Multi-material bubble structure lightweight preparation method and application based on vacuum / hydrogen filling, helium environment 3D printing

Abstract

The application discloses a kind of multi-material bubble structure light weight preparation method and application based on vacuum / hydrogen, helium environment 3D printing, it is related to additive manufacturing and material light weight technical field.The application is by building airtight 3D printing cavity, creates high vacuum or normal pressure high-purity hydrogen, helium gas environment, makes a plurality of 3D printing materials into honeycomb or airtight bubble structure, makes the vacuum cavity or hydrogen, helium gas cavity in structure inside, realizes 60%-95% light weight rate under the premise of guaranteeing material mechanics performance.The application is widely applicable to materials, and has heat insulation, heat preservation and buffering characteristics, can effectively replace down, can greatly save fuel and reduce carbon emissions when applied in civil aviation field, and the process controllability is strong, has very high market application and environmental protection value.

Description

Technical Field

[0001] This invention relates to the fields of additive manufacturing and lightweight materials technology, and more specifically to a method and application for lightweight preparation of multi-material bubble structures based on vacuum / hydrogen-filled, helium-enriched 3D printing. Background Technology

[0002] Traditional down feathers have drawbacks such as being prone to clumping, difficult to clean, susceptible to moisture, poor hygiene, and short lifespan, making new lightweight alternative materials urgently needed. In the civil aviation sector, every 1kg reduction in aircraft weight can save approximately 3.6 tons of fuel and reduce carbon emissions by approximately 11 tons annually. Lightweighting is the core path for energy conservation and emission reduction in the aviation industry, and the industry's demand is extremely urgent.

[0003] Traditional lightweighting technologies have a limited range of applicable materials, only suitable for some polymer materials, and the lightweighting effect is limited. Existing 3D printing is carried out in an atmospheric pressure air environment, and the porous structure formed is filled with air, which cannot achieve extreme weight reduction. At the same time, it is difficult to achieve both high strength and ultra-lightweight, and cannot meet the lightweighting requirements of multiple scenarios. Summary of the Invention

[0004] In view of this, and addressing the shortcomings of existing lightweight technologies such as poor material compatibility, insufficient weight reduction, and difficulty in balancing strength and weight, this invention provides a lightweight fabrication method and application for multi-material bubble structures based on 3D printing in vacuum / hydrogen-filled and helium environments. By combining vacuum / hydrogen and helium environments with 3D printing of bubble structures, down feather replacement and significant weight reduction and energy saving in aerospace equipment can be achieved, solving the pain points of traditional technologies.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A lightweight fabrication method for multi-material bubble structures based on vacuum / hydrogen-filled, helium-enriched environment 3D printing includes the following steps: (1) Construct a closed 3D printing working chamber, configure a vacuum extraction system and a hydrogen and helium filling system, and regulate the environment inside the chamber to a high vacuum state or fill it with high-purity hydrogen and helium with a purity of ≥99.999% to form a normal pressure pure hydrogen and helium environment. (2) Based on the target application scenario and material properties, select the corresponding 3D printing material and design the honeycomb / closed bubble structure parameters as follows: cell diameter 0.5mm~20mm, cell wall thickness 0.1mm~2mm, and structure filling rate 5%~30%; (3) In a set vacuum or hydrogen / helium environment, the material is printed layer by layer using an appropriate 3D printing process to obtain a bubble-like composite lightweight material with an internally encapsulated stable vacuum cavity or hydrogen / helium cavity. (4) Perform sealing tests, mechanical property tests and post-treatment on the molding material to ensure long-term stability of the internal vacuum / hydrogen and helium state and prevent leakage.

[0007] The material obtained by this invention has a vacuum structure equivalent density of 0.05~0.5 g / cm³. 3 The equivalent density of hydrogen-filled and helium-filled structures is 0.08~0.6 g / cm³. 3 The weight reduction rate is 60%~95%, and the mechanical strength retention rate is ≥85% compared with solid materials of the same volume.

[0008] Preferably, the high vacuum pressure in step (1) is 101 Pa to 103 Pa.

[0009] Preferably, the 3D printing material in step (2) includes one or more of the following: PLA, ABS, PETG, nylon, TPU / TPE, PC, PEEK, aluminum alloy, titanium alloy, stainless steel, carbon fiber / glass fiber composite material, ceramic, and adhesive jetting material.

[0010] Preferably, the 3D printing process in step (3) includes any one of FDM fused deposition modeling, SLA photopolymerization, SLM selective laser melting, DMLS direct metal laser sintering, and binder jetting.

[0011] Another objective of this invention is to provide the application of the above-mentioned method for preparing lightweight multi-material bubble structures based on vacuum / hydrogen-filled, helium-environment 3D printing in the preparation of down substitutes, civil aviation cabin supplies, and lightweight aerospace structural components.

[0012] As can be seen from the above technical solution, compared with the prior art, the present invention has the following technical effects: 1. Versatile for multiple materials: Covers all categories of 3D printing substrates including plastics, resins, metals, ceramics, and composite materials; 2. Significantly lightweight: 60%~95% weight reduction, can directly replace down, meeting the extreme weight reduction requirements of aviation; 3. Excellent mechanical properties: The bubble-like closed structure ensures that the compressive strength, impact resistance, and toughness meet the standards; 4. Outstanding additional functions: It combines heat insulation, thermal insulation, cushioning, and sound insulation properties; 5. Environmentally friendly, energy-saving, and highly efficient: It replaces down feathers, reducing pollution from animal husbandry, and significantly saves fuel and reduces carbon emissions in aviation applications; 6. High process controllability: 3D printing allows for precise control of structural parameters, eliminates the need for mold making, and enables customization and mass production. Attached Figure Description

[0013] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0014] Figure 1 This is a schematic diagram of the overall honeycomb structure of the lightweight material obtained by the present invention. Figure 2 Schematic diagram of a single-cell structure and bubble cross-section; Figure 3 This is a schematic diagram of a bubble-like (air bubble type) lightweight structure; Figure 4 A schematic diagram of a 3D-printed sealed working chamber structure; Figure 5 Schematic diagram of lightweight components used in aviation interiors; Figure 6 A schematic diagram of the structure of a down substitute filling material. Detailed Implementation

[0015] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0016] Example 1: Hydrogen-filled Nylon and Helium Bubble Structure Down Substitute Material (1) Construct a closed 3D printing working chamber, configure a hydrogen and helium filling system, inject 99.999% high-purity hydrogen and helium, and maintain the chamber pressure at 0.1MPa; (2) Select Nylon 6 (density 1.15 g / cm³) 3 The material used for 3D printing is a closed-cell bubble structure with the following parameters: cell diameter 2mm, cell wall thickness 0.2mm, and infill rate 10%. (3) In the set vacuum environment, FDM fused deposition modeling process is used, with a printing temperature of 230℃ and a printing speed of 50mm / s; (4) Perform sealing tests, mechanical property tests and post-treatment on the molding material to ensure long-term stability of the internal vacuum / hydrogen and helium state and prevent leakage.

[0017] Performance testing: The equivalent density of the prepared material is 0.12 g / cm³. 3It has a weight reduction rate of 90%, a compressive strength of 12MPa, an elongation at break of 220%, a thermal insulation coefficient of 0.03W / (m·K), a soft and washable texture, and can directly replace down for use as filling in clothing and home textiles.

[0018] Example 2: Aluminum Alloy Vacuum Honeycomb Structure Aircraft Cabin Supplies The preparation method is the same as in Example 1, and the parameters are set as follows: 1. Material selection: Aluminum alloy AlSi10Mg powder, density 2.7 g / cm³ 3 ; 2. Environmental Control: Activate the vacuum system and evacuate the chamber to 10°C. 2 Pa high vacuum; 3. Structural parameters: cell diameter 10mm, cell wall thickness 1mm, fill rate 15%; 4. Printing process: SLM selective laser melting printing, laser power 200W, scanning speed 1000mm / s; 5. Performance testing: The equivalent density of the prepared material is 0.25 g / cm³. 3 With a weight reduction rate of 91% and a compressive strength of 280MPa, it meets the mechanical standards for aircraft cabin seats and interiors. A single aircraft application can reduce weight by 80kg, saving 288 tons of fuel and reducing carbon emissions by 880 tons per year.

[0019] Example 3: Resin Vacuum Bubble Aerospace Thermal Insulation Component The preparation method is the same as in Example 1, and the parameters are set as follows: 1. Material selection: Photosensitive resin, density 1.2 g / cm³ 3 ; 2. Environmental control: Pump the cavity to 10°C. 3 Pa high vacuum; 3. Structural parameters: bubble diameter 5mm, bubble wall thickness 0.3mm, filling rate 12%; 4. Printing process: SLA photopolymerization printing, UV light power 150mW, curing speed 80mm / s; 5. Performance testing: The equivalent density of the prepared material is 0.15 g / cm³. 3 With a weight reduction of 87.5% and excellent thermal insulation performance, it is suitable for components such as aircraft cabin heat insulation panels and storage boxes.

[0020] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to the method section.

[0021] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for lightweight fabrication of multi-material bubble structures based on 3D printing in a vacuum / hydrogen-filled, helium environment, characterized in that, Includes the following steps: (1) Construct a closed 3D printing working chamber, configure a vacuum extraction system and a hydrogen and helium filling system, and regulate the environment inside the chamber to a high vacuum state or fill it with high-purity hydrogen and helium with a purity of ≥99.999% to form a normal pressure pure hydrogen and helium environment. (2) Based on the target application scenario and material properties, select the corresponding 3D printing material and design the honeycomb / closed bubble structure parameters as follows: cell diameter 0.5mm~20mm, cell wall thickness 0.1mm~2mm, and structure filling rate 5%~30%; (3) In a set vacuum or hydrogen / helium environment, the material is printed layer by layer using an appropriate 3D printing process to obtain a bubble-like composite lightweight material with an internally encapsulated stable vacuum cavity or hydrogen / helium cavity. (4) Perform sealing tests, mechanical property tests and post-treatment on the molding material to ensure long-term stability of the internal vacuum / hydrogen and helium state and prevent leakage.

2. The lightweight fabrication method for multi-material bubble structures based on vacuum / hydrogen and helium-helium environment 3D printing according to claim 1, characterized in that, The high vacuum pressure mentioned in step (1) is 10. 1 Pa~10 3 Pa.

3. The lightweight fabrication method for multi-material bubble structures based on vacuum / hydrogen-filled, helium-enriched 3D printing according to claim 1, characterized in that, The 3D printing materials mentioned in step (2) include one or more of the following: PLA, ABS, PETG, nylon, TPU / TPE, PC, PEEK, aluminum alloy, titanium alloy, stainless steel, carbon fiber / glass fiber composite material, ceramic, and adhesive jetting material.

4. The lightweight fabrication method for multi-material bubble structures based on vacuum / hydrogen-filled, helium-enriched environment 3D printing according to claim 3, characterized in that, The 3D printing process mentioned in step (3) includes any one of FDM fused deposition modeling, SLA photopolymerization, SLM selective laser melting, DMLS direct metal laser sintering, and binder jetting.

5. The application of the lightweight preparation method for multi-material bubble structures based on vacuum / hydrogen-filled, helium environment 3D printing as described in any one of claims 1-4 in the preparation of down substitute filling materials, civil aviation cabin supplies, and lightweight aviation structural components.

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