CN109421268B - 用于三维打印的固体颗粒的静电聚合物气溶胶沉积和融合 - Google Patents

用于三维打印的固体颗粒的静电聚合物气溶胶沉积和融合 Download PDF

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CN109421268B
CN109421268B CN201810870172.2A CN201810870172A CN109421268B CN 109421268 B CN109421268 B CN 109421268B CN 201810870172 A CN201810870172 A CN 201810870172A CN 109421268 B CN109421268 B CN 109421268B
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D·M·约翰逊
S·A·埃尔罗德
D·K·比格尔森
V·A·贝克
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Abstract

一种增材制造系统，其具有用于使粉末雾化的气溶胶产生器、沉积表面、用于向沉积表面施加毯覆式电荷的表面充电元件、用于从沉积表面选择性地去除一部分毯覆式电荷的充电打印头以及用于将气溶胶粉末从气溶胶产生器传递到沉积表面的传递系统，所述传递系统具有用于向气溶胶粉末施加与毯覆式电荷相反的电荷的气溶胶充电元件。增材制造过程包括在喷雾产生器处由粉末产生气溶胶、将气溶胶充电以产生具有第一电荷的带电气溶胶、在沉积表面上形成具有与第一电荷极性相反的第二电荷的毯覆式电荷、选择性地去除一部分毯覆式电荷区域以及将带电气溶胶传递到带电区域以在带电区域由带电气溶胶形成结构。

Description

用于三维打印的固体颗粒的静电聚合物气溶胶沉积和融合
技术领域
本公开涉及聚合物喷雾沉积，更具体地说，涉及使用粉末的聚合物喷雾沉积。
背景技术
定制零件制造业是一个不断发展的行业，并且具有广泛的应用范围。传统上，注塑机和其它加工技术被用来创建物件模型或自己创建物件。更具体地说，将加热的材料(如玻璃，金属，热塑性塑料和其它聚合物)注入特定形成所需物件形状的注塑模具中。材料可以在模具中冷却并且呈现模具的形状以形成物件。注射模具的产生是昂贵和耗时的，并且在不进一步增加产生物件的时间和费用的情况下，对物件形状的变化是难以实现的。
增材制造工业由于改变注射模具以产生模型或物件本身的费用、时间和困难而产生。已知的增材制造技术尤其包括熔合沉积建模(FDM)、立体光刻(SLA)、选择性激光烧结(SLS)以及喷射系统。每种已知的增材制造技术在材料、费用和/或容积功能方面具有局限性，其阻止使用完全热塑性材料设定来进行短期、定制制造和原型开发。此外，已知的增材制造技术不能精确产生具有由传统技术(如注塑)制造的高质量物件的机械特性、表面光洁度以及特征复制的零件。
在增材制造不能产生具有足够的应用性能的零件的情形下，出现使用低成本工具的快速计算机数字控制(CNC)机械加工和快速注塑的整个行业。然而，这些技术与增材制造技术相比明显更加昂贵并且具有其自身过程局限性。
行业中被迫在由传统但昂贵、不灵活以及耗时的技术(如注塑)产生的高质量、高容积功能物件与产生质量较差的物件(可能不具有所需结构完整性并且有时不具有所需材料，但具有更高的速度和灵活性)的增材制造技术之间做出取舍。
举例来说，FDM和SLS在能够使用的材料类型方面具有局限性并且产生小于100％密度物件。快速CNC模制具有质量更好的物件，且具有高特征细节和光洁度，但仍较昂贵。由已知的增材制造技术产生的技术原型通常经优化直到选择最终设计，此时产生用于大规模、高质量注塑制造的注射模制。这类多阶段制造过程也是耗时和昂贵的。
一种方法涉及聚合物喷雾沉积(PSD)。这种方法形成聚合物小滴的喷雾或气溶胶，并且将其充电以使得其在带电表面上选择性沉积。气溶胶的形成可由多种形式进行。其中许多通常需要受控温度和惰性气氛。这些形式通常引起更高的成本和更复杂的制造环境。
发明内容
一个实施例是一种增材制造系统，其具有用于使粉末雾化的气溶胶产生器、沉积表面、用于向沉积表面施加毯覆式电荷的表面充电元件、用于从沉积表面选择性地去除一部分毯覆式电荷的充电打印头以及用于将气溶胶粉末从气溶胶产生器传递到沉积表面的传递系统，所述传递系统具有用于向气溶胶粉末施加与毯覆式电荷相反的电荷的气溶胶充电元件。
另一实施例是一种增材制造过程，其包括在喷雾产生器处由粉末产生气溶胶、将气溶胶充电以产生具有第一电荷的带电气溶胶、在沉积表面上形成具有与第一电荷极性相反的第二电荷的毯覆式电荷、选择性地去除一部分毯覆式电荷区域以及将带电气溶胶传递到带电区域以在带电区域由带电气溶胶形成结构。
附图说明
图1显示三维增材制造系统的实施例。
图2显示三维增材制造系统的另一视图。
图3显示返回和再循环路径的实施例。
图4显示具有支撑材料的三维增材制造系统的实施例。
图5显示三维增材制造的方法的实施例。
具体实施方式
本文中的实施例提供三维、数字、增材制造技术的优势，其具有与用其它方式可实现的范围相比更广泛的热塑性材料范围。其引起所产生的物件的特征尺寸解析在复杂性和结构完整性方面与更传统的制造技术(如注塑过程)类似。本文中的系统和方法可以使高分子量聚合物粉末和其它热塑性塑料(如尼龙、聚苯乙烯、聚碳酸酯、聚丙烯、聚砜和缩醛)雾化并且产生三维物件。使用粉末可以缓解一些对会影响流体的温度和大气压的制造限制。
图1显示实例聚合物沉积系统100的方块图，其包括气溶胶产生器102、传递系统104、多喷嘴阵列106以及物件产生台108。气溶胶产生器102接收来自粉末源110的粉末并且可以由所属领域中众所周知的许多不同方法形成粉末的气溶胶，如美国专利案第2,862,646号中公开或在www.tsi.com/small-scale-powder-disperser-3443方法的发现。在一个实施例中，将高速气体物料流吹入部分填充有电力的容器中。气流夹带颗粒，并且流体的混乱性质混合空气和粉末使得其产生气溶胶。这一气溶胶可由另一流体或真空从容器去除。
接着，传递系统104将气溶胶化粉末从气溶胶产生器102传递到多喷嘴阵列106，其将粉末分配到物件产生台中的表面上。传递系统104包括电荷元件116，其向喷雾充填第一极性电荷。如下文中将更详细讨论，沉积表面将具有含有相反电荷的区域，以将气溶胶化粉末颗粒吸引到这些区域。接着，使用针对沉积表面的多喷嘴阵列将带电气溶胶施用于表面。可以通过材料循环器120再循环任何‘废料’或残余物质。
图2显示增材制造系统200的替代性视图。气溶胶产生器206使显示为颗粒204的粉末气溶胶化。传递系统208，可能由空气流202组成，将气溶胶化粉末从气溶胶产生器206传递到沉积表面214。在一个实施例中，传递系统可包括导管(视需要绝缘)、空气鞘流，并且可能进行过滤。此外，传输流可包括惯性冲击器以实现尺寸选择，以及按需要选用的过滤器。
电荷元件210向气溶胶施加第一极性电荷。这可能涉及用于产生电场的传递系统的任一侧上的电极集合，其中气溶胶穿过所述电场。沉积表面214将接收带电颗粒，如216。在一个实施例中，沉积表面驻留在台218上，所述台可以是三轴(x、y以及z)台，其相对于沉积喷嘴阵列移动。
在带电颗粒到达沉积表面之前，沉积表面的选择性区域接收相反电荷。在一个实施例中，第一充电装置，如电晕管220(电晕充电装置)，向沉积表面施加毯覆式电荷，所述电荷具有与第一极性相反的极性。尽管图2显示充电装置220，但其将仅在粉末喷雾到达之前存在。
在沉积表面上形成毯覆式电荷之后，另一充电装置，如离子打印头，中和来自表面的非零件部分的电荷。颗粒将附着到沉积表面上仍具有相反电荷的部分。
在来自粉末喷雾的颗粒到达沉积表面并且‘粘着’到带有相反电荷的区域后，将开始形成零件或其它结构。在形成零件期间或之后，粉末材料可以经历加热以使材料融合成零件。融合可以通过施加热和/或压力实现。热可以通过使用红外线源、加热滚筒或使用高温空气来施加。其它实施例可能涉及施用紫外光以使由UV固化粉末制成的粉末形成物固化。此外，也可以对粉末气溶胶加压以帮助融合。
随着粉末材料在沉积表面的选定区域汇集，一部分粉末喷雾将从沉积表面掉落。在一些实施例中，可以使未粘着的粉末材料再循环回到气溶胶产生器206。材料再循环将通常在远离用于使沉积表面的带电区域处形成的零件融合的热或其它能量的地方进行。图3显示来自图1的再循环路径120的实例。粉末材料流经沉积表面214，并且一些颗粒216附着到沉积表面214的一些区域。
如图4中所示，在粉末材料融合以形成零件(如300)之后，可以在间隙(如308)中填充任选的支撑材料302以产生光滑的平坦表面。材料可以从喷嘴304和刮刀306到达间隙，或其它工具可以将其平滑地填充到间隙中以提供结构上更坚固的零件。
图5显示整体过程流程的实施例。在400处，沉积表面在400处接收毯覆式电荷。在402处，另一装置，如离子打印头，选择性中和来自沉积表面的电荷。同时，在404处，系统由粉末产生气溶胶并且将其传递到沉积表面406。在408处，在气溶胶被传递时，其经历充电。在410处，当气溶胶到达沉积表面时，其在表面上融合以形成所需结构。在一个任选的步骤中，支撑材料填充间隙，如上文所讨论。
以这种方式，三维增材制造可以使用粉末在制造过程中产生零件。这可以提供复杂性较低并且更便宜的用于形成供喷雾沉积使用的聚合物的制造过程。
应了解，可以将上文所公开和其它的特征和功能的变型或其替代方案组合成许多其它不同系统或应用。其中各种目前未预见到或未预期的替代方案、修改、变化或改进可以随后由所属领域的技术人员来进行，并且也旨在由以下权利要求书涵盖。

Claims (10)

1.一种增材制造系统，包含；
气溶胶产生器，其用于使粉末雾化以产生气溶胶粉末；
沉积表面：
表面充电元件，其用于向所述沉积表面施加毯覆式电荷；
充电打印头，其用于从所述沉积表面选择性地去除一部分所述毯覆式电荷；以及
传递系统，其用于将所述气溶胶粉末从所述气溶胶产生器传递到所述沉积表面，所述传递系统具有气溶胶充电元件以向所述气溶胶粉末施加与所述毯覆式电荷相反的电荷，使得所述气溶胶在所述沉积表面中保留电荷的部分上形成结构。
2.根据权利要求1所述的系统，进一步包含所述传递系统中的用于选择颗粒尺寸的惯性冲击器。
3.根据权利要求1所述的系统，进一步包含所述传递系统中的过滤器。
4.根据权利要求1所述的系统，进一步包含分配器，其用于将支撑材料分配于各所述结构之间。
5.根据权利要求1所述的系统，进一步包含在上面放置所述沉积表面的可移动台。
6.根据权利要求1所述的系统，其中所述表面充电元件包含电晕管。
7.一种增材制造方法，包含：
在喷雾产生器处由粉末产生气溶胶；
将所述气溶胶充电以产生具有第一电荷的带电气溶胶；
在沉积表面上形成具有与所述第一电荷的极性相反的第二电荷的毯覆式电荷；
选择性地去除一些所述毯覆式电荷区域，在所述沉积表面上留下带电区域；以及
将所述带电气溶胶传递到所述带电区域，以在所述带电区域上由所述带电气溶胶形成结构。
8.根据权利要求7所述的方法，进一步包含施加能量以使所述结构融合。
9.根据权利要求7所述的方法，进一步包含施用支撑材料以填充所述结构之间的间隙。
10.根据权利要求7所述的方法，其中在所述沉积表面上形成所述毯覆式电荷包含使用电晕管形成所述电荷。
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