Manufacturing method for lightweight parts combining porous metal substrate and functional resin

Abstract

A method for manufacturing a lightweight part combined with a porous metal base material and a functional resin is disclosed. The method for manufacturing a lightweight part combined with a porous metal base material and a functional resin comprises: a base material preparation step of preparing a porous metal base material; a base layer stacking step of forming a flat base layer covering the surface of the base material by heating and extruding a resin filament onto the surface of the base material while moving the nozzle of an FDM 3D printer along a predetermined first set movement coordinate; and a build layer stacking step of stacking one or more flat or curved build layers on the base layer while moving the nozzle along the first set movement coordinate or a second set movement coordinate different from the first set movement coordinate, wherein the resin filament is a functional resin material.

Description

Technology Field

[0001] The present invention relates to a method for manufacturing a lightweight part bonded to a porous metal base material and a functional resin, and more specifically, to a method for manufacturing a lightweight part in which a functional resin is bonded to a base material having pores. Background Technology

[0002] Generally, porous metal refers to a metal material having numerous pores inside.

[0003] It refers to porous materials. These porous metals are representative lightweight materials that possess excellent sound insulation / absorption, shock absorption, compressibility, electromagnetic shielding, machinability, and thermal conductivity, and have the characteristic of being able to have a wide range of strengths by changing their density.

[0004] Furthermore, porous metals are widely used in various industrial environments, particularly as structural materials, sound insulation materials, vibration damping materials, heat exchangers, shock absorbers and buffering materials, thermal insulation materials, filter materials, sound-absorbing materials, biomaterials, and vibration-absorbing materials.

[0005] These porous metals are used particularly for lightweighting parts. However, it is difficult to satisfy both lightness and strength requirements with porous materials alone. Therefore, lightweight parts are being manufactured by combining porous materials with non-porous (solid) materials.

[0006] Conventional methods for combining porous and non-porous materials involve fabricating porous and non-porous metal materials through welding; however, when joining porous and non-porous metal materials, pores occur and problems such as the Heat Affected Zone (HAZ) and thermal deformation arise, degrading product quality. Furthermore, the need to undergo multiple processes leads to increased manufacturing costs.

[0007] Meanwhile, welding or joining porous metal materials and non-porous functional resins together is impossible due to the difference in properties between the two materials.

[0008] Accordingly, the inventors have come to invent a method for manufacturing a lightweight part combined with a porous metal base material and a functional resin, which can achieve part weight reduction by combining a porous metal material and a non-porous functional resin. The problem to be solved

[0009] Therefore, the problem that the present invention aims to solve is to provide a porous metal base material and a method for manufacturing a lightweight part bonded with a functional resin, which enables the production of a lightweight part endowed with various properties such as mechanical strength, corrosion resistance, wear resistance, and electrical insulation of the functional resin. means of solving the problem

[0010] A method for manufacturing a lightweight part bonded to a porous metal base material and a functional resin according to one embodiment of the present invention comprises: a base material preparation step of preparing a porous metal base material; a base layer stacking step of forming a base layer bonded to the base material by heating and extruding a resin filament while moving the nozzle of an FDM 3D printer along a predetermined first set movement coordinate, thereby penetrating the molten resin into a pore or depression on the surface of the base material; and a build layer stacking step of stacking one or more flat or curved build layers over the base layer while moving the nozzle along the first set movement coordinate or a second set movement coordinate different from the first set movement coordinate, wherein the resin filament is a functional resin material.

[0011] In one embodiment, the resin filament may be a functional polymer material.

[0012] In one embodiment, the porous metal base material is a porous metal base material of the alveolar type, and the porous metal base material may be an aluminum material.

[0013] In one embodiment, the planar layer and the build layer are formed through a combination of linear layers in which the resin filament is heated and extruded through the nozzle and stacked.

[0014] When the above FDM 3D printer stacks the above linear layers, the extrusion conditions of the resin filament can be set to a nozzle speed of 1.5 mm / s, a nozzle temperature of 220 degrees, and a porous metal substrate heating temperature of 70 degrees. Effects of the invention

[0015] According to the method for manufacturing a lightweight part bonded with a porous metal base material and a functional resin according to the present invention, by printing and bonding a functional resin onto the surface of a porous material, there is an advantage in being able to manufacture a lightweight part endowed with various properties such as mechanical strength, corrosion resistance, wear resistance, and electrical insulation of the functional resin. Brief explanation of the drawing

[0016] FIG. 1 is a flowchart illustrating a method for manufacturing a lightweight part bonded to a porous metal substrate and a functional resin according to one embodiment of the present invention. Figure 2 is a drawing showing the appearance of the base layer being stacked in the base layer stacking step illustrated in Figure 1. Figure 3 is a drawing showing the stacking of build layers in the build layer stacking step illustrated in Figure 1. Figure 4 shows a polymer laminated on the surface of a porous metal substrate through the process of a method for manufacturing a lightweight part bonded with a functional resin and a porous metal substrate according to one embodiment of the present invention. FIG. 5 is a drawing exemplarily showing a lightweight part that can be manufactured through a method for manufacturing a lightweight part combining a porous metal base material and a functional resin according to one embodiment of the present invention. Specific details for implementing the invention

[0017] Hereinafter, a method for manufacturing a porous metal base material and a functional resin-bonded lightweight part according to an embodiment of the present invention will be described in detail with reference to the attached drawings. As the present invention is susceptible to various modifications and may take various forms, specific embodiments are illustrated in the drawings and described in detail in the text. However, this is not intended to limit the present invention to the specific disclosed forms, and it should be understood that it includes all modifications, equivalents, and substitutions that fall within the spirit and scope of the present invention. Similar reference numerals have been used for similar components in the description of each drawing. In the attached drawings, the dimensions of the structures are shown enlarged compared to the actual dimensions for the clarity of the present invention.

[0018] Terms such as "first," "second," etc., may be used to describe various components, but said components should not be limited by said terms. These terms are used solely for the purpose of distinguishing one component from another. For example, without departing from the scope of the present invention, the first component may be named the second component, and similarly, the second component may be named the first component.

[0019] The terms used in this application are used merely to describe specific embodiments and are not intended to limit the invention. The singular expression includes the plural expression unless the context clearly indicates otherwise. In this application, terms such as "comprising" or "having" are intended to specify the existence of the features, numbers, steps, actions, components, parts, or combinations thereof described in the specification, and should be understood as not precluding the existence or addition of one or more other features, numbers, steps, actions, components, parts, or combinations thereof.

[0020] Unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meaning as generally understood by those skilled in the art to which the present invention pertains. Terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant technology, and should not be interpreted in an ideal or overly formal sense unless explicitly defined in this application.

[0021] The present invention provides a method for manufacturing lightweight parts by laminating a functional resin onto a porous metal substrate.

[0022] FIG. 1 is a flowchart illustrating a method for manufacturing a lightweight part bonded to a porous metal substrate and a functional resin according to one embodiment of the present invention.

[0023] Referring to FIG. 1, a method for manufacturing a lightweight component combining a porous metal base material and a functional resin according to one embodiment of the present invention may include a base material preparation step (S110); a base layer lamination step (S120); and a build layer lamination step (S130).

[0024] In the base material preparation step (S110), a porous metal base material (100) is prepared. For example, the porous metal base material (100) may be aluminum foam, but is not particularly limited thereto, and any material having protrusions or depressions on its surface in any shape, regular or irregular, is possible.

[0025] In the base layer stacking step (S120), as shown in FIG. 2, the nozzle (210) of the FDM 3D printer (200) is moved along a predetermined first set movement coordinate while the resin filament (220) is heated and extruded to infiltrate the molten resin into the pores or depressions on the surface of the base material (100), thereby forming a base layer (10) that is bonded to the base material (100). For example, the first set movement coordinate may be a coordinate set to move along at least one of the X-axis and Y-axis parallel to the horizontal and vertical directions of the surface of the base material (100), and the base layer (10) covering the surface of the base material (100) may be formed by repeatedly moving along the first set movement coordinate. At this time, the base layer (10) can be formed by combining linear layers (not shown) extruded by melting the resin filament (220) in the form of a thread, by overlapping them in a horizontal direction.

[0026] This base layer lamination step (S120) can be performed to form a two-dimensional planar layer on the surface of the base material (100).

[0027] In the build layer stacking step (S130), as illustrated in FIG. 3, the nozzle (210) can be moved along the first set movement coordinate or a second set movement coordinate that is predetermined differently from the first set movement coordinate, and one or more flat or curved build layers (20) can be stacked on the base layer (10). For example, the second set movement coordinate may be a coordinate set to move along at least one axis among the X-axis, Y-axis, and Z-axis parallel to the width, length, and height of the surface of the base material (100), and by repeating the movement along the first set movement coordinate or the second set movement coordinate, one or more build layers (20) can be formed to cover and stack the base layer (10).

[0028] This build layer stacking step (S130) can be performed to form a layer of a two-dimensional or three-dimensional shape on the base layer (10).

[0029] The above base layer (10) and the above build layer (20) can be cured at room temperature.

[0030] The resin filament (220) used in these steps (S110, S120, S130) may be a functional resin material. For example, it may be a functional polymer material.

[0031] In the method for manufacturing a lightweight part combined with a porous metal base material and a functional resin according to one embodiment of the present invention, when the base layer (10) and the build layer (20) are laminated on the surface of the base material (100), the base layer (10) and the build layer (20) are melted and laminated, bonded together, and hardened, and some of the linear layers forming the base layer (10) penetrate into the pores of the base material (100) and then harden, thereby creating a bonding force between the base layer (10) and the base material (100). Accordingly, the functional resin is bonded to the surface of the porous metal base material (100), and a lightweight part can be manufactured in which the surface of the porous metal base material (100) is covered with a functional resin having strength.

[0032] Figure 4 is a drawing showing a polymer laminated on the surface of a porous metal substrate through the process of a method for manufacturing a lightweight part bonded with a functional resin and a porous metal substrate according to one embodiment of the present invention.

[0033] As shown in FIG. 4, through the process of manufacturing a lightweight part combining a porous metal base material and a functional resin according to one embodiment of the present invention, a polymer, which is a functional resin, was laminated on the surface of the porous metal base material, and as confirmed through the enlarged cross-section of the laminated portion, it was confirmed that the polymer penetrated into the pores of the porous metal base material (Foam) (100) and bonded with the porous metal base material (100).

[0034] In order to obtain a result in which a functional resin and a porous metal substrate are bonded as shown in Fig. 4, when the FDM 3D printer stacks the linear layers, the extrusion conditions of the resin filament can be set to a nozzle speed of 1.5 mm / s, a nozzle temperature of 220 degrees, and a porous metal substrate heating temperature of 70 degrees. These extrusion conditions of the resin filament are conditions for the bonding of the polymer and may vary depending on the type of functional resin.

[0035] According to the method for manufacturing a lightweight part bonded with a porous metal base material and a functional resin according to one embodiment of the present invention, by printing and bonding a functional resin onto the surface of a porous material, a lightweight part can be manufactured that is endowed with various properties such as mechanical strength, corrosion resistance, wear resistance, and electrical insulation of the functional resin.

[0036] For example, as shown in Fig. 5, it is possible to manufacture parts such as lightweight gears, in which the interior is made of porous metal and the exterior is made of functional resin, and it is also possible to manufacture lightweight parts of various other shapes.

[0037] The description of the presented embodiments is provided so that any person skilled in the art may use or practice the present invention. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments without departing from the scope of the present invention. Thus, the present invention is not limited to the embodiments presented herein, but should be interpreted in the broadest possible scope consistent with the principles and novel features presented herein.

Claims

Claim 1 A method for manufacturing a lightweight part combined with a porous metal base material and a functional resin, comprising: a base material preparation step of preparing a porous metal base material made of a porous aluminum foam material; a base layer stacking step of maintaining the metal base material at a heated temperature and heating and extruding a resin filament while moving the nozzle of an FDM 3D printer along a predetermined first set movement coordinate to infiltrate the molten resin into the porous pores or depressions on the surface of the base material to form a base layer that is bonded to the base material; and a build layer stacking step of stacking one or more flat or curved build layers on top of the base layer while moving the nozzle along the first set movement coordinate or a second set movement coordinate different from the first set movement coordinate, wherein the resin filament is a functional resin material, and the functional resin is bonded to the surface of the porous metal base material so that the surface of the porous metal base material has strength and a lightweight part is manufactured by covering the surface of the porous metal base material with the functional resin. Claim 2 A method for manufacturing a lightweight part combining a porous metal substrate and a functional resin, wherein the resin filament is a functional polymer material, in accordance with claim 1. Claim 3 delete Claim 4 A method for manufacturing a lightweight part combining a porous metal substrate and a functional resin according to claim 2, wherein the base layer and the build layer are formed through a combination of linear layers in which the resin filament is heated and extruded through the nozzle and stacked, and when the FDM 3D printer stacks the linear layers, the extrusion conditions of the resin filament are set to a nozzle speed of 1.5 mm / s, a nozzle temperature of 220 degrees, and a porous metal substrate heating temperature of 70 degrees.

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