CN109648843A - 增材制造结构中的复合材料镶嵌 - Google Patents
增材制造结构中的复合材料镶嵌 Download PDFInfo
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Abstract
公开了用于将复合材料镶嵌到器具壳体中的技术。在一方面,提供了一种增材制造的器具壳体,复合材料镶嵌和固化在该器具壳体中。器具壳体的表面设置有凹槽或其它机构,以使得能够在复合材料和器具壳体之间粘合。得到的整体结构被用作运输结构中的部件。
Description
相关申请的交叉引用
本申请要求2017年10月11日提交的且名称为“增材制造结构中的复合材料镶嵌”的美国专利申请No.15/730,675的权益,其内容通过引用明确地整体并入本文。
技术领域
本公开总体涉及制造技术,并且更具体地涉及用于车辆,船,飞行器和其它运输结构的3-D打印的部件。
背景技术
许多类型的部件被制造并用在运输结构中,比如车辆、卡车、火车、摩托车、船、飞行器以及类似物。这样的部件可以包括“现成的”和定制的部件两者,其可以在运输结构内或作为其部分用于功能、结构或美学目的中的任一个或多个。
许多类型的这种部件构成了由金属、合金、聚合物或其它合适材料组成的一般的刚性结构构件。该结构构件可以具有预定形状,并且可以包括被制造成粘合到适当模制的复合材料的单独层上的一个或多个表面、凹槽或空腔。例如,车辆中的内门板的部分可包括镶嵌有碳纤维加强聚合物(CRFP)的金属或塑料结构。在该示例中,CRFP层可以被包括以增加面板的强度和耐用性,同时保持相对轻质和美观的设计。根据像运输结构的类型以及部件的性质与预期用途之类的因素,可以使用许多其它类型的复合材料。
将用于模制复合材料层的器具壳体加工成用于这种结构的所需形状常常是昂贵且耗时的工艺。在传统的生产技术中,用于模制复合材料的器具通常使用劳动密集型的工艺制造。例如,可以使用加工工艺来制造一对器具壳体,每个器具壳体可以各自构成模具的正部分和负部分中的一个。材料和树脂可以放置在正和负器具壳体部分之间的模具中,从而形成结构。器具壳体继而通常由一种或多种材料组成,这些材料在化学上和结构上适用于在模制主体材料中使用。通常,这种结构具有使它们得难以精确切割成所需模具形状或难以形成细节特征的性质。
在完成复合材料层的模制之后,器具壳体在形成单一类型的部件的用途范围外可以具有局限地或者不再具有其它的用途。进一步地,其中要镶嵌模制材料的结构可能必须使用不相关的技术单独加工,从而可能致使制造工艺甚至更加昂贵和费力。
发明内容
在下文中将参考三维打印技术更全面地描述镶嵌在增材制造器具壳体的复合材料。
制造用于运输结构的部件的方法的一个方面包括,三维(3-D)打印器具壳体,器具壳体包括被构造成粘合到材料上的表面,使用作为模具部件的器具壳体将材料施加到表面,并形成包括器具壳体和材料的整体结构,该整体结构用于装配为运输结构中的部件。
制造用于运输结构的部分的方法的另一方面包括,三维(3-D)打印器具壳体,并且生产整体结构,其包括器具壳体和施加于器具壳体的表面的材料,该整体结构用作运输结构中的部件,生产整体结构进一步包括使用器具壳体来模制复合材料,以及将复合材料固定到器具壳体上。
应当理解,对于本领域技术人员,用于运输结构的部件的生产方法的其它方面将从以下详细描述中变得显而易见,其中通过示例的方式仅描述示出与描述了几个实施例。如本领域技术人员将认识到的,部件与制造部件的方法能够具有其它且不同的实施例,并且其若干细节能够在各个其它方面进行修改,所有这些都不脱离本发明的范围。因此,附图和详细描述本质上被认为是说明性的而不是限制性的。
附图说明
现在将在附图中通过示例而非限制的方式在详细描述中介绍镶嵌增材制造的器具壳体的复合材料,其中:
图1示出了启动3-D打印过程的示例性过程的流程图。
图2示出了示例性3-D打印机的框图。
图3示出了3-D打印的器具壳体的立体图。
图4示出了其中插入有CFRP的3-D打印的器具壳体的立体图。
图5示出了组合材料与器具壳体的截面立体图。
图6示出了使用双装配部件的运输结构中的示例性内门板610的侧视图。
图7示出了说明用于生产具有复合材料加强件的部件的示例性过程的流程图,所述复合材料加强件覆盖器具壳体以形成用作运输结构中的部件的整体结构。
图8示出了由增材制造器具上的覆盖的织物复合材料加强件组成的整体结构的示例。
图9示出了包括形成有内部网格结构的器具的整体结构的示例。
图10示出了具有凹口和带有拓扑优化的器具的整体结构的示例。
图11示出了使用共同模制的节点的整体结构的示例。
图12示出了说明用于加工部件的示例性过程的流程图,该部件具有在器具壳体上的复合材料以生产用作运输结构中部件的整体结构。
图13示出了整体结构的示例,该整体结构包括夹在节点之间并通过机械夹具固定的复合材料。
图14A-B示出了使用复合材料表皮和多材料器具的整体结构的示例。
图15示出了在固化的复合材料表面上使用剥离层的整体结构的示例。
具体实施方式
以下联系附图阐述的详细描述旨在提供用于增材制造器具上的织物复合材料加强件的各种示例性实施例的描述,而非旨在代表可以实践本发明的仅有的实施例。贯穿本公开使用的术语“示例性”意味着“用作例子,实例或示例”,并且不应必须被解释为比本公开中给出的其它实施例更优或有利。详细描述包括用于提供彻底和完整公开的目的的具体细节,该公开向本领域技术人员充分传达了本发明的范围。然而,可以在没有这些具体细节的情况下实践本发明。在一些实例中,众所周知的结构和部件可以以框图形式示出,或者完全省略,以便避免模糊贯穿本公开内容给出的各种概念。
在复合材料器具的背景下使用增材制造(也称为3-D打印)为使得机械结构和机械化装配件的制造商制造具有复杂几何形状的部件提供了显着的灵活性。例如,3-D打印技术为制造商提供了设计和构建具有复杂的内部网格结构和/或轮廓的部件的灵活性,这些部件是不可能通过传统制造加工制造的。
图1示出了启动3-D打印过程的示例性过程的流程图100。渲染待打印的期望3-D物体的数据模型(步骤110)。数据模型是3-D物体的虚拟设计。因此,数据模型可以反映3-D物体的几何和结构特征,以及其材料成分。可以使用各种方法创建数据模型,包括3D扫描,3D建模软件,摄影测量软件和相机成像。
用于创建数据模型的3D扫描方法还可以使用用于生成3-D模型各种技术。这些技术可以包括例如时差测距、体积扫描、结构光、调制光、激光扫描、三角测距以及类似技术。
反过来,3-D建模软件可以包括许多商业上可获得的3-D建模软件应用程序中的一款。可以使用合适的计算机辅助设计(CAD)包来渲染数据模型,例如以STL格式。STL文件是与商业上可获得的CAD软件相关联的文件格式的一个示例。CAD程序可以用于将3-D物体的数据模型创建为STL文件。随即,STL文件可以经历一个识别文件中的错误并解决的过程。
在错误解决之后,数据模型可以被称为切片器的软件应用程序“切片”,从而产生用于3-D打印物体的一组指令,其中该指令与所用的特定3-D打印技术兼容并且相关联(步骤120)。商业上可以获得很多切片器程序。切片器程序将数据模型转换为代表待打印物体的薄切片(例如,100微米厚)的一系列独立的层,以及包括打印机特定指令的文件,所述指令用于3-D打印这些连续的独立的层以产生数据模型的实际3-D打印代表物。
用于此目的的常见文件类型是G代码文件,其为数字控制编程语言,该语言包括用于3-D打印物体的指令。将G代码文件或构成指令的其它文件上传到3-D打印机(步骤130)。因为包括这些指令的文件通常被构造成可以用特定的3-D打印过程操作,所以应当理解,根据所使用的3-D打印技术,可以有许多格式的指令文件。
除了指示物体的渲染内容和方式的打印指令外,由渲染物体的3-D打印机所使用的必需的合适的物理材料使用几种常规的且常见的打印机专用方法中的任一种加载到3-D打印机中(步骤140)。例如,在熔融沉积建模(FDM)3-D打印机中,材料通常作为细丝装载在线轴上,线轴放置在一个或多个线轴保持器上。通常将细丝输送到挤出器装置中,在将材料喷射到构建板或其它基底上之前,挤出器装置在操作中将细丝加热成熔融形式,如下面进一步说明的。在选择性激光烧结(SLS)打印和其它方法中,材料可以作为粉末装载到腔室中,该腔室将粉末输送到构建平台。取决于3-D打印机,可以使用其它用于装载打印材料的技术。
然后,基于提供的指令,使用材料打印3-D物体的相应数据切片(步骤150)。在使用激光烧结的3-D打印机中,激光扫描粉末床并且在结构期望的位置处将粉末融化在一起,并避免扫描切片数据表明不打印任何东西的区域。该过程可以重复数千次,直到形成期望的结构,在此之后从制造机中取出打印的部件。在熔融沉积建模中,通过将连续的模型层与支撑材料层施加到基板上来打印部件。总的来说,为实施本公开,可以采用任何合适的3-D打印技术。
图2示出了示例性3-D打印机200的框图。虽然可以适当地采用任何数量的3-D打印技术,但图2的3-D打印机200在FDM技术的背景进行说明。3-D打印机200包括进而包括挤出喷嘴250A和250B的FDM头210、可移动构建台220、以及构建台220顶部的构建板230。
取决于结构的预期组成和对用于为结构的悬垂元件提供支撑(否则可能会受到可能的重力变形或坍塌)的任何支撑材料的需要,可以使用多种材料来打印物体。一种或多种合适的细丝材料260可以缠绕在线轴(未示出)上并且输送到FDM头210中。(在上述其它技术中,材料可以被提供为粉末或其它形式)。FDM头210可以通过数字控制机构(例如步进电机或伺服电机)根据接收到的打印指令在X-Y方向上移动。在一个示例性实施例中构成热塑性聚合物的材料可以被输送到包括挤出喷嘴250A和250B的FDM头210。FDM头210中的挤出器将细丝材料260加热成熔融形式,并且挤出喷嘴250a喷射熔融材料并将其沉积到构建台220的构建板230上。
响应于所接收的打印指令,FDM头210关于水平(X-Y)平面移动,使得挤出喷嘴250A将材料260落在目标位置处以形成所施加材料的行240。(FDM头210还可以被构造成在Z方向上移动和/或绕某些构造的一个或多个轴线旋转)。包括行240的材料260的层270通过逐行沉积材料260而形成,其中材料260的每个行在材料沉积在构建板230上时硬化。在X-Y平面中的适当位置处形成一个层270之后,可以以类似的方式形成下一层。
构建板230可以是可至少在竖直Z方向上移动的受控工作台的部件。当完成层270的渲染时,构建台220和构建板230可以在竖直(Z)方向上降低与层270的厚度成比例的量,使得打印机可以开始实施下一层,并以此类推,直到形成具有期望形状和组成的多个截面层240。
虽然出于简化的目的,在此示例中示出了基本上矩形的层结构,但是应当理解,实际的打印结构可以根据数据模型基本上实施为任何形状和构造。也就是说,渲染层的实际形状将对应于正被打印的3-D模型的限定的几何形状。
另外,如上所指出的,可以使用多种不同的材料来打印物体。在一些情况下,两种不同的材料260和280可以由相应的挤出器喷嘴250A和250B同时施加。
在一个示例性实施例中,使用适当形状和结构化的器具壳体以模制一层或多层复合材料,形成了用于运输结构的部件。复合材料粘合到器具壳体的表面上以形成包括复合材料和器具壳体两者的整体结构。该整体结构可操作用作运输结构(比如,车辆)中的部件。在一个示例性实施例中,器具壳体是3-D打印的,从而排除了与费力的加工过程相关的通常昂贵且耗时的技术。在这些实施例中,器具壳体可以起到模制复合材料和用作结合模制材料以形成用于装配在运输结构其内部的部件(例如车辆面板、接头或其它部件、飞行器机翼以及类似物)的有用结构的双重作用。
图3示出了3-D打印的器具壳体300的立体图。器具壳体可包括具有用于模制另一种材料的适当或合适特性的任何材料。例如,如果使用器具壳体模制的材料是碳纤维加强聚合物(CFRP),则Invar合金可能是用于模制该材料的合适候选材料,因为其热膨胀系数非常类似于碳纤维的热膨胀系数。在其它情况下,器具结构可以由其它材料组成,包括金属、合金和塑料。器具壳体300中的凹槽302可以具有合适的体积,用于容纳适当量的待模制材料。在另一个示例性实施例中,可以提供器具壳体的上半部,以便在固化期间密封材料。而在其它实施例中,真空和流体通道可以集成到器具壳体300中,以便能够将树脂材料提供给凹槽302,以便于制造材料的过程。在其它实施例中,因为器具壳体300除了模具之外最终可以用作结构部件,所以可以制造器具壳体300的材料的选择也会受适合于最终装配到运输结构中的部件的材料类型的限制。
在一个实施例中,用于CRFP和金属3-D打印模具的粘合剂可以是CFRP本身的基质材料。
进一步包括在图3中的是小表面凹槽304,其已经3-D打印到材料中。因为器具壳体302和待模制的材料最终可以形成用于装配到运输结构中的单个部件,所以在一些实施例中可能希望提供一种机构来使部件粘合到器具壳体300的内部302上。小表面凹槽304的目的是辅助在器具壳体300的内部部分与待模制在器具壳体300中的材料之间提供表面粘合。在其它实施例中,表面凹槽也可以形成在器具壳体的内壁306上,以进一步便于表面粘合过程。在替代实施例中,可以使用其它方法来辅助表面粘合。例如,在插入待模制的材料之前,可以将树脂施加到内表面302上。或者,可以使用夹具、螺钉、螺母和螺栓、钉子、热熔合等将复合材料固定到器具壳体上。
图4示出了其中插入有CFRP的3-D打印的器具壳体的立体图。如上所述,根据模具的构造方式,待模制在器具壳体400内的结构的几何形状404可以设计成顺应器具壳体400的内表面的形状。以这种方式,器具壳体用作模具的一部分以使复合材料成形,该复合材料将固化到部件的一部分中,如下面进一步描述的。
可以使用器具壳体400执行包括复合材料叠层的复合材料加工过程。在该实例中,作为生产部件的第一步骤,碳纤维材料(或其它合适的材料)可以通过叠层过程施加在器具壳体400的内表面上。碳纤维材料可以铺设在器具壳体400上,压缩并固化。
图5示出了组合了材料502与器具壳体504的截面立体图500。材料502和器具壳体504之间的阴影的差异表明该特定实施例中的两个结构具有不同的材料成分,尽管在某些实施例中这样的特征不必是必需的。
图6示出了使用双装配部件600的运输结构中的示例性内门板610的侧视图。在该实施例中,门板包括第一部件606和第二部件608,其中任一个可以被模制或3-D打印。在该示例性实施例中,第一部件606通过任何可用的方法粘合到图3-5中描述的部件600的表面607。第二部件608通过任何可用的方法粘合到图4的部件的表面609(即,图4中的部件的未示出的底部)。因此,内板610可以用在运输结构中,其中碳纤维材料604被恰当放置。应该理解的是,部件与内门板的整合纯粹是为了说明的目的,而图4的部件可用在运输结构的各个部分中的大量实际应用中。
在一个示例性实施例中,叠层使用了预浸渍(“预浸料”)碳纤维层,其被递送到施加有树脂基质的器具壳体400(图4)上。预浸料技术提供了有效的树脂渗透并有助于确保树脂的基本均匀分散。可以将预浸料层施加到器具壳体400上以形成层压堆叠。
在另一个实施例中,干叠层使用干燥的编织纤维片。因此,在叠层完成后,例如通过树脂灌注,可以将树脂施加到干燥层上。在一个替代示例性实施例中,可以使用湿叠层,其中每个层可以用树脂涂覆并在放置后压实。
如上所述,用于模具的顶部壳体或密封件可以被3-D打印并施加在器具壳体400上,以提供将结构502(图5)模制到例如器具壳体400的内部(图4)的几何形状404中的方法。在完成模制过程后,碳纤维材料可以例如真空压实并在炉子中烘烤指定的时间段。
在这些阶段期间使用的特定的模制和树脂灌注过程可以根据诸如模制技术、设计约束和期望制造收益的变量而变化。通常,3-D打印的器具壳体可以与各种复合材料制造技术结合使用,所述技术包括例如树脂传递模制(RTM)、手工叠层、预浸料、片材模制以及真空辅助树脂传递模制(VARTM)。
图7示出了用于生成用在运输结构中的部件的方法的示例性流程图。在702,使用一定几何形状来3-D打印器具壳体,该几何形状最终能够使其作为整体结构的部分进一步用于诸如车辆面板的另一结构内。器具壳体可以被设计用于可能地粘合到随后使用的材料上。在704,施加诸如CFRP或另一种复合材料织物的材料,并使用复合材料加工过程来模制并硬化材料。在706,当复合材料加工完成时,材料粘合到器具壳体并且形成所得的部件,其包括由固化材料和器具壳体组成的整体结构。在708,将整体结构作为部件装配到运输结构中。
在另一个示例性实施例中,首先使用3-D打印的塑料框架作为用于复合材料器具的模板。在复合材料的固化完成后,所得的装配件然后可以用作框架或运输结构的其它部件。图8示出了由增材制造器具上的复合材料织物加强件覆盖物组成的结构的示例。3-D打印技术选择可以由材料要求和打印过程的速度驱使。形成了3-D打印的塑料框架802。有利地,塑料打印过程通常比金属打印过程快25-50倍。使用增材制造的塑料器具的进一步的好处是能够获得更大的部件,因为塑料3-D打印机的构建室通常比金属3-D打印机的构建室大得多。此外,在许多情况下塑料3-D打印机可以打印更光滑的表面。在一个实施例中,使用的材料是丙烯腈-丁二烯-苯乙烯(ABS),一种常见的热塑性聚合物。然而,取决于应用和所需材料的性质,可以使用任何数量的合适材料。
进一步地,在所示的实施例中,CNC泡沫芯806被增材制造并使用粘合剂或其它可用方法联接到塑料框架802。在一个实施例中,框架802和芯806在单次渲染中被共同打印。泡沫芯可以由与塑料框架802相同的材料构成。在另一个实施例中,使用蜂窝板构造代替泡沫芯。应当理解,图8的所示的实施例本质上是示例性的,因为许多材料和形状可以替代地用于本公开的目的。
取决于强度要求和其它因素,各种纤维复合材料织物可用于随后的复合材料加工过程中。一些可能材料的例子包括玻璃纤维、碳纤维、Kevlar以及类似物。在所示的实施例中,玻璃纤维预浸料804覆盖在增材制造的器具上。在一个示例性实施例中,玻璃纤维预浸料层804可包括纤维加强聚合物(FRP)表皮(E玻璃)。也可以使用其它复合材料,包括碳纤维。在FRP上执行叠层。在材料固化之后,由具有框架802与泡沫芯806的ABS器具和覆盖的玻璃纤维复合材料804组成的整体结构然后可以用作运输结构中的部件。
为了节省附加重量和/或为了改善承载能力,根据整体结构的应用和预期用途,3-D打印的器具可包括使用优化拓扑的结构。图9示出了包括形成有内部网格结构的器具的整体结构的示例。塑料器具902包括网格结构,该网格结构设计用于当它被装配为部件时将承受的载荷。包括有泡沫芯或蜂窝板结构906,玻璃纤维加强聚合物904覆盖在器具结构上。这种结构的一个优点包括通过使用网格实现节省塑料材料。
在另一个示例性实施例中,器具可以被增材制造有用于齐平光洁度的凹口。图10示出了具有凹口和带有拓扑优化的器具的整体结构的示例。如图10所示,器具部件1002是3-D打印的,其具有凹口1007,1009和中空部分1008。凹口1007使得围绕器具的玻璃纤维材料的末端区域具有齐平的光洁度。该结构进一步包括具有蜂窝或泡沫填充物的部件1006。另外,为了提供凹口1007,1009(在需要或必需的机械加强处)之一的加强,可以使用CFRP或其它复合材料来为凹口提供局部加强。如前所述,GFRP(或另一种合适的复合材料)的预浸料层可以在器具上覆盖并固化以产生整体结构。
在一些实施例中,可能需要机械夹紧以将复合材料固定到位。图11示出了使用共模制节点的整体结构的示例。如在先前的实施例中,器具壳体1102使用ABS或其它合适的材料增材制造。FRP或其它合适的材料1104镶嵌并固化在器具壳体上。3-D打印的内节点1114与器具共同打印或单独打印并被添加以固定复合材料1104的部分1120的第一侧。类似的,3-D打印的外节点1112插在复合材料的部分1120的第二侧上。复合材料从而被夹紧并固定到器具壳体,并且整个整体结构可以用作运输结构中的部件。在一个示例性实施例中,使用铝共同打印节点以确保强度。然而,其它材料可能同样适合。
在示例性实施例中,AM金属节点可以实现作为用于与整个运输结构相关联的挤压轨道的悬挂拾取点或接口。挤压轨道是吸收能量的轨道结构,其可以实施在车辆上,以使得车辆能够以受控和定向的方式从冲击中吸收能量。导轨可以夹在金属节点之间,金属节点继而可以附接到车辆悬架上。图13中示出了这种布置的例子。在另一个实施例中,机械夹紧可以与真空连接器结合使用以固化复合材料叠层。
图13示出了整体结构1300的示例,该整体结构1300包括夹置在节点之间并通过机械夹具固定的复合材料。结构1300包括上部和下部铝节点1302a-b,它们可以被增材制造。在节点1302b下面是器具壳体1308,其可以使用FDM或另一合适的技术增材制造。在一个实施例中,器具壳体1308由ABS或诸如ULTEM(聚醚酰亚胺)的热塑性塑料构成。
两个可以由GFRP构成的复合材料表皮层1306a和1306b放置在器具壳体1308上方。在它们的末端附近,GFRP层1306a和1306b与节点1302a-b接触。GFRP层1306a和1306b可以在AL节点1302b和FDM器具壳体1308二者的顶部固化。然后可以通过节点1302a夹紧GFRP层1306a-b,节点1302a可以放置在GFRP层1306a和1306b的顶部。
为了确保层1306a和1306b的夹紧,可以采用用于机械紧固的特征1304。该实施例中的特征1304是大开口,其中可以插入螺栓或其它紧固件。紧固件可以提供固定层1306a与b的力,例如通过使用标准螺纹螺栓、螺母-螺栓组合或任何其它合适的机械紧固或夹紧机构。在其它实施例中,夹紧特征可以不同于孔1304,并且可以包括其它类型的紧固件或容纳紧固件的开口。
图13中还示出了来自节点1302b的突起1310。突起包括孔,其被构造成“卡扣配合”到另一个突起1312中,突起1312可以是来自FDM器具壳体1308的突起。在一个实施例中,突起1312是布置在竖直方向上的较长的FDM构件(从视图中被1320b隐藏)突出的渐变突起,其中较大的突起1312位于端部。AL节点1302b可以接触并压靠较长的FDM构件。当AL节点1302b相对于较长的FDM构件向下移动时,压力或力使较大的FDM突起1312卡入到位。在一个实施例中,突起1312可以固定到车辆悬架系统,从而将结构1300紧固到悬架系统。这些技术使得铝夹紧机构与FDM器具连接。
图12示出了说明用于生产部件的示例性过程的流程图,该部件具有在器具壳体上的复合材料以生产用作运输结构中部件的整体结构。在1202,使用合适的3-D打印机,例如FDM 3-D打印机,增材制造塑料器具壳体,例如ABS壳体。因此,在1204,泡沫芯或蜂窝板被3-D打印,并且铝节点也被3-D打印。在一个实施例中,在共同的步骤1202,1204中增材制造的三个结构中,两个或更多结构被共同打印。应该注意,根据实施例和目的,可以使用与所认定的材料不同的材料。
在1206,将器具壳体联接至泡沫芯或邻接泡沫芯。在一些实施例中,其中两个部件被增材制造为单一元件,该步骤不是必须的。在其它实施例中,可以使用适当的粘合剂、螺钉、夹具或其它连接方法。
在1208,将合适的材料(例如GFRP)镶嵌在器具壳体上,并在复合材料加工过程中制备和固化。在一些实施例中,器具壳体和泡沫芯具有粘合装置以粘合到复合材料上。在其它实施例中,可以使用其它粘合机构。例如,在1210,可以以上面关于图11所述的方式使用在1204打印的铝节点将复合材料夹紧到器具壳体。
因此,在1212,所得到的整体结构可以用作运输结构中的部件。在上面讨论的一些实施例中,该结构可以使用网格或其它机械布置,例如CFRP层,以根据结构可能承受的应力提供额外的支撑。器具壳体可被优化并打印有凹口,该凹口用于在需要处放置额外的加强件。在一个实施例中,GFRP与器具结构重叠,但CFRP用在器具壳体上的凹口中以优化用于载荷传递的载荷路径。这些构造还可以使得能够在器具壳体上的凹口/特征中使用单向加强件以及编织加强件(单向的加强件具有在一个方向上的纤维,而编织的加强件具有在0度和90度角度下穿行的纤维)。在运输结构和其它轮式车辆中,载荷传递是在纵向和横向加速过程期间中由不同车轮承担的载荷的变化,所述加速包括制动和减速。运输结构和机械化装配件中也可能涉及其它类型的载荷。剪切载荷是施加到结构元件时引起剪切应力的力。在部件的传递机制决定载荷(包括预期的剪切载荷)的情况下,可能需要使用复合纤维材料、网格和其它结构的加强件。
在其它实施例中,可以使用多材料的器具。例如,器具的某些部分可以用可溶解的材料打印。一旦复合材料重叠并固化,这些部分可以溶解。对于节省重量的机构和在仅需要复合材料壳体的设计中,该技术可能是理想的。在某一部分仅需要复合材料表皮的情况下,可以使用多材料器具。在一个实施例中,可以使用脱模机构(脱模剂,器具表面制备等)使得器具的某些部分在复合材料固化后脱出或变得可用,以实现仅具有复合表皮的部分。
图14A-B示出了使用复合表皮和多材料器具的整体结构1400的示例。参照图14A,可以增材制造包括部件1404和1406的多材料器具壳体。这里,与部件1404不同(部件1404可以是普通热塑性塑料或使用FDM渲染的其它合适材料,或者在一些情况下,它可以是使用一些其它AM技术渲染的金属材料),部件1406可以构成已知的可溶解材料。如上所述,诸如GFRP或CFRP的材料1402或表皮被铺设在的器具壳体上。期望的是,最终的整体结构包括部件1404和1402。然而,部件1406仅用于模制目的,以使材料1402成形并稳定并且以允许其固化。因此,在材料1402固化之后,可以使用常规已知的技术将部件1406溶解掉以产生图14b中的最终整体结构1400。结合本文公开的方法使用这些多材料技术,可以生产越来越多各种各样的结构。
在本公开的另一个方面中,剥离层可以设置在固化的复合材料的表面上以改善粘合剂结合。图15示出了包括复合材料1514(例如GFRP,CFRP以及类似物)的整体结构1500的例子。如在先前的实施例中,增材制造的器具1516用于在叠层过程期间模制复合材料1514以及用于成为正在构建的结构的部件。为了改善固化的复合材料1514与3-D打印的器具1516之间的结合,可以在器具1516和复合材料1514之间布置一层具有合适化学性质的材料,例如剥离层1512。为了在一些实施例中实现精密的效果,可以在复合材料1514上插入另一层剥离层1512。在上层剥离层1512和袋状膜1508之间的是通气装置1510。袋状膜1508可包括用于生成负压的穿通袋的真空连接器。密封剂1502可用于密封袋状膜1508,并且闪蒸带1504可用于将剥离层1512固定到复合材料1514。
在固化完成时,剥离层1512的性质使得固化的复合材料1514从器具1516上移除。剥离层1512可在固化的复合材料1514的表面上留下一定的纹理,这有助于粘合剂结合。在丢弃剥离层1512之后,可以在器具-复合材料界面之间施加粘合剂,从而在器具1516和复合材料1514之间形成牢固的结合。
提供先前的描述是为了使所属领域的任一技术人员能够实践本文中所描述的各个方面。贯穿本公开内容给出的对这些示例性实施例的各种修改对于本领域技术人员而言将是显而易见的,并且本文公开的概念可以应用于用于材料的复合材料镶嵌的其它技术。因此,权利要求不旨在限于贯穿本公开内容给出的示例性实施例,而是与符合语言权利要求的全部范围相一致。贯穿本公开内容所描述的示例性实施例的元件的所有结构和功能等效物都是本领域普通技术人员已知的或者后来为本领域技术人员所公知的,旨在由权利要求书涵盖。此外,无论在权利要求中是否明确地叙述了这样的公开内容,本文所公开的内容都不旨在奉献于公众。在35U.S.C§112(f)或适用司法辖区的类似法律的规定下,将不解释任何权利要求的要素,除非使用短语“方法用于”明确叙述该要素,或者在方法权利要求的情况下,使用短语“步骤用于”来叙述该要素。
Claims (39)
1.一种制造用于运输结构的部件的方法,包括:
三维(3-D)打印器具壳体,所述器具壳体包括被构造成粘合到材料的表面;
使用作为模具的部分的所述器具壳体将所述材料施加在所述表面上;并且
形成包括所述器具壳体和所述材料的整体结构,所述整体结构用于装配为所述运输结构中的部件。
2.根据权利要求1所述的方法,进一步包括,将所述整体结构装配为运输结构中的部件。
3.根据权利要求1所述的方法,其中,所述3-D打印所述器具壳体进一步包括在所述表面上打印粗糙部分以增加与材料的粘合。
4.根据权利要求1所述的方法,其中,所述材料包括复合材料。
5.根据权利要求4所述的方法,其中,所述复合材料包括碳纤维加强聚合物。
6.根据权利要求1所述的方法,其中,所述将所述材料施加到所述表面上包括使用复合材料加工工艺。
7.根据权利要求5所述的方法,其中,所述将所述材料施加到所述表面包括施加具有粘合性质的碳纤维的基质材料以将所述碳纤维固定到所述器具壳体。
8.根据权利要求1所述的方法,其中,所述3-D打印所述器具壳体包括在所述器具壳体中形成空腔,所述表面位于所述空腔内。
9.根据权利要求8所述的方法,其中,所述将所述材料施加到所述表面上包括在所述空腔内镶嵌碳纤维。
10.根据权利要求9所述的方法,其中,额外一部分碳纤维凸出于器具,并联接至所述镶嵌的碳纤维。
11.根据权利要求9所述的方法,其中,额外一部分碳纤维作为桥接区域而联接至所述镶嵌部分。
12.根据权利要求1所述的方法,其中,所述器具壳体包括塑料材料。
13.根据权利要求1所述的方法,其中,所述其中3-D打印所述器具壳体进一步包括3-D打印泡沫芯材料。
14.根据权利要求1所述的方法,其中,所述3-D打印所述器具壳体进一步包括3-D打印蜂窝板。
15.根据权利要求1所述的方法,其中,所述器具壳体包括网格结构。
16.根据权利要求1所述的方法,其中,所述3-D打印所述器具壳体进一步包括在所述器具壳体中形成至少一个凹口,所述凹口被构造成对于所述施加的材料能够获得齐平的光洁度。
17.根据权利要求16所述的方法,其中,所述至少一个凹口用复合材料加强。
18.根据权利要求1所述的方法,进一步包括,至少一个增材制造的节点联接至所述施加的材料。
19.根据权利要求1所述的方法,进一步包括,将加强材料添加到整体结构的区域中。
20.根据权利要求19所述的方法,其中,所述加强材料包括复合纤维材料。
21.根据权利要求1所述的方法,其中,所述器具壳体包括至少一部分可溶解材料。
22.根据权利要求21所述的方法,其中,所述形成所述整体结构进一步包括溶解所述至少一部分。
23.根据权利要求4所述的方法,进一步包括,
将一层或多层剥离层插入到所述器具壳体与所述复合材料之间;
固化所述复合材料;
在固化所述复合材料时移除一层或多层剥离层;并且
使用粘合剂,将所述复合材料的至少一部分与所述器具壳体结合。
24.一种制造用于运输结构的部件的方法,包括:
三维(3-D)打印器具壳体;并且
生产整体结构,包括:
使用所述器具壳体模制复合材料;并且
将所述复合材料固定到所述器具壳体。
25.根据权利要求24所述的方法,其中,所述整体结构可操作用于装配到所述运输结构中。
26.根据权利要求24所述的方法,其中,所述复合材料包括碳纤维加强聚合物。
27.根据权利要求24所述的方法,其中,所述生产整体结构进一步包括施加具有粘合性质的复合基质材料。
28.根据权利要求24所述的方法,其中,所述3-D打印所述器具壳体包括在所述表面上打印粗糙部分以增加与复合材料的粘合。
29.根据权利要求24所述的方法,其中,所述3-D打印所述器具壳体包括在所述器具壳体中形成空腔,所述表面位于所述空腔内。
30.根据权利要求24所述的方法,其中,所述将所述材料施加到所述表面上包括在所述空腔内镶嵌碳纤维。
31.根据权利要求24所述的方法,其中,所述生产整体结构包括使用复合材料加工工艺施加所述复合材料。
32.一种制造用于运输结构的部件的方法,包括:
三维(3-D)打印包括表面的塑料器具壳体;
使用作为模具的部分的所述塑料器具壳体将复合材料施加到所述表面上;并且
形成包括所述塑料器具壳体和所述材料的整体结构,所述整体结构用于装配作为所述运输结构中的部件。
33.根据权利要求32所述的方法,其中,所述器具壳体进一步包括网格或蜂窝结构。
34.根据权利要求32所述的方法,进一步包括,通过多个增材制造的节点夹紧所述施加的复合材料。
35.根据权利要求34所述的方法,其中,所述增材制造的节点包括用于运输结构的挤压轨道的悬挂接口。
36.根据权利要求34所述的方法,进一步包括,使用所述增材制造的节点以夹紧所述施加的复合材料与所述塑料器具壳体。
37.根据权利要求32所述的方法,其中,所述多个节点包括铝。
38.根据权利要求32所述的方法,进一步包括,在所述器具壳体中形成凹口以获得所述施加的复合材料的齐平光洁度。
39.根据权利要求32所述的方法,进一步包括,
将一层或多层剥离层插入到所述复合材料与所述工作壳体的至少一部分之间;
固化所述复合材料;
在固化时移除所述一层或多层剥离层;并且
使用粘合剂将所述复合材料和所述器具壳体的至少一部分结合。
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