Complex shape multi-material forming device and method based on magnetorheological core and microwave

Abstract

The present invention relates to a complex-shaped multi-material forming device and method based on a magnetorheological core and microwaves. The device comprises a core having an internal cavity, a magnetorheological fluid delivery assembly, a magnetorheological core, a magnetic field generating assembly, and a microwave generating assembly. The top of the core has a feed port. The magnetorheological core is disposed in the cavity and is replaced through the feed port. The magnetorheological fluid delivery assembly is used to deliver magnetorheological fluid to the inner cavity of the magnetorheological core or to extract magnetorheological fluid from the inner cavity of the magnetorheological core. The magnetic field generating assembly applies a magnetic field to the magnetorheological fluid in the magnetorheological core to solidify the magnetorheological fluid. The microwave generating assembly sintering forms the material entering the cavity through the feed port. By using magnetorheological material as a core, a variety of materials with different inner cavity shapes can be prepared and interlaced. At the same time, microwave heating technology is used to quickly and evenly heat the materials, which is conducive to the combination of multiple materials. The device is suitable for processing multi-material structures in which multiple materials of complex shapes are interlaced.

Description

Technical Field

[0001] The present invention belongs to the field of advanced manufacturing technology, and in particular relates to a complex-shape multi-material forming device and method based on a magnetorheological core and microwaves. Background Art

[0002] In modern engineering design and product development, the demand for high-performance, multifunctional, integrated components is growing. A single material often struggles to meet the comprehensive requirements for diverse physical and chemical properties (such as mechanical strength, toughness, thermal conductivity, electromagnetic properties, corrosion resistance, and biocompatibility) in complex applications. Consequently, multi-material structures have emerged. By precisely arranging and combining materials with diverse properties in space, they can optimize and complement their performance, achieving comprehensive performance advantages far exceeding those of a single material. For example, in the consumer goods sector, such as tool handles with soft grips, they typically combine a hard polymer core (such as polypropylene) that provides structural support with a soft elastomer outer layer (such as TPE) that provides a comfortable grip and non-slip properties. In the automotive industry, interior components such as dashboards integrate a rigid structural skeleton, a soft foam layer for collision energy absorption, and a surface layer that combines aesthetics and durability. In pipeline applications, such as the biomedical and energy fields, there is a need for multi-material pipeline components with internal rust and corrosion resistance and external flexibility and wear resistance, such as reinforced thermoplastic composite pipe (RTP / TCP). In some areas, these pipeline components also need to be manufactured into complex spiral structures. In the field of lattice structures, lattice structures with multiple materials inside and outside have important application prospects in areas such as heat dissipation and shock absorption.

[0003] In particular, multi-material components with complex shapes or internal cavities demonstrate enormous application potential and value. These structures enable a high degree of functional integration, for example: constructing internal fluid channels for efficient thermal management (heating or cooling); forming lightweight lattice or honeycomb sandwich structures to improve specific strength and stiffness; fabricating bioscaffolds with specific pore structures and functional gradients to guide tissue regeneration; or directly constructing reaction chambers, waveguide structures, or integrated circuit pathways within the component. Multi-material structures with multiple layers nested from the inside out, in particular, enable more precise performance control and functional stratification, offering unique advantages in areas such as energy absorption, electromagnetic shielding, and controlled drug release.

[0004] However, traditional manufacturing methods face significant challenges and limitations when preparing the above-mentioned complex shapes, especially multi-material components with fine and complex internal cavity structures or multi-layer nested structures.

[0005] While multi-component injection molding (such as overmolding and two-shot molding) can produce some multi-material parts with external coatings or simple interface combinations, mold design becomes extremely complex and costly for complex internal cavities with recessed or staggered features, as well as for multi-layered nested structures that require layer-by-layer construction. Core pulling is physically impossible. Co-extrusion is primarily suitable for producing continuous profiles or films with parallel layers, but it struggles to achieve complex three-dimensional shapes or non-parallel internal cavities. While bonding or mechanical assembly can combine preforms made of different materials, they often introduce interface weaknesses, increase the number of steps, and make seamless integration difficult, especially for complex internal structures. While additive manufacturing (3D printing) shows potential for producing complex shapes, multi-material printing still faces challenges in material compatibility, interfacial bonding strength, printing speed, cavity precision control, and effective and selective curing of different materials within a confined space (especially those requiring high-temperature sintering or specialized curing).

[0006] A key technical bottleneck is the difficulty existing technologies offer in easily and efficiently creating and removing temporary cores (also known as mold cores or core bones) used to define complex internal cavities, particularly when different materials need to be deposited and cured sequentially, layer by layer, to form nested structures. Traditional removable cores (e.g., metal, sand, low-melting-point alloys, or water-soluble materials) often have shape limitations, are difficult to remove, may contaminate the material, or are unsuitable for specialized subsequent curing processes.

[0007] Therefore, there is an urgent need to develop a new manufacturing technology that can break through the limitations of existing methods and achieve efficient and precise forming of multi-material components with complex shapes, fine cavities and multi-layer nested structures. Summary of the Invention

[0008] The present invention makes improvements to the problems existing in the above-mentioned prior art. That is, the technical problem to be solved by the present invention is to provide a complex-shaped multi-material forming device and method based on magnetorheological cores and microwaves, which is rationally designed and used to produce multi-layer nested and interlaced multi-material structures.

[0009] In order to achieve the above-mentioned purpose, the technical solution adopted by the present invention is: a complex shape multi-material forming device based on magnetorheological core and microwave, comprising a core with a cavity inside, a magnetorheological fluid delivery component, a magnetorheological core, a magnetic field generating component and a microwave generating component, the top of the core having a feed port connected to the cavity; the magnetorheological core is arranged in the cavity and can be replaced through the feed port; the magnetorheological fluid delivery component is connected to the magnetorheological core, and is used to deliver magnetorheological fluid to the inner cavity of the magnetorheological core or to extract magnetorheological fluid from the inner cavity of the magnetorheological core; the magnetic field generating component is used to apply a magnetic field to the magnetorheological fluid in the inner cavity of the magnetorheological core to solidify the magnetorheological fluid; the microwave generating component is used to sinter and form the material entering the cavity through the feed port.

[0010] Furthermore, the magnetorheological fluid delivery assembly includes a storage tank for storing magnetorheological fluid, a delivery pump and a magnetorheological fluid delivery pipe, one end of the magnetorheological fluid delivery pipe is connected to the storage tank, and the other end passes through the feed port and is connected to the magnetorheological core in the mold cavity; the delivery pump is installed on the magnetorheological fluid delivery pipe, and the delivery pump delivers the magnetorheological fluid in the storage tank to the magnetorheological core through the magnetorheological fluid delivery pipe, or delivers the magnetorheological fluid in the magnetorheological core to the storage tank.

[0011] Furthermore, a magnetic flux port is provided at the bottom of the mold core, and the magnetic flux port corresponds to the position of the feed port; the magnetic field generating assembly includes a magnetic field transmitter and a magnetic field receiver, and the magnetic field transmitter and the magnetic field receiver are distributed on the upper and lower sides of the mold core, the magnetic field transmitter corresponds to the position of the feed port and emits a magnetic field downward; the magnetic field receiver corresponds to the position of the magnetic flux port and receives the magnetic field.

[0012] Furthermore, the microwave generating assembly includes a first microwave generator and a second microwave generator, the first microwave generator is located on the left side of the mold core, and the microwave output end of the first microwave generator is connected to the left end of the mold core through a first waveguide; the second microwave generator is located on the front side of the mold core, and the microwave output end of the second microwave generator is connected to the front end of the mold core through a second waveguide.

[0013] Furthermore, the mold core includes an upper mold core and a lower mold core that are connected together at the upper and lower parts, and the inner cavity of the upper mold core and the inner cavity of the lower mold core are spliced ​​along the upper and lower directions to form a mold cavity.

[0014] Furthermore, the mold core includes a left mold core and a right mold core that are connected to each other on the left and right sides as one body, and the inner cavity of the left mold core and the inner cavity of the right mold core are spliced ​​along the left and right directions to form a mold cavity.

[0015] Furthermore, the mold core is made of microwave transparent material, and a cladding layer is provided on the outside of the mold core. The cladding layer is made of a material with microwave reflection and magnetic field penetration functions, and a yield hole is provided at the magnetic flux opening; a steel mesh plate is provided in the magnetic flux opening.

[0016] Furthermore, the covering layer is a mesh-shaped flexible fabric woven from a conductive material, and the mesh diameter of the covering layer is 1 to 2 mm.

[0017] Furthermore, the mesh diameter of the steel mesh plate is 3 to 4 mm.

[0018] Another technical solution adopted by the present invention is: a complex shape multi-material forming method based on magnetorheological core and microwave, comprising the following steps:

[0019] Step (1): inserting the first magnetorheological core into the mold cavity of the mold core in a non-magnetic softened state, and connecting the magnetorheological fluid delivery component to the first magnetorheological core;

[0020] Step (2): the delivery pump pours the magnetorheological fluid into the first magnetorheological core through the magnetorheological fluid delivery pipe, the magnetic field transmitter emits a magnetic field, and the magnetic field receiver receives the magnetic field, so that the magnetorheological fluid in the first magnetorheological core solidifies;

[0021] Step (3): the material of the first layer of the multi-material structure is fed into the core cavity through the feed port, a first microwave generator generates a first microwave, and the first microwave is fed into the cavity through a first waveguide; a second microwave generator generates a second microwave, and the second microwave is fed into the cavity through a second waveguide, and the first microwave and the second microwave sinter the material of the first layer of the multi-material structure;

[0022] Step (4): stopping the magnetic field transmitter from emitting the magnetic field and simultaneously stopping the magnetic field receiver from receiving the magnetic field, so that the magnetorheological fluid in the first magnetorheological core becomes soft, using a delivery pump to extract the magnetorheological fluid from the first magnetorheological core, and then taking the first magnetorheological core out of the mold cavity through the feed port;

[0023] Step (5): inserting the second magnetorheological core into the mold cavity of the mold core in a non-magnetic softened state, and connecting the magnetorheological fluid delivery assembly to the second magnetorheological core;

[0024] Step (6): the delivery pump injects the magnetorheological fluid into the second magnetorheological core through the magnetorheological fluid delivery pipe; the magnetic field transmitter emits a magnetic field, and the magnetic field receiver receives the magnetic field, so that the magnetorheological fluid in the second magnetorheological core solidifies;

[0025] Step (7): the material of the second layer of the multi-material structure enters the cavity through the feed port, the first microwave generator generates a first microwave, and uses the first waveguide to send the first microwave into the cavity; the second microwave generator generates a second microwave, and uses the second waveguide to send the second microwave into the cavity, and the first microwave and the second microwave sinter the material of the second layer of the multi-material structure;

[0026] Step (8): stopping the magnetic field transmitter from emitting the magnetic field and simultaneously stopping the magnetic field receiver from receiving the magnetic field, so that the magnetorheological fluid in the second magnetorheological core becomes soft, using a delivery pump to extract the magnetorheological fluid from the second magnetorheological core, and then taking the second magnetorheological core out of the mold cavity through the feed port;

[0027] Step (9): Repeat this process to form other layers of the multi-material structure, thereby obtaining a multi-material structure with a variety of different inner cavity structure combinations.

[0028] Compared with the existing technology, the present invention has the following effects: the present invention is reasonably designed, and by using magnetorheological material as the core, a variety of materials with different inner cavity shapes can be prepared and interlaced; at the same time, by using microwave heating technology, the material can be heated quickly and evenly, which is conducive to the combination of multiple materials; the present invention is suitable for processing multi-material structures in which a variety of complex-shaped materials are interlaced. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 1 is a schematic diagram of the structure of an embodiment of the present invention;

[0030] Figure 2 yes Figure 1 Schematic diagram of the main section;

[0031] Figure 3 Schematic diagram of the multi-layer capsule forming process (outer layer material forming) according to an embodiment of the present invention;

[0032] Figure 4 yes Figure 3 Schematic diagram of the main section;

[0033] Figure 5 Schematic diagram of the multi-layer capsule forming process according to an embodiment of the present invention (second magnetorheological core introduction);

[0034] Figure 6 yes Figure 5 Schematic diagram of the main section;

[0035] Figure 7 Schematic diagram of the multi-layer capsule forming process (forming of the inner layer material) according to an embodiment of the present invention;

[0036] Figure 8 yes Figure 7Schematic diagram of the main section;

[0037] Figure 9 2 is a schematic diagram of the overall structure of a multi-layer capsule according to an embodiment of the present invention;

[0038] Figure 10 yes Figure 9 Schematic diagram of the main section;

[0039] Figure 11 Schematic diagram of the structure of the coating layer in an embodiment of the present invention;

[0040] Figure 12 1 is a schematic diagram of the forming process of the handle of a soft-grip tool in an embodiment of the present invention (first magnetorheological core introduction);

[0041] Figure 13 yes Figure 12 Schematic diagram of the main section;

[0042] Figure 14 1. is a schematic diagram of the shaping process of the handle of a soft grip tool (shaping of the soft rubber outer layer material) in an embodiment of the present invention;

[0043] Figure 15 yes Figure 14 Schematic diagram of the main section;

[0044] Figure 16 1. is a schematic diagram of the forming process of the handle of a soft-grip tool in an embodiment of the present invention (second type of magnetorheological core introduction);

[0045] Figure 17 yes Figure 16 Schematic diagram of the main section;

[0046] Figure 18 1. is a schematic diagram of the handle forming process of a soft grip tool (hard core skeleton forming) in an embodiment of the present invention;

[0047] Figure 19 yes Figure 18 Schematic diagram of the main section;

[0048] Figure 20 This is a schematic diagram of the overall structure of the soft grip tool handle in an embodiment of the present invention;

[0049] Figure 21 2 is a schematic diagram of the hard core skeleton structure of the soft grip tool handle in an embodiment of the present invention;

[0050] Figure 22 Schematic diagram of the soft rubber outer layer structure of the soft grip tool handle in an embodiment of the present invention.

[0051] Figures 1-6: 1-mold core; 2-mold cavity; 3-magnetorheological core; 4-steel mesh plate; 11-upper mold core; 12-lower mold core; 13-feed port; 14-magnetic flux port; 21-first microwave generator; 22-first waveguide; 23-second microwave generator; 24-second waveguide; 31-magnetic field transmitter; 32-magnetic field receiver; 41-first magnetorheological core; 42-magnetorheological fluid delivery pipe; 43-delivery pump; 44-storage tank; 45-second magnetorheological core;

[0052] Figure 7-13 Middle: 46 - first magnetorheological core A; 47 - second magnetorheological core A; 51 - left mold core; 52 - right mold core; 53 - feed port; 54 - magnetic flux port; 61 - material with microwave reflection and magnetic field penetration functions; 71 - first multi-material outer layer; 72 - first multi-material inner layer; 73 - multi-material core; 74 - sealing material; 81 - second multi-material outer layer; 811 - locking protrusion of the second multi-material outer layer; 82 - second multi-material inner layer; 821 - cavity of the second multi-material inner layer; 822 - locking groove of the second multi-material inner layer. DETAILED DESCRIPTION

[0053] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0054] like Figures 1-2 As shown, the present invention is a complex shape multi-material forming device based on magnetorheological core and microwave, which uses the innovative idea of ​​combining microwave heating technology and magnetorheological material core to produce multi-layer nested and staggered multi-material structures, specifically: comprising a core 1 with a cavity 2 inside, a magnetorheological fluid delivery component, a magnetorheological core 3, a magnetic field generating component and a microwave generating component, the top middle position of the core 1 has a feed port 13 connected to the cavity 2, the feed port is to facilitate the entry of materials of each layer of the multi-material structure into the cavity; the magnetorheological core 3 is arranged in the cavity 2 The magnetorheological core can be replaced through the feed port 13, that is, the magnetorheological core can be taken out of the mold cavity or loaded into the mold cavity through the feed port. The magnetorheological fluid delivery assembly is connected to the magnetorheological core 3 and is used to deliver magnetorheological fluid to the inner cavity of the magnetorheological core 3 or to extract magnetorheological fluid from the inner cavity of the magnetorheological core 3. The magnetic field generating assembly is used to apply a magnetic field to the magnetorheological fluid in the inner cavity of the magnetorheological core 3 to solidify the magnetorheological fluid in the inner cavity of the magnetorheological core. The microwave generating assembly is used to sinter and form the material entering the mold cavity through the feed port 13. By using magnetorheological material as a core, a variety of materials with different inner cavity shapes can be prepared and interlaced. At the same time, using microwave heating technology, the materials can be heated quickly and evenly, which is conducive to the combination of multiple materials. The present invention is suitable for processing multi-material structures in which multiple materials with complex shapes are interlaced.

[0055] When the forming device is working, the first magnetorheological core 41 enters the mold cavity 2 through the feed port 13 in a non-magnetic softened state, and then magnetorheological fluid is added and solidified by a magnetic field. The first material enters the mold cavity 2 through the feed port 13 and is solidified under microwave heating. Then the first magnetorheological core 41 softens and exits the mold cavity 2 in a non-magnetic state, and the second magnetorheological core 45 enters the mold cavity 2 through the feed port 13 in a non-magnetic softened state, and then magnetorheological fluid is added and solidified by a magnetic field. The second material enters the mold cavity through the feed port 13 and is solidified under microwave heating; this process is repeated to obtain a multi-material structure with a variety of different inner cavity structure combinations.

[0056] In this embodiment, each layer of the multi-material structure can be made of powder or liquid. When forming different inner cavity structures made of different materials, the magnetorheological core can be replaced as needed, for example, the first magnetorheological core 41 can be replaced with a second magnetorheological core 45, a third magnetorheological core, a fourth magnetorheological core, and so on.

[0057] In this embodiment, the magnetorheological fluid delivery assembly includes a storage tank 44 storing magnetorheological fluid, a delivery pump 43 and a magnetorheological fluid delivery pipe 42, one end of the magnetorheological fluid delivery pipe 42 is connected to the storage tank 44, and the other end passes through the feed port 13 and is connected to the magnetorheological core 3 in the cavity 2; the delivery pump 43 is installed in the magnetorheological fluid delivery pipe 42, and the delivery pump 43 delivers the magnetorheological fluid in the storage tank 44 to the magnetorheological core 3 through the magnetorheological fluid delivery pipe 42, or delivers the magnetorheological fluid in the magnetorheological core 3 to the storage tank 44.

[0058] In this embodiment, a magnetic flux opening 14 is provided at the middle position of the bottom of the mold core 1 , and the magnetic flux opening 14 corresponds to the position of the feed opening 13 , and the magnetic flux opening is not connected to the mold cavity.

[0059] In this embodiment, the magnetic field generating assembly includes a magnetic field transmitter 31 and a magnetic field receiver 32, and the magnetic field transmitter 31 and the magnetic field receiver 32 are distributed on the upper and lower sides of the middle part of the mold core 1. The magnetic field transmitter 31 corresponds to the position of the feed port 13 and emits a magnetic field downward; the magnetic field receiver 32 corresponds to the position of the magnetic flux port 14 and receives the magnetic field emitted by the magnetic field transmitter 31, and uses the magnetic field to solidify the magnetorheological fluid in the magnetorheological core.

[0060] In this embodiment, the microwave generating assembly includes a first microwave generator 21 and a second microwave generator 23. The first microwave generator 21 is located on the left side of the mold core 1, and the microwave output end of the first microwave generator 21 is connected to the middle of the left end of the mold core 1 via a first waveguide 22. The second microwave generator 23 is located on the front side of the mold core 1, and the microwave output end of the second microwave generator 23 is connected to the middle of the front end of the mold core 1 via a second waveguide 24. The first microwave generator generates a first type of microwave and transmits the first type of microwave into the mold cavity via the first waveguide. The second microwave generator generates a second type of microwave and transmits the second type of microwave into the mold cavity via the second waveguide. The first and second microwaves sinter the material entering the mold cavity through the feed port.

[0061] In this embodiment, the mold core is a split splicing structure, which has two forms, one is up and down splicing, and the other is left and right splicing. Specifically:

[0062] When the mold core is spliced ​​up and down: the mold core 1 comprises an upper mold core 11 and a lower mold core 12, which are connected and integrated. The inner cavities of the upper mold core 11 and the lower mold core 12 are spliced ​​in the upward and downward directions to form the mold cavity 2. In this configuration, the feed port 13 is located in the top center of the upper mold core 11, and the magnetic flux port 14 is located in the bottom center of the lower mold core 12. The first waveguide 22 is connected to the left end of the connection between the upper and lower mold cores, and the second waveguide 24 is connected to the front end of the connection between the upper and lower mold cores.

[0063] When the mold core is spliced ​​left and right: the mold core 1 comprises a left mold core 51 and a right mold core 52, joined together on the left and right sides. The inner cavities of the left mold core 51 and the right mold core 52 are spliced ​​together along the left and right sides to form the mold cavity 2. In this configuration, the feed port 13 is located in the top center of the connection between the left and right mold cores, and the magnetic flux port 14 is located in the bottom center of the connection between the left and right mold cores. The first waveguide 22 is connected to the middle of the left end of the left mold core 51, and the second waveguide 24 is connected to the middle of the front end of the connection between the left and right mold cores.

[0064] In this embodiment, the mold core 1 (including the upper mold core 11, the lower mold core 12, the left mold core 51, and the right mold core 52) is made of a microwave-transparent material that does not absorb or convert microwaves. Furthermore, the exterior of the mold core 1 is uniformly wrapped or coated with a cladding layer. This cladding layer is uniformly wrapped or coated onto the exterior of the mold core. The cladding layer is made of a material 61 that reflects microwaves and transmits magnetic fields, such as a mesh-like flexible fabric woven from a conductive material such as carbon fiber or metal wire. The mesh diameter of the cladding layer is 1 to 2 mm.

[0065] In this embodiment, the cladding layer is provided with a clearance hole at the magnetic flux opening 14, and a steel mesh plate 4 is provided in the magnetic flux opening, that is, the core in the magnetic flux opening 14 area is not wrapped or coated with a material having microwave reflection and magnetic field penetration functions, but is embedded with a steel plate with a distributed mesh diameter of 3 to 4 mm, a total diameter of 30 mm, and a thickness of 1 mm.

[0066] In this embodiment, a complex-shaped multi-material forming method based on a magnetorheological core and microwaves includes the following steps:

[0067] Step (1): inserting the first magnetorheological core 41 into the cavity 2 of the mold core 1 in a non-magnetic softened state, and connecting the magnetorheological fluid delivery assembly to the first magnetorheological core 41;

[0068] Step (2): The delivery pump 43 pours the magnetorheological fluid in the storage tank 44 into the first magnetorheological core 41 through the magnetorheological fluid delivery pipe 42, the magnetic field transmitter 31 transmits the magnetic field, and the magnetic field receiver 32 receives the magnetic field, so that the magnetorheological fluid in the first magnetorheological core 41 solidifies;

[0069] Step (3): The material of the first layer of the multi-material structure is fed into the core cavity 2 through the feed port 13, the first microwave generator 21 generates a first microwave, and the first microwave is fed into the cavity 2 through the first waveguide 22; the second microwave generator 23 generates a second microwave, and the second microwave is fed into the cavity 2 through the second waveguide 24, and the first microwave and the second microwave sinter the material of the first layer of the multi-material structure;

[0070] Step (4): Stop the magnetic field transmitter 31 from emitting the magnetic field, and simultaneously stop the magnetic field receiver 32 from receiving the magnetic field, so that the magnetorheological fluid in the first magnetorheological core 41 becomes soft, and use the delivery pump 43 to pump the magnetorheological fluid from the first magnetorheological core 41 into the storage tank, and then take the first magnetorheological core 41 out of the mold cavity through the feed port;

[0071] Step (5): inserting the second magnetorheological core 45 into the cavity 2 of the mold core 1 in a non-magnetic softened state, and connecting the magnetorheological fluid delivery assembly to the second magnetorheological core 45;

[0072] Step (6): the delivery pump 43 pours the magnetorheological fluid in the storage tank into the second magnetorheological core 45 through the magnetorheological fluid delivery pipe 42; the magnetic field transmitter 31 transmits the magnetic field, and the magnetic field receiver 32 receives the magnetic field, so that the magnetorheological fluid in the second magnetorheological core 45 solidifies;

[0073] Step (7): The material of the second layer of the multi-material structure enters the cavity through the feed port 13, the first microwave generator 21 generates a first microwave, and uses the first waveguide 22 to send the first microwave into the cavity 2; the second microwave generator 23 generates a second microwave, and uses the second waveguide 24 to send the second microwave into the cavity 2, and the first microwave and the second microwave sinter the material of the second layer of the multi-material structure;

[0074] Step (8): Stop the magnetic field transmitter 31 from emitting the magnetic field, and simultaneously stop the magnetic field receiver 32 from receiving the magnetic field, so that the magnetorheological fluid in the second magnetorheological core 45 becomes soft, and use the delivery pump 43 to pump the magnetorheological fluid from the second magnetorheological core 45 to the storage tank, and then take the second magnetorheological core 45 out of the cavity 2 through the feed port;

[0075] Step (9): Repeat this process to form other layers of the multi-material structure. Each formed layer corresponds to a magnetorheological core, thereby obtaining a multi-material structure with a variety of different inner cavity structure combinations.

[0076] In this embodiment, magnetorheological material is a smart material whose viscosity or yield strength can change rapidly and reversibly under an external magnetic field. Taking advantage of this property, magnetorheological material is a dynamic reconfigurable core that can be injected and removed through small holes and can be "cured on demand, softened on demand", and can be reusable, providing a new solution for the forming of complex cavities and the sequential construction of multi-layer materials. Microwave heating, as a volumetric heating method, has the advantages of being fast, selective, highly efficient and energy-saving. Its application in multi-material forming can achieve rapid, uniform or selective heating curing / sintering of specific materials or areas, which is particularly beneficial for processing materials with different thermophysical properties, promoting good interface bonding between heterogeneous materials, and may shorten the overall manufacturing cycle.

[0077] Combining magnetorheological core technology with microwave curing overcomes the bottlenecks of traditional processes in manufacturing complex internal cavity structures and multi-layered, nested, multi-material components, opening up a significant new path for the manufacture of high-performance, highly integrated, and complex multi-material components. The device and method proposed in this invention are based on this innovative concept and aim to provide an efficient and flexible technical solution capable of manufacturing unprecedented complex multi-material structures.

[0078] Specific implementation process 1

[0079] Taking a multi-layer capsule with a multi-material structure as an example, it has a two-layer structure (outer layer and inner layer) with a core drug inside. When the mold core is spliced ​​in the upper and lower parts, combined with the attached Figure 1-11 , the forming method comprises the following steps:

[0080] Step (1): If Figure 1 As shown, the first magnetorheological core 41 in the shape of an ellipsoid is installed in the interior of the upper mold core 11 and the lower mold core 12 (i.e., in the mold cavity 2 of the mold core) in a non-magnetic softened state. The storage tank 44 stores magnetorheological fluid. The storage tank 44, the delivery pump 43, the magnetorheological fluid delivery pipe 42, and the first magnetorheological core 41 are connected;

[0081] Step (2): If Figure 3 As shown, the delivery pump 43 pours the magnetorheological fluid in the storage tank 44 into the first magnetorheological core 41 through the magnetorheological fluid delivery pipe 42, the magnetic field transmitter 31 emits a magnetic field, and the magnetic field receiver 32 receives the magnetic field, so that the magnetorheological fluid in the ellipsoidal first magnetorheological core 41 solidifies;

[0082] Step (3): the first multi-material outer layer 71 acrylic resin powder with a small amount of carbon black is introduced into the core cavity 2 through the feed port 13, the first microwave generator 21 generates a first microwave of 2.45 GHz, and the first microwave is sent into the cavity 2 through the first waveguide 22; the second microwave generator 23 generates a second microwave of 2.45 GHz, and the second microwave is sent into the cavity 2 through the second waveguide 24, and the first multi-material outer layer acrylic resin powder with a small amount of carbon black is sintered and formed by the first microwave and the second microwave;

[0083] Step (4): If Figure 5 As shown, the magnetic field transmitter 31 stops emitting the magnetic field, and the magnetic field receiver 32 stops receiving the magnetic field, so that the magnetorheological fluid in the ellipsoidal first magnetorheological core 41 becomes soft, and the magnetorheological fluid is pumped out of the first magnetorheological core 41 into the storage tank by the delivery pump 43, and then the ellipsoidal first magnetorheological core 41 is taken out of the mold cavity through the feed port 13;

[0084] Step (5): replacing the first magnetorheological core 41 with the reduced ellipsoidal second magnetorheological core 45, loading the second magnetorheological core 45 with the reduced ellipsoidal shape into the cavity 2 of the mold core 1 in a non-magnetic softened state, and connecting the magnetorheological fluid delivery assembly to the second magnetorheological core 45 with the reduced ellipsoidal shape;

[0085] Step (6): If Figure 7 As shown, the delivery pump 43 pours the magnetorheological fluid in the storage tank into the second magnetorheological core 45 in the reduced ellipsoidal shape through the magnetorheological fluid delivery pipe 42; the magnetic field transmitter 31 transmits the magnetic field, and the magnetic field receiver 32 receives the magnetic field, so that the magnetorheological fluid in the second magnetorheological core 45 in the reduced ellipsoidal shape solidifies;

[0086] Step (7): The liquid of the first multi-material inner layer 72 polyethylene glycol enters the cavity through the feed port 13, the first microwave generator 21 generates a first microwave of 2.45 GHz, and uses the first waveguide 22 to send the first microwave into the cavity; the second microwave generator 23 generates a second microwave of 2.45 GHz, and uses the second waveguide 24 to send the second microwave into the cavity, and the first multi-material inner layer 72 polyethylene glycol is sintered and formed by the first microwave and the second microwave;

[0087] Step (8): Stop the magnetic field transmitter 31 from emitting the magnetic field, and simultaneously stop the magnetic field receiver 32 from receiving the magnetic field, so that the magnetorheological fluid in the second magnetorheological core 45 becomes soft, and use the delivery pump 43 to extract the magnetorheological fluid from the second magnetorheological core 45 in the reduced ellipsoidal shape to the storage tank 44, and then take the second magnetorheological core 45 in the reduced ellipsoidal shape out of the mold cavity 2 through the feed port 13;

[0088] Step (9): If Figure 9-10 As shown, the multi-material core drug 73 is injected into the cavity in the middle of the multi-material inner layer polyethylene glycol 72, and then the gap is sealed with a sealing material acrylic resin 74, thus forming a complete multi-material structure.

[0089] The multi-material, multi-layer capsule in this embodiment has an outer layer of enteric-coated material that prevents the core drug from being decomposed in gastric fluid, and its ellipsoidal shape makes it easier to swallow. The inner layer of polyethylene glycol is a sustained-release material that can regulate the time of drug release. In this embodiment, the enteric dissolution time can be controlled by controlling the inner cavity size of the outer layer of acrylic resin with a small amount of carbon black, thereby controlling the thickness of the outer layer. The drug content can also be controlled by adjusting the size of the cavity in the middle of the inner layer. By controlling the shape of the magnetorheological variable core, multi-layer capsules of different shapes and capacities can be designed.

[0090] In this embodiment, the melting point of the inner layer polyethylene glycol is about 60° C., and the melting point of the outer layer acrylic resin is about 100° C. to 200° C., so the solidification of the inner layer will not cause the outer layer to melt, soften, deform or degrade.

[0091] Specific implementation process 2

[0092] Take the multi-material structure of the soft grip tool handle as an example. It has a two-layer structure (outer layer and inner layer). When the mold core is spliced ​​in the left and right forms, combined with the attached Figure 11-22 , the forming method comprises the following steps:

[0093] Step (1): If Figure 11As shown, the first magnetorheological core A46 in the shape of an ellipsoid is installed in the interior of the left mold core 51 and the right mold core 52 (i.e., in the mold cavity 2 of the mold core 1) in a non-magnetic softened state, and the storage tank 44, the delivery pump 43, the magnetorheological fluid delivery pipe 42, and the first magnetorheological core A46 in the shape of an ellipsoid are connected;

[0094] Step (2): If Figure 13 As shown, the delivery pump 43 pours the magnetorheological fluid in the storage tank 44 into the ellipsoidal first magnetorheological core A46 through the magnetorheological fluid delivery pipe 42. The magnetic field transmitter 31 transmits the magnetic field, and the magnetic field receiver 32 receives the magnetic field, so that the magnetorheological fluid in the ellipsoidal first magnetorheological core A46 solidifies.

[0095] Step (3): The second multi-material outer layer 81 of thermoplastic vulcanized rubber (TPV) with a small amount of carbon black powder is fed into the mold cavity 2 of the mold core through the feed port 13, the first microwave generator 21 generates a first microwave of 2.45 GHz, and feeds the first microwave into the mold cavity 2 through the first waveguide 22; the second microwave generator 23 generates a second microwave of 2.45 GHz, and feeds the second microwave into the mold cavity 2 through the second waveguide 24, and the second multi-material outer layer 81 of thermoplastic vulcanized rubber (TPV) with a small amount of carbon black powder is sintered and formed by the first microwave and the second microwave;

[0096] Step (4): If Figure 15 As shown, the magnetic field transmitter 31 stops emitting the magnetic field, and the magnetic field receiver 32 stops receiving the magnetic field, so that the magnetorheological fluid in the ellipsoidal first magnetorheological core A46 becomes soft, and the magnetorheological fluid is pumped out of the ellipsoidal first magnetorheological core A46 into the storage tank 44 by the delivery pump 43, and then the ellipsoidal first magnetorheological core A46 is taken out of the mold cavity through the feed port;

[0097] Step (5): Replace the ellipsoidal first magnetorheological core A46 with the rhombus-shaped second magnetorheological core A47, install the rhombus-shaped second magnetorheological core A47 into the mold cavity 2 of the mold core 1 in a non-magnetic softened state, and connect the magnetorheological fluid delivery component to the rhombus-shaped second magnetorheological core A47, as shown in FIG. Figure 10 As shown;

[0098] Step (6): If Figure 17 As shown, the delivery pump 43 pours the magnetorheological fluid in the storage tank into the diamond-shaped second magnetorheological core A47 through the magnetorheological fluid delivery pipe 42; the magnetic field transmitter 31 transmits the magnetic field, and the magnetic field receiver 32 receives the magnetic field, so that the magnetorheological fluid in the diamond-shaped second magnetorheological core A47 solidifies;

[0099] Step (7): The second multi-material inner layer 82 ABS plastic with a small amount of carbon black powder is fed into the mold cavity through the feed port 13, the first microwave generator 21 generates a first microwave of 2.45 GHz, and the first microwave is fed into the mold cavity by the first waveguide 22; the second microwave generator 23 generates a second microwave of 2.45 GHz, and the second microwave is fed into the mold cavity by the second waveguide 24, and the second multi-material inner layer ABS plastic with a small amount of carbon black powder is sintered and formed by the first microwave and the second microwave;

[0100] Step (8): Stop the magnetic field transmitter 31 from emitting the magnetic field, and simultaneously stop the magnetic field receiver 32 from receiving the magnetic field, so that the magnetorheological fluid in the rhombus-shaped second magnetorheological core A47 becomes soft, and use the delivery pump 43 to extract the magnetorheological fluid from the rhombus-shaped second magnetorheological core A47 to the storage tank 44, and then take the rhombus-shaped second magnetorheological core A47 out of the mold cavity 2 through the feed port 13;

[0101] Step (9): Get the soft grip tool handle.

[0102] The soft-grip tool handle in this embodiment features a thermoplastic vulcanized rubber (TPV) outer layer, providing a comfortable grip, non-slip properties, and shock absorption. Its ellipsoidal shape makes it easier to hold. The inner layer is a high-strength ABS plastic with a small amount of carbon black, providing overall rigidity and structural strength, and providing a foundation for connection to the metal rod.

[0103] In this embodiment, by adjusting the shape of the ellipsoidal first magnetorheological core A46 and the diamond-shaped second magnetorheological core A47, the center of the second multi-material inner layer of ABS plastic with a small amount of carbon black is provided with a diamond-shaped space 821, facilitating connection with the metal rod. A locking groove 822 is provided on the side to mate with the locking protrusion 811 within the second multi-material outer layer of thermoplastic vulcanizate (TPV) with a small amount of carbon black. In this embodiment, by adjusting the inner cavity size of the outer thermoplastic vulcanizate (TPV) layer, the thickness of the outer layer can be controlled, thereby adjusting the overall comfort of the grip. The size of the diamond-shaped space 821 in the center of the inner layer can also be adjusted to adjust the size of the assembly area between the metal rods of different materials.

[0104] Through the complex inner cavity structure brought by the magnetorheological core and rapid microwave sintering, different materials are firmly combined together through hot melting and mechanical locking structure to form a macroscopic whole with obvious functional divisions.

[0105] In this embodiment, the melting point of the inner layer ABS plastic is approximately 100°C to 120°C, and the melting point of the outer layer thermoplastic vulcanizate (TPV) is approximately 160°C to 170°C. Therefore, the curing of the inner layer will not cause the outer layer to melt, soften, deform or degrade.

[0106] The advantages of the present invention are:

[0107] (1) Breaking through the bottleneck of complex inner cavity forming and realizing high-freedom internal structure manufacturing: The present invention uses magnetorheological materials as dynamic reconfigurable cores, which can achieve in-situ solidification and softening under magnetic field control and can be easily injected and removed through small holes. This fundamentally overcomes the limitations of traditional rigid cores and sacrificial cores in shape complexity, removal difficulty, material contamination, and multi-step molding, making it possible to manufacture components with fine recesses, staggered features, multi-layer nesting, and asymmetric complex inner cavity structures, greatly expanding the design freedom of the internal structure of multi-material components;

[0108] (2) Realizing the manufacturing of multi-layer nested multi-material structures: By sequentially introducing magnetorheological cores of different shapes and depositing and solidifying materials layer by layer, the present invention can conveniently construct multi-material structures with multi-layer nested features, which is difficult or even impossible to achieve with traditional injection molding, extrusion and other processes, and provides a new approach for the design and manufacturing of functional gradient materials, controlled release systems, integrated devices, etc.

[0109] (3) Improve forming efficiency and interface bonding quality: Combined with microwave heating technology, powder or liquid materials can be quickly and efficiently heated and solidified or sintered. Compared with traditional heat conduction heating, microwave heating is fast, which helps to shorten the manufacturing cycle; its volume heating characteristics may achieve a more uniform temperature distribution, which is conducive to improving material density and performance; at the same time, rapid heating and in-situ solidification may promote interface diffusion and chemical bonding between different material layers, thereby obtaining stronger interface bonding strength;

[0110] (4) Enhanced manufacturing flexibility and reduced mold costs: When using the same set of external molds, multi-material components with different internal structures can be manufactured by simply replacing or adjusting the shape of the internal magnetorheological core. This greatly reduces the cost and time required to develop and manufacture complex molds for different internal structure designs, and improves the flexibility of the manufacturing system and its adaptability to small-batch and customized production.

[0111] (5) Potential diversity of material selection and selective heating possibilities: The present invention is theoretically applicable to a variety of powder or liquid materials that can be cured / sintered by microwave heating (such as polymers, ceramics, composite materials, etc.); in addition, by utilizing dual microwave sources (which may achieve different frequency or mode control) and the differences in microwave absorption characteristics of different materials, there is the potential to achieve selective heating of specific material layers, thereby more accurately controlling the forming process and final performance of complex multi-material structures.

[0112] The above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit the same. Although the present invention has been described in detail with reference to preferred embodiments, persons skilled in the art should understand that the specific implementation methods of the present invention may still be modified or some technical features may be replaced by equivalents without departing from the spirit of the technical solutions of the present invention, and all of these should fall within the scope of the technical solutions claimed for protection by the present invention.

Claims

1. A complex-shaped multi-material forming device based on a magnetorheological core and microwaves, characterized by: The invention comprises a mold core (1) having a mold cavity (2) therein, a magnetorheological fluid delivery component, a magnetorheological core (3), a magnetic field generating component and a microwave generating component, wherein the top of the mold core (1) is provided with a feed port (13) connected to the mold cavity (2); the magnetorheological core (3) is arranged in the mold cavity (2) and can be replaced through the feed port (13); the magnetorheological fluid delivery component is connected to the magnetorheological core (3) and is used to deliver magnetorheological fluid to the inner cavity of the magnetorheological core (3) or to extract magnetorheological fluid from the inner cavity of the magnetorheological core (3); the magnetic field generating component is used to apply a magnetic field to the magnetorheological fluid in the inner cavity of the magnetorheological core (3) to solidify the magnetorheological fluid; and the microwave generating component is used to sinter and form the material entering the mold cavity (2) through the feed port (13).

2. The complex shape multi-material forming device based on magnetorheological core and microwave according to claim 1 is characterized in that: The magnetorheological fluid delivery assembly includes a storage tank (44) storing magnetorheological fluid, a delivery pump (43) and a magnetorheological fluid delivery pipe (42), one end of the magnetorheological fluid delivery pipe (42) is connected to the storage tank (44), and the other end passes through the feed port (13) and is connected to the magnetorheological core (3) in the cavity (2); the delivery pump (43) is installed on the magnetorheological fluid delivery pipe (42), and the delivery pump (43) delivers the magnetorheological fluid in the storage tank (44) to the magnetorheological core (3) through the magnetorheological fluid delivery pipe (42), or delivers the magnetorheological fluid in the magnetorheological core (3) to the storage tank (44).

3. The complex shape multi-material forming device based on magnetorheological core and microwave according to claim 1 is characterized in that: The bottom of the mold core (1) is provided with a magnetic flux port (14), and the position of the magnetic flux port (14) corresponds to the position of the feed port (13); the magnetic field generating component includes a magnetic field transmitter (31) and a magnetic field receiver (32), and the magnetic field transmitter (31) and the magnetic field receiver (32) are distributed on the upper and lower sides of the mold core (1), the magnetic field transmitter (31) corresponds to the position of the feed port (13) and emits a magnetic field downward; the magnetic field receiver (32) corresponds to the position of the magnetic flux port (14) and receives the magnetic field.

4. The complex shape multi-material forming device based on magnetorheological core and microwave according to claim 1 is characterized in that: The microwave generating assembly comprises a first microwave generator (21) and a second microwave generator (23), wherein the first microwave generator (21) is located on the left side of the mold core (1), and the microwave output end of the first microwave generator (21) is connected to the left end of the mold core (1) through a first waveguide (22); and the second microwave generator (23) is located on the front side of the mold core (1), and the microwave output end of the second microwave generator (23) is connected to the front end of the mold core (1) through a second waveguide (24).

5. The complex shape multi-material forming device based on magnetorheological core and microwave according to claim 1 is characterized in that: The mold core (1) comprises an upper mold core (11) and a lower mold core (12) which are connected to form an integral body. The inner cavity of the upper mold core (11) and the inner cavity of the lower mold core (12) are spliced ​​in the upper and lower directions to form a mold cavity (2).

6. The complex shape multi-material forming device based on magnetorheological core and microwave according to claim 1 is characterized in that: The mold core (1) comprises a left mold core (51) and a right mold core (52) which are connected to each other on the left and right sides and integrated into one body. The inner cavity of the left mold core (51) and the inner cavity of the right mold core (52) are spliced ​​along the left and right directions to form a mold cavity (2).

7. The complex shape multi-material forming device based on magnetorheological core and microwave according to claim 3, characterized in that: The mold core (1) is made of microwave transparent material. A cladding layer is provided on the outside of the mold core (1). The cladding layer is made of a material (61) having microwave reflection and magnetic field penetration functions. A clearance hole is provided at the magnetic flux opening (14) of the cladding layer. A steel mesh plate (4) is provided in the magnetic flux opening.

8. The complex shape multi-material forming device based on magnetorheological core and microwave according to claim 7, characterized in that: The covering layer is a mesh-shaped flexible fabric woven from a conductive material, and the mesh diameter of the covering layer is 1 to 2 mm.

9. The complex shape multi-material forming device based on magnetorheological core and microwave according to claim 7, characterized in that: The mesh diameter of the steel mesh plate (4) is 3 to 4 mm.

10. A complex shape multi-material forming method based on magnetorheological core and microwave, characterized by: The method comprises adopting a complex shape multi-material forming device based on a magnetorheological core and microwaves as claimed in any one of claims 1 to 9, comprising the following steps: Step (1): inserting the first magnetorheological core (41) into the cavity (2) of the mold core (1) in a non-magnetic softened state, and connecting the magnetorheological fluid delivery component to the first magnetorheological core (41); Step (2): the delivery pump (43) injects the magnetorheological fluid into the first magnetorheological core (41) through the magnetorheological fluid delivery pipe (42), the magnetic field transmitter (31) emits a magnetic field, and the magnetic field receiver (32) receives the magnetic field, so that the magnetorheological fluid in the first magnetorheological core (41) solidifies; Step (3): the material of the first layer of the multi-material structure is fed into the cavity (2) of the mold core (1) through the feed port (13); the first microwave generator (21) generates a first type of microwave, and the first type of microwave is sent into the cavity (2) through the first waveguide (22); the second microwave generator (23) generates a second type of microwave, and the second type of microwave is sent into the cavity (2) through the second waveguide (24); the first microwave and the second microwave sinter the material of the first layer of the multi-material structure; Step (4): stopping the magnetic field transmitter (31) from emitting the magnetic field and simultaneously stopping the magnetic field receiver (32) from receiving the magnetic field, so that the magnetorheological fluid in the first magnetorheological core (41) becomes soft, using the delivery pump (43) to extract the magnetorheological fluid from the first magnetorheological core (41), and then taking the first magnetorheological core (41) out of the mold cavity through the feed port (13); Step (5): inserting the second magnetorheological core (45) into the mold cavity (2) of the mold core (1) in a non-magnetic softened state, and connecting the magnetorheological fluid delivery assembly to the second magnetorheological core (45); Step (6): the delivery pump (43) injects the magnetorheological fluid into the second magnetorheological core (45) through the magnetorheological fluid delivery pipe (42); The magnetic field transmitter (31) transmits a magnetic field, and the magnetic field receiver (32) receives the magnetic field, so that the magnetorheological fluid in the second magnetorheological core (45) solidifies; Step (7): the material of the second layer of the multi-material structure enters the cavity through the feed port (13), the first microwave generator (21) generates a first type of microwave, and uses the first waveguide (22) to send the first type of microwave into the cavity (2); the second microwave generator (23) generates a second type of microwave, and uses the second waveguide (24) to send the second type of microwave into the cavity (2), and the first microwave and the second microwave sinter the material of the second layer of the multi-material structure into shape; Step (8): stopping the magnetic field transmitter (31) from emitting the magnetic field and simultaneously stopping the magnetic field receiver (32) from receiving the magnetic field, so that the magnetorheological fluid in the second magnetorheological core (45) becomes soft, using the delivery pump (43) to extract the magnetorheological fluid from the second magnetorheological core (45), and then taking the second magnetorheological core (45) out of the mold cavity through the feed port; Step (9): Repeat this process to form other layers of the multi-material structure, thereby obtaining a multi-material structure with a variety of different inner cavity structure combinations.

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