Pressure-Injected Z-Pin Resin Network for Interlayer Bonding
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Solution Overview
Problem
Conventional continuous fiber additive manufacturing lacks effective longitudinal strengthening structures, leading to weak interlayer bonding and potential damage to in-plane performance due to direct implantation of Z-pin structures, which exacerbates pore defects.
Innovation Solution
A method involving a continuous fiber print head and a thermosetting resin extrusion head to create Z-pin-like structures by pressure injection, forming a resin network across layers to strengthen interlayer bonding and suppress pore defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional Z-pin technology is used to implant reinforced fibers in the thickness direction, then interlayer bonding performance is improved, but in-plane performance is damaged due to local material damage
Solution Approach 1:
The patent introduces a resin network as an intermediary substance that fills the spaces between continuous fiber layers during the additive manufacturing process. This resin network acts as a bonding mediator that strengthens interlayer connections without requiring mechanical implantation of Z-pins, thereby avoiding damage to in-plane performance while achieving the desired interlayer bonding enhancement
Solution Approach 2:
The resin network is formed preliminarily during the additive manufacturing process itself, before the parts are subjected to any post-treatment. By pre-forming the bonding structures during manufacturing, the need for subsequent Z-pin implantation or other strengthening treatments is eliminated, preventing any potential damage to the finished part
2Strength
If direct Z-pin structures are implanted into additive manufacturing parts, then longitudinal strengthening is achieved, but original pore defects are expanded degrading overall performance
Solution Approach 1:
The patent converts the harmful effect of pore defects into a beneficial feature by using the same pore spaces as the intended locations for resin network formation. The resin selectively fills these pore regions during manufacturing, transforming what would be weakness points into bonded reinforcement zones, thereby achieving longitudinal strengthening without expanding defects
Solution Approach 2:
The resin serves as an intermediary material that occupies the pore defect spaces and transforms them into bonding regions. Rather than trying to eliminate or repair pores after manufacturing, the resin network is deliberately formed in these spaces during the manufacturing process, converting the harmful pore structures into beneficial bonding zones
3Strength
If auxiliary processes using energy sources such as laser or hot rolling are used to promote interlayer resin entanglement, then interlayer bonding is improved, but device complexity and process difficulty increase
Solution Approach 1:
The patent merges the interlayer bonding function with the primary additive manufacturing extrusion process itself. By forming the resin network during the normal layer-by-layer construction process through controlled resin extrusion and infiltration, the need for separate auxiliary processes like laser treatment or hot rolling is eliminated, simplifying the overall system while achieving effective interlayer bonding
Solution Approach 2:
The resin network formation process is self-service in nature, utilizing the resin material itself and the existing pore structures to achieve bonding without requiring external energy sources or additional equipment. The resin automatically infiltrates and bonds the layers through the extrusion and infiltration mechanism inherent to the additive manufacturing process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances interlayer bonding performance and suppresses pore defects without additional energy sources, improving the overall performance of additive manufacturing parts.
Implementation Method 1
pressure injection of thermosetting resin... by controlling injection pressure to form a resin network
Data Source
AI summary
An interlayer strengthening method for continuous fiber additive manufacturing based on pressure injected Z-pin-like structures is provided. A grid frame is printed with continuous fibers in horizontal slices of continuous fiber additive manufacturing, grid holes are regularly arranged and combined to form intermittent through spaces between layers, then thermosetting resin is injected into the spaces through pressure to build continuous longitudinally strengthened Z-pin-like structures across slice layers, and the resin is guided to penetrate and gradually fill universal interlayer pores in continuous fiber additive manufacturing by controlling resin filling extrusion pressure, thereby suppressing associated pore defects in additive manufacturing without introducing other auxiliary energy fields, ultimately achieving interlayer strengthening, and improving overall performance.