3D bound additive manufactured structure and method of making

Abstract

The application provides a 3D binding additive manufacturing structure and a preparation method thereof, which is based on the principle of a stapler binding paper, and a binding anchor is installed in a thickness direction during the laying of each layer of material layers, the binding anchor comprises a horizontal section and a vertical section, the binding anchor and the material layers are alternately installed and laid, so that the two are interwoven and consolidated, a tight connection is formed, and thus the 3D binding additive manufacturing structure and the preparation method thereof are formed. The application breaks through the technical bottleneck that the existing 3D printing material cannot be used to prepare a three-dimensional continuous fiber structure, and improves the interlayer performance of the 3D printing material.

Description

Technical Field

[0001] This invention belongs to the field of three-dimensional weaving technology, specifically a 3D binding additive manufacturing structure and its preparation method. Background Technology

[0002] Preforms are integral structural materials formed from fibers through specific processing. The integral fiber structure overcomes the problem of laminates where interlayer properties rely solely on the reinforcing matrix, resulting in lower mechanical properties, and has become an important component of high-performance composite materials. Currently, there are many methods for forming preforms, such as weaving, stitching, needle punching, and sewing, but each process has its limitations. For example, weaving is complex and inefficient; stitching and other processes are significantly affected by thickness, which to some extent hinders the further development of preforms.

[0003] 3D printing, due to its unique additive manufacturing characteristics, has become a hot topic in current materials manufacturing research. Breakthroughs have been achieved in 3D printing of various isotropic materials, realizing engineering applications and demonstrating promising development prospects. Continuous fiber additive 3D printing has also received significant attention from the composite materials research community, showing strong growth momentum. However, due to its layered fabrication concept, 3D printing currently only allows for the printing of continuous planar fibers. Although some research institutions have proposed fiber bending strategies to achieve "non-planar" arrangement, these still fall within the scope of planar printing. The inability to fabricate three-dimensional continuous fiber structures using planar continuous fiber 3D printing remains a bottleneck in the technology's development. This invention overcomes the technical bottleneck of existing 3D printing materials' inability to fabricate three-dimensional continuous fiber structures, improving the interlayer properties of 3D printing materials. Summary of the Invention

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

[0005] The technical solution to achieve the purpose of this invention is as follows:

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

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

[0008] Step 2: Material Laying: Place the raw material in the 3D printer head and alternately lay multiple layers of material along the height direction in the first and second directions;

[0009] Step 3: Place the first binding anchors for the second cycle: Place multiple first binding anchors on the material surface in the first and second directions, and the 3D printer head continues to alternately lay multiple layers of material along the height direction in the first and second directions;

[0010] Step 4: Bending the first binding anchor: When the laid material reaches the middle part of the bottom first binding anchor, bend the middle part of the bottom first binding anchor to form the second horizontal section, and press the second horizontal section onto the surface of the top material.

[0011] Step 5: Repeat steps 1, 2, 3, and 4. 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 top layer material until the material reaches the designed height. At this point, the bending of the middle part of the top layer first binding anchor is completed, thus completing the preparation of the composite material. The first direction and the second direction are not parallel.

[0012] A method for fabricating a 3D binding additive manufacturing structure includes the following steps:

[0013] Step 1: Install the second binding anchor: Place multiple second binding anchors along the first direction and the second direction respectively. The second binding anchor includes a third horizontal segment and a second vertical segment. The third horizontal end is connected to the lower end of the first vertical segment. The third horizontal segments of the multiple second binding anchors in the first direction are on the same straight line. The third horizontal segments of the multiple second binding anchors in the second direction are parallel to each other. The second vertical segment in each direction is vertically upward.

[0014] Step 2: Material Laying: Place the raw material in the 3D printer head, which lays the material between the second vertical segments of adjacent second binding anchors along the first and second directions;

[0015] Step 3: Rotate the second binding anchor: Rotate the second binding anchor in one direction where two layers of material have been pressed, so that the second vertical section of the second binding anchor in one direction presses against the surface of the uppermost material. Continue to install the second binding anchor in that direction in the manner described in Step 1. Then, lay material in that direction using the 3D printer head. 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 presses against the surface of the uppermost material. Then, continue to install the second binding anchor in that direction in the manner described in Step 1.

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

[0017] A method for fabricating a 3D binding additive manufacturing structure includes the following steps:

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

[0019] Step 2: Install a third binding anchor in at least part of the channel. 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 channel. The fourth horizontal section is pressed against the upper surface of the uppermost material layer.

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

[0021] Furthermore, in step four, the middle part of the first binding anchor is bent by: softening the middle part of the first binding anchor by a heating device above the material, and bending the middle part of the first binding anchor into a second horizontal section by a pressure roller and pressing it onto the surface material.

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

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

[0024] Furthermore, the first horizontal segment is perpendicular to the second horizontal segment.

[0025] Furthermore, the channel is a straight channel or an oblique channel.

[0026] Furthermore, the cross-section of each segment of the first binding anchor and / or the second binding anchor and / or the third binding anchor is polygonal, circular, or elliptical.

[0027] Furthermore, 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 is prepared using the above-described preparation method.

[0029] Compared with existing technologies, its significant advantages are:

[0030] This invention uses a low-damage method (3D printing) to weave the fiber layer plane and uses binding anchors to connect the fibers between layers, reducing fiber damage during the weaving process and improving the performance of the preform. Attached Figure Description

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

[0032] Figure 2 This is a schematic diagram of the pressure roller in Example 1.

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

[0034] Figure 4 This is a schematic diagram of the second horizontal section formed by bending the pressure roller after heating in Example 1.

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

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

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

[0038] Figure 8 This is a schematic diagram of the rotation and pressing of the second binding anchor in Example 2.

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

[0040] Figure 10 This is a schematic diagram of the rotation and pressing of the second binding anchor in Example 2.

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

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

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

[0044] Figure 14 This is a schematic diagram of the prefabricated frame for installing the third binding anchor in Example 3. Detailed Implementation

[0045] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0046] This invention is based on the principle of "stapler" binding paper. During the laying of each layer of material, binding anchors are installed along the thickness direction to form a 3D binding additive manufacturing structure and its preparation method, which breaks through the technical bottleneck that existing 3D printing materials cannot prepare three-dimensional continuous fiber structures.

[0047] Example 1

[0048] First, combine Figure 1 , Figure 1 A schematic diagram of the laying process is provided. First, the structure of the first binding anchor in this embodiment is explained. The first binding anchor includes a first horizontal segment and a first vertical segment. One end of the first horizontal segment is connected to the lower end of the first vertical segment (i.e., forming an "L" shape). At least the middle portion of the first vertical segment is flexible and can be bent into a second horizontal segment (the second horizontal segment is as follows). Figure 4 As shown in the figure, the first horizontal segment and the second horizontal segment are not parallel. In this embodiment, the first horizontal segment is perpendicular to the second horizontal segment, but other angles such as 30° and 60° are also possible. When installing the first binding anchor, in the first direction, there is a first gap between the first horizontal segments of adjacent front and rear first binding anchors, and in the second direction, there is a second gap between the first horizontal segments of adjacent left and right first binding anchors.

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

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

[0051] Bending the first binding anchor: When the laid material reaches the middle part of the bottom first binding anchor, the middle part of the bottom first binding anchor is bent to form a second horizontal section. The second horizontal section is pressed against the surface of the top material. The middle part of the first binding anchor is softened by a heating device above the material, and a pressure roller is used to bend the middle part of the first binding anchor into a second horizontal section and press it against the surface material. Figure 2-4 As shown;

[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 uppermost material. The continuously bent second horizontal section can intertwine and solidify 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 uppermost first binding anchor is completed, thereby completing the preparation of the composite material. The first direction and the second direction are not parallel, and are preferably perpendicular.

[0053] Example 2

[0054] First, install the second binding anchor: (e.g.) Figure 5 As shown, multiple second binding anchors are placed along the first and second directions respectively. Figure 5 The example shows two second binding anchors (in practice, there can be multiple). Each second binding anchor includes a third horizontal segment and a second vertical segment. The third horizontal end is connected to the lower end of the first vertical segment (i.e., forming an "L" shape). In the first direction, the third horizontal segments of the multiple second binding anchors are on the same straight line, and the third horizontal segments of the multiple second binding anchors in the second direction are parallel to each other. The second vertical segment in each direction is vertically upward. Figure 5 The image shows the state of one second binding anchor in two directions, but there can actually be multiple anchors.

[0055] Material Laying: Raw material is placed in the 3D printer head, which lays the material between the second vertical segments of adjacent second stapling anchors along a first direction and a second direction. Figure 5 A schematic diagram is given showing the first layer of material being laid in one of the directions. Figure 6 A schematic diagram of laying a second layer of material in another direction is given;

[0056] Rotate the second binding anchor: as Figure 7-10 As shown, rotate the second binding anchor in one direction of the two-layer material press so that the second vertical section of the second binding anchor in one direction presses against the surface of the uppermost material. Continue to install the second binding anchor in that direction in the manner described in step one. Then, lay material in that direction using the 3D printer head. 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 presses against the surface of the uppermost material. Then, continue to install the second binding anchor in that direction in the manner described in step one.

[0057] The second binding anchor and the material are alternately rotated and laid in the manner described above. After each rotation of the second binding anchor, a layer of material is laid, and then another layer of the second binding anchor is installed. This cycle is repeated so that the material layers and the second binding anchor are intertwined and fixed 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, but preferably perpendicular.

[0058] Example 3

[0059] First, combine Figure 11 , 12 The structure of the third binding anchor in this embodiment is described below. The third binding anchor includes a fourth horizontal segment, a third vertical segment, and a fourth vertical segment. The fourth horizontal segment is connected to the upper ends of the third vertical segment and the fourth vertical segment. Figure 11 For "orthogonal coordinate" type binding anchors, Figure 12 Use a zigzag binding anchor; of course, there can be more than two vertical segments, which are then connected to the fourth horizontal segment in sequence.

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

[0061] like Figure 13 A third binding anchor is installed in part or all of the channel, the third vertical segment and the fourth vertical segment are inserted into the channel, and the fourth horizontal segment is pressed against the upper surface of the uppermost material layer.

[0062] Continue laying multiple material layers alternately along the height direction in both the first and second directions. During this process, continuously install third anchors within the ducts as described above, ensuring that the uppermost material layer pressed by the fourth horizontal section of the third anchor includes both the material layers from the first and second directions, until all material layers are laid to form a composite material product. Figure 14 As shown.

[0063] Preferably, the channel is a straight channel or an oblique channel.

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

[0065] Preferably, the first binding anchor and / or the second binding anchor and / or the third binding anchor are made of a verification material. The binding anchor is made of composite material substrate through 3D printing or fiber preform composite and then machined into binding anchors of various shapes. It is consistent with the material of the composite material and does not affect the performance of the composite material.

[0066] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for preparing a 3D binding additive manufacturing structure, characterized in that, Includes the following steps: Step 1: Install the first binding anchor: Place multiple first binding anchors in the first direction and the second direction respectively. Each first binding anchor includes a first horizontal segment and a first vertical segment. One end of the first horizontal segment is connected to the lower end of the first vertical segment. The middle part of the first vertical segment is flexible and can be bent into a second horizontal segment. The first horizontal segment and the second horizontal segment are not parallel. In the first direction, there is a first gap between the first horizontal segments of adjacent front and rear first binding anchors. In the second direction, there is a second gap between the first horizontal segments of adjacent left and right first binding anchors. Step 2: Material Laying: Place the raw material in the 3D printer head and alternately lay multiple layers of material along the height direction in the first and second directions; Step 3: Place the first binding anchors for the second cycle: Place multiple first binding anchors on the material surface in the first and second directions, and the 3D printer head continues to alternately lay multiple layers of material along the height direction in the first and second directions; Step 4: Bending the first binding anchor: When the laid material reaches the middle part of the bottom first binding anchor, bend the middle part of the bottom first binding anchor to form the second horizontal section, and press the second horizontal section onto the surface of the top material. Step 5: Repeat steps 1, 2, 3, and 4. 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 top layer material until the material reaches the designed height. At this point, the bending of the middle part of the top layer first binding anchor is completed, thus completing the preparation of the composite material. The first direction and the second direction are not parallel.

2. A method for preparing a 3D binding additive manufacturing structure, characterized in that, Includes the following steps: Step 1: Install the second binding anchor: Place multiple second binding anchors along the first direction and the second direction respectively. The second binding anchor includes a third horizontal segment and a second vertical segment. The third horizontal end is connected to the lower end of the first vertical segment. The third horizontal segments of the multiple second binding anchors in the first direction are on the same straight line. The third horizontal segments of the multiple second binding anchors in the second direction are parallel to each other. The second vertical segment in each direction is vertically upward. Step 2: Material Laying: Place the raw material in the 3D printer head, which lays the material between the second vertical segments of adjacent second binding anchors along the first and second directions; Step 3: Rotate the second binding anchor: Rotate the second binding anchor in one direction where two layers of material have been pressed, so that the second vertical section of the second binding anchor in one direction presses against the surface of the uppermost material. Continue to install the second binding anchor in that direction in the manner described in Step 1. Then, lay material in that direction using the 3D printer head. 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 presses against the surface of the uppermost material. Then, continue to install the second binding anchor in that direction in the manner described in Step 1. Step 4: Alternately rotate the second anchor and the laying material in the same manner as in Step 3 until the material reaches the designed height, thus completing the preparation of the composite material. The first and second directions are not parallel.

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

4. The method for preparing a 3D binding additive manufacturing structure according to claim 1, characterized in that, In step four, the middle part of the first binding anchor is bent by: softening the middle part of the first binding anchor by a heating device above the material, and bending the middle part of the first binding anchor into a second horizontal section by a pressure roller and pressing it onto the surface material.

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

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

7. The method for preparing a 3D binding additive manufacturing structure according to claim 1, characterized in that, The first horizontal segment is perpendicular to the second horizontal segment.

8. The method for preparing a 3D binding additive manufacturing structure according to claim 3, characterized in that, The channel can be a straight channel or an oblique channel.

9. The method for preparing a 3D binding additive manufacturing structure according to claim 1, 2, or 3, characterized in that, The cross-sections of each segment of the first binding anchor and / or the second binding anchor and / or the third binding anchor are polygonal, circular, or elliptical.

10. The method for preparing a 3D binding additive manufacturing structure according to claim 1, 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 the preparation method described in any one of claims 1-10.

Images