in the first direction and the second direction respectively. The first binding anchor includes a first horizontal section and a first vertical section. One end of the first horizontal section is connected to the lower end of the first vertical section. The middle part of the first vertical section is flexible and can be bent into a second horizontal section. The first horizontal section and the second horizontal section are not parallel. In the first direction, there is a first spacing between the first horizontal sections of adjacent front and rear first binding anchors. In the second direction, there is a second spacing between the first horizontal sections of adjacent left and right first binding anchors; Step 2: Lay the material: Place the raw material in the 3D printer head and lay multiple layers of materials alternately in the height direction in the first direction and the second direction; Step 3: Place the first binding anchors of the second cycle: Place a plurality of first binding anchors in the first and second directions on the surface of the material. The 3D printer head continues to lay multiple layers of materials alternately in the height direction in the first direction and the second direction; Step 4: Bend the first binding anchor: When the laid material reaches the middle part of the bottommost first binding anchor, bend the middle part of the bottommost first binding anchor to form a second horizontal section, and press the second horizontal section to the surface of the topmost material; Step 5: Repeat Steps 1, 2, 3, and 4. When the laid material reaches the middle part of the corresponding layer of the first binding anchor, bend the middle part of the corresponding layer of the first binding anchor to form a second horizontal section and press it to the surface of the topmost material until the material reaches the designed height. At this time, complete the bending of the middle part of the topmost first binding anchor, thereby completing the preparation of the composite material. Among them, the first direction and the second direction are not parallel.

2. A preparation method for a 3D binding additive manufacturing structure, characterized in that, It includes the following steps: Step 1: Install the second binding anchor: Place a plurality of second binding anchors in the first direction and the second direction respectively. The second binding anchor includes a third horizontal section and a second vertical section. The third horizontal end is connected to the lower end of the first vertical section. Among them, the third horizontal sections of the plurality of second binding anchors in the first direction are on the same straight line, the third horizontal sections of the plurality of second binding anchors in the second direction are parallel to each other, and the second vertical sections in each direction are vertically upward; Step 2: Lay the material: Place the raw material in the 3D printer head, and the printer head lays the material between the second vertical sections of adjacent second binding anchors in the first direction and the second direction; Step 3: Rotate the second binding anchor: Rotate the second binding anchor in one of the directions where there are already two layers of materials pressed, so that the second vertical section of the second binding anchor in one of the directions is pressed to the surface of the topmost material. In this one of the directions, continue to install the second binding anchor in this direction according to the method of Step 1, and then lay the material with the 3D printer head in this one of the directions. Then rotate the second binding anchor in the other direction so that the second vertical section of the second binding anchor in the other direction is pressed to the surface of the topmost material. Then continue to install the second binding anchor in this other direction according to the method of Step 1 in this other direction; Step 4: Alternately and cyclically rotate the second binding anchor and lay the material according to the method of Step 3 until the material reaches the designed height, thereby completing the preparation of the composite material. The first direction and the second direction are not parallel.

3. A method for preparing a 3D binding additive manufacturing structure, characterized in that, The steps include the following: Step 1: Place raw materials in the 3D printer head. The head alternately lays multiple layers of materials in the height direction in a first direction and a second direction, with gaps left between materials at the same height in each direction. The gaps formed between the alternately laid material layers in the first direction and the second direction form multiple channels in the height direction. The first direction and the second direction are not parallel; Step 2: Install third binding anchors in at least some of the channels. The third binding anchor includes a fourth horizontal section, a third vertical section, and a fourth vertical section. The fourth horizontal section is connected to the upper ends of the third vertical section and the fourth vertical section. The third vertical section and the fourth vertical section are inserted into the channels, and the fourth horizontal section is pressed against the upper surface of the topmost material layer; Step 3: Continue to alternately lay multiple layers of materials in the height direction in the first direction and the second direction. During this process, continuously install third binding anchors in the channels in the manner of Step 2, ensuring that the topmost material layer pressed by the fourth horizontal section of the third binding anchor includes material layers in the first direction and the second direction until all material layers are laid to form a composite material product.

4. The preparation method of the 3D binding additive manufacturing structure according to claim 1, characterized in that, The way to bend the middle part of the first binding anchor in Step 4 is as follows: Soften the middle part of the first binding anchor through a heating device above the material, and use a pressure roller to bend the middle part of the first binding anchor so that the second horizontal section is pressed against the surface material.

5. The preparation method of the 3D binding additive manufacturing structure according to claim 1 or 2 or 3, characterized in that, The material is a composite polymer or a fiber raw material polymer.

6. The preparation method of the 3D binding additive manufacturing structure according to claim 1 or 2 or 3, characterized in that, The first direction and the second direction are perpendicular.

7. The preparation method of the 3D binding additive manufacturing structure according to claim 1, characterized in that, The first horizontal section is perpendicular to the second horizontal section.

8. The preparation method of the 3D binding additive manufacturing structure according to claim 3, characterized in that, The channels are straight channels or inclined channels.

9. The preparation method of the 3D binding additive manufacturing structure according to claim 1 or 2 or 3, characterized in that, The cross-section of each section of the first binding anchor and / or the second binding anchor and / or the third binding anchor is polygonal, circular, or elliptical.

10. The preparation method of the 3D binding additive manufacturing structure according to claim 1 or 2 or 3, characterized in that, The material of the first binding anchor and / or the second binding anchor and / or the third binding anchor is a composite material.

11. A 3D binding additive manufacturing structure, characterized in that, The structure is prepared by using the preparation method described in any one of claims 1-10.

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