CN107962771A - 制造复合制品的方法 - Google Patents

制造复合制品的方法 Download PDF

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CN107962771A
CN107962771A CN201710966307.0A CN201710966307A CN107962771A CN 107962771 A CN107962771 A CN 107962771A CN 201710966307 A CN201710966307 A CN 201710966307A CN 107962771 A CN107962771 A CN 107962771A
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X·金
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GM Global Technology Operations LLC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C71/00—After-treatment of articles without altering their shape; Apparatus therefor
    • B29C71/02—Thermal after-treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/20—Post-treatment, e.g. curing, coating or polishing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2063/00—Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B29K2067/06—Unsaturated polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/16—Fillers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing

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Abstract

一种使用用于3D打印制品的快速热处理热固性树脂材料来创建复合制品的方法，所述制品包括复杂几何形状的制品。该方法包括利用真空浸渍和随后的热处理作为印后工艺，以进一步加强和改善制品的功能。

Description

制造复合制品的方法
技术领域
与示例性实施例一致的装置涉及一种用于制造制品的方法。更具体地，与示例性实施例一致的装置涉及一种通过引入印后浸渍以加强制品的复合制品的三维(3D)打印/加法制造方法。
背景技术
本部分中的陈述仅提供与本公开相关的背景信息，并且可以构成或可以不构成现有技术。
在产品开发的原型设计部门，3D打印被誉为是在部件进入开发制造阶段之前创建部件的快速、有效手段。
尽管3D打印在测试针对形式和适配以确保在任何产品被绿色制造之前不需要设计和工程调整的部件方面是可行的技术，但在使用该技术时也存在缺点。
这些范围从材料的有限使用到创建部件再到关于部件的物理特性是否相对于其在开发中的功能提供有用信息的担忧。
在传统的3D打印中，选择的材料是热塑性树脂，因为其可以沉积在熔融层中以形成最终部件。然而，由热塑性树脂材料制成的部件具有带有微孔和显著的各向异性的趋势，这限制了部件的功能。由于热塑性材料的印后加工性的严重局限，打印部件的这种功能缺陷难以校正。开发更简单的工具或过程来纠正这些功能缺陷将是有益的。
发明内容
一个或多个示例性实施例通过提供一种用于制造制品的方法来解决上述问题。更具体地，与示例性实施例一致的装置涉及一种使用热固性树脂通过印后浸渍来三维(3D)打印复合制品的方法。
根据示例性实施例的一方面，创建复合制品的方法包括创建制品的三维(3D)虚拟模型。示例性实施例的另一方面包括将虚拟模型分割成多个邻接的二维层。根据示例性实施例的再一方面包括将分割后的虚拟模型加载到可操作以创建由热固性聚合物树脂材料制成的三维制品的三维打印设备中。示例性实施例的另一方面包括将分割的虚拟模型加载到可操作以创建由热塑性聚合物树脂制成的三维制品的三维打印设备中。
并且，示例性实施例的另外方面包括用增强热固性材料浸渍三维制品并且在一定的时间段内对浸渍后的3D制品进行热处理。
根据示例性实施例的其他方面，其中热固性聚合物树脂材料是环氧树脂。仍然根据示例性实施例的方面，其中热固性聚合物树脂是酚醛树脂。并且，示例性实施例的另一方面，其中环氧树脂或酚醛树脂体系包括使用至少一种增强填料。
示例性实施例的另外方面，其中热固性聚合物树脂是不饱和聚酯基树脂体系。并且，示例性实施例的另一方面，其中不饱和聚酯基树脂体系包括使用至少一种增强填料。示例性实施例的又一方面，其中增强填料是玻璃纤维。
根据示例性实施例的又一方面，其中浸渍三维制品还包括使用具有固化剂的液态热固性树脂。并且又一方面，其中浸渍三维制品通过真空浸渍工艺实现。示例性实施例的另外方面，其中浸渍三维制品通过加压浸渍工艺实现。
根据示例性实施例的再一方面，其中液态热固性树脂是环氧树脂。并且示例性实施例的另一方面，其中液态热固性树脂是酚醛树脂。根据示例性实施例的又一方面，其中液态热固性树脂是不饱和聚酯基树脂体系。
根据示例性方法的另一方面，其中液态热固性树脂包括至少一种增强填料。示例性实施例的再一方面，其中对浸渍后制品进行热处理还包括对浸渍后的三维制品进行热处理。并且示例性实施例的又一方面，其中热处理条件取决于制品尺寸和用于创建它的树脂材料。
附图说明
参照附图，从下面阐述的描述中将更好地理解本示例性实施例，附图中：
图1是根据示例性实施例的利用3D打印工艺创建的成品的图示；
图1A是根据示例性实施例的利用3D打印创建的制品的子部分的放大视图的图示；
图2是根据示例性实施例的形成3D打印制品的多个邻接层的分解视图的图示；
图3是根据示例性实施例的使用热固性树脂来3D打印制品的方法的算法的图示；
图4是根据示例性实施例的用于便利使用热固性树脂来3D打印制品的方法的装置的图示；以及
图4A是根据示例性实施例的使用热固性树脂来3D打印制品的方法创建的制品的图示。
具体实施方式
以下描述本质上仅仅是示例性的，并不意图限制本公开、其应用或用途。
图1提供了根据示例性实施例的利用常规3D打印工艺创建的成品110的图示，其中110a是下面将要描述的子部分。应当理解，这里作为基本立方体呈现的成品110作仅仅是为了解释根据示例性实施例的用于3D打印制品的方法的目的，并且不旨在限制关于可以从其应用创建的3D制品的多样性或几何复杂性的范围。根据示例性实施例的各方面，使用热固性树脂材料制造制品，但当采用适当的浸渍和热处理以有益于制品的功能和结构时，也可以使用热塑性树脂材料制造制品。
参照图1A，示出了根据示例性实施例的利用3D打印创建的图1中的制品的子部分110a的放大视图的图示。应当理解，成品110由多个微尺寸的超细粒子120形成，这些粒子通过烧结工艺结合在一起以创建包括粒子120之间的微尺寸空间130的3D制品110，使得创建的3D制品110在微观层面上是高度多孔的。与相同形式和材料的完全实心制品相比，这些微尺寸空间130不仅使得3D制品110可渗透流体，而且降低了其结构强度。
现在参照图2，示出了根据示例性实施例的形成3D打印制品110的多个邻接层2101、2102、2103至210n的分解视图200的图示。在3D打印过程中，使用加法过程来实现3D制品110的创建。
在加法过程中，通过铺设快速热处理热固性树脂材料的连续邻接层2101、2102、2103至210n直到创建3D制品110来创建物体。热固性树脂材料比热塑性材料的热稳定性好得多，这允许使用印后工艺来改善3D制品110的强度。
这些邻接层2101、2102、2103至210n中的每一层可以被看作是3D制品110的薄切片水平横截面。根据3D制品的尺寸、3D打印机和所使用的材料，该过程可能需要几分钟到几个小时甚至几天才能完成。
图3是根据示例性实施例的使用热固性树脂来3D打印制品的方法的算法300的图示。在框310，该方法开始于创建3D制品110的三维虚拟模型。该虚拟模型可以作为计算机辅助设计(CAD)、立体平版印刷(STL)或虚拟现实建模语言(VRML)文件创建。
在框320，该方法继续以将虚拟模型划分割为如图2中所示的多个邻接的二维层。然后，在框330，该方法通过将分割后的虚拟模型加载到三维打印设备中而继续，该三维打印设备可操作以创建根据示例性实施例的由热固性聚合物树脂材料制成的3D制品110。根据示例性实施例的用于形成3D制品100的热固性树脂材料包括但不限于环氧树脂、酚醛树脂或不饱和聚酯基树脂体系。当采用适当的浸渍和热处理以有益于制品的功能和结构时，可以采用热塑性树脂材料。应当理解，当采用适当的浸渍和热处理以有益于制品的功能和结构时，制品也可由热塑性树脂材料制成。
在框340，该方法通过用增强材料浸渍3D制品110以增强制品的多样性和强度而继续。根据示例性实施例，印后浸渍可以使用具有各种固化剂的液态热固性树脂，包括环氧树脂、酚醛树脂或不饱和聚酯体系。浸渍工艺可以使用真空浸渍或加压浸渍工艺来实现。应当理解，其他液态热固性树脂和浸渍工艺可以用于本文所述的预期目的，而不超出示例性实施例的范围。
在框350，该方法结束于对浸渍后的三维制品进行热处理，优选地通过热处理工艺。用于对3D制品110进行热处理的温度和时间将取决于制品的尺寸和用于形成它的材料。根据示例性实施例，固化/热处理条件可以在环境温度-180℃之间的范围内。固化时间范围为约30分钟至几小时。
图4是根据示例性实施例的用于便利使用热固性树脂浸渍3D打印制品的方法的装置的图示。树脂罐410保持热固性材料，通过泵420将热固性材料从树脂罐410抽吸到真空浸渍室430内。当通过真空泵440将空气从真空室430抽出时，用热固性树脂材料浸渍3D制品110。在浸渍工艺之后，将彻底浸渍的3D制品460放置在诸如烘箱450的热处理室中，以根据3D制品460a的尺寸和材料在热处理条件下进行热处理。
图4A是根据示例性实施例的利用3D打印由热固性树脂浸渍的制品的方法创建的制品460a的图示。用热固性树脂打印结合印后浸渍和热处理的3D制品460a，创建了具有更均匀强度和增强功能的多样性部件。
本发明的描述本质上仅仅是示例性的，并且不脱离本发明要点的变型旨在落在本发明的范围内。这些变型不认为是脱离本发明的精神和范围。

Claims (10)

1.一种创建复合制品的方法，包括：
创建所述制品的三维虚拟模型；
将所述虚拟模型分割为多个邻接的二维层；
将分割后的虚拟模型加载到可操作以创建由热固性聚合物树脂材料制成的三维制品的三维打印设备中；
用增强材料浸渍所述三维制品；以及
对浸渍后的三维制品进行热处理。
2.根据权利要求1所述的方法，其中，所述热固性聚合物树脂材料是具有或不具有增强填料的环氧树脂。
3.根据权利要求1所述的方法，其中，所述热固性聚合物树脂是具有或不具有增强填料的酚醛树脂。
4.根据权利要求1所述的方法，其中，所述热固性聚合物树脂是具有或不具有增强填料的不饱和聚酯基树脂体系。
5.根据权利要求1所述的方法，其中，浸渍所述三维制品还包括使用具有固化剂的液态热固性树脂。
6.根据权利要求1所述的方法，其中，浸渍所述三维制品通过真空浸渍工艺实现。
7.根据权利要求1所述的方法，其中，浸渍所述三维制品通过加压浸渍工艺实现。
8.根据权利要求5所述的方法，其中，所述液态热固性树脂是环氧树脂。
9.根据权利要求5所述的方法，其中，所述液态热固性树脂是酚醛树脂。
10.根据权利要求5所述的方法，其中，所述液态热固性树脂是不饱和聚酯基树脂体系。
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