CN109890592A - 具有可变固化装置的增材制造系统 - Google Patents

具有可变固化装置的增材制造系统 Download PDF

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Publication number
CN109890592A
CN109890592A CN201780067672.6A CN201780067672A CN109890592A CN 109890592 A CN109890592 A CN 109890592A CN 201780067672 A CN201780067672 A CN 201780067672A CN 109890592 A CN109890592 A CN 109890592A
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head
light source
matrix
manufacturing system
material manufacturing
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肯尼斯·泰勒
赖安·斯托科特
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Cc3d Ltd
CC3D LLC
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Cc3d Ltd
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    • 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
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • 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
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    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
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    • B29C64/118—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明公开了一种用于增材制造系统的头部。头部可包括：喷嘴，其被配置为排出用纤维增强的基质；以及多个光源，其至少部分地围绕喷嘴。多个光源可被配置为增强基质的固化。多个光源中的至少两个被配置为生成位于不同频谱内的光。

Description

具有可变固化装置的增材制造系统
相关申请的交叉引用
本专利申请要求于2016年4月11日递交的序列No.62/417,709的美国临时申请的优先权的权益。该专利申请的全部内容通过引用并入本文中。
技术领域
本发明总体涉及一种制造系统，并且更具体地，涉及一种具有可变固化装置的增材制造系统。
背景技术
挤出制造是用于生产连续结构的已知方法。在挤出制造期间，将液体基质(例如，热固性树脂或加热的热塑性塑料)推过具有所需横截面形状和尺寸的模具。材料一旦离开模具，则材料固化并硬化成最终形式。在一些应用中，UV光和/或超声波振动用于在液体基质离开模具时加速液体基质的固化。通过挤出制造工艺生产的结构可以具有任何连续长度，同时具有笔直或弯曲的轮廓、一致的横截面形状以及优异的表面光洁度。尽管挤出制造可以是连续制造结构的有效方式，但是所得到的结构可能缺乏某些应用所需的强度。
拉挤成型制造是用于生产高强度结构的已知方法。在拉挤成型制造期间，各个纤维束、股线编织物和/或织物用液体基质(例如，热固性树脂或加热的热塑性塑料)涂覆或以其他方式浸渍并被拉动通过固定模具，在固定模具中，液体基质固化并且硬化成最终形式。与挤出制造一样，在一些拉挤成型应用中，UV光和/或超声波振动用于在液体基质离开模具时加速液体基质的固化。由拉挤成型制造工艺生产的结构具有与挤出结构相同的许多属性，以及具有由于集成纤维而增加的强度。
尽管拉挤成型制造可以是连续制造高强度结构的有效方式，但是所得到的结构可能缺乏某些应用所需的形式(形状、尺寸和/或精度)。另外，常规拉挤制造可能缺乏可以使用的基质类型和/或这些基质的固化速率的灵活性。
所公开的系统旨在解决上述问题和/或现有技术的其他问题中的一个或多个。
发明内容
在一个方面，本发明涉及一种用于增材制造系统的头部。头部包括：喷嘴，其配置为排出用纤维增强的基质；以及多个光源，其至少部分地围绕喷嘴。多个光源可以被配置为增强基质的固化。多个光源中的至少两个被配置为生成位于不同频谱内的光。
在另一方面，本发明涉及一种用于增材制造系统的头部。头部可以包括：喷嘴，其配置为排出用纤维增强的基质；UV光源，其邻近喷嘴；以及至少一个额外光源，其邻近喷嘴。所述至少一个额外光源可以被配置成产生红外光和蓝光中的至少一种。UV光源和至少一个附额外光源可以在不同时间活跃，以在头部的不同侧处产生单独照明区域。UV光源和至少一个额外光源也可以选择性地同时活跃，以产生至少一个重叠照明区域。
在又一方面，本发明涉及一种增材制造系统。增材制造系统可以包括：支撑件，以及头部，其安装至支撑件。头部包括：喷嘴，其配置为排出用纤维增强的基质；以及多个光源，其至少部分地围绕喷嘴。多个光源可以被配置为增强基质的固化。多个光源中的至少两个被配置为生成位于不同频谱内的光。增材制造系统还可以包括控制器，其被配置为调节支撑件和多个光源的操作。
附图说明
图1是公开的示例性制造系统的示意图；
图2是可以与图1的制造系统结合使用的公开的示例性头部的示意图；以及
图3是可以由图1的系统和图2的头部执行的公开的示例性过程的示意图。
具体实施方式
图1示出了示例性系统10，该系统10可用于连续制造具有任何所需横截面形状(例如，圆形、多边形等)的复合结构12。系统10可包括至少支撑件14和头部16。头部16可以联接到支撑件14并由支撑件14移动。在图1所公开的实施例中，支撑件14是能够在制造结构12期间在多个方向上移动头部16的机械臂，使得结构12的所得纵向轴线是三维的。然而，可以想到的是，支撑件14可以替代地是架空龙门架(overhead gantry)，其也能够在制造结构12期间在多个方向上移动头部16。尽管支撑件14被示出为能够进行6轴线运动，但是可以想到，如果需要，也可以使用能够以相同或不同方式移动头部16的任何其他类型的支撑件14。在一些实施例中，驱动器可以将头部16机械地联接到支撑件14，并且可以包括协作移动头部16和/或向头部16供应动力或材料的部件。
头部16可被配置成接收或以其他方式容盛基质材料。基质材料可包括可固化的任何类型的基质材料(例如，液体树脂，例如零挥发性有机化合物树脂；粉末状金属等)。示例性树脂包括热固性材料、单组分或多组分环氧树脂、聚酯树脂、阳离子环氧树脂、丙烯酸酯化环氧树脂、氨基甲酸酯、酯类物质、热塑性塑料、光聚合物、聚环氧化物、硫醇、烯烃、硫醇烯等。在一个实施例中，头部16内的基质材料可以例如通过外部装置(例如，挤出机或其他类型的泵(未示出))而被加压，该外部装置经由对应导管(未示出)流体连接到头部16。然而，在另一个实施例中，压力可以通过类似类型的装置完全在头部16内部产生。在其他实施例中，基质材料可以通过头部16重力进料和/或在头部16内混合。在一些情况下，头部16内的基质材料可能需要保持冷却和/或阴暗，以抑制过早固化；而在其他情况下，由于同样的原因，基质材料可能需要保温。在任一种情况下，头部16可以是特殊配置的(例如，绝热的、冷却的和/或加热的)以满足这些需求。
基质材料可用于涂覆、包裹或以其他方式围绕任何数量的连续增强件(例如，单独的纤维、丝束、粗纱、和/或材料片)，并且与增强件一起构成复合结构12的至少一部分(例如，壁)。增强件可以储存在头部16内(例如，位于单独的内部线轴(未示出)上)或以其他方式穿过头部16(例如，从外部线轴供给)。当同时使用多个增强件时，增强件可以是相同类型的并具有相同的直径和横截面形状(例如，圆形、方形、扁平等)，或者是具有不同直径和/或横截面形状的不同类型的。增强件可包括例如碳纤维、植物纤维、木纤维、矿物纤维、玻璃纤维、金属线、光学管等。应当注意，术语“增强件”意味着包括结构和非结构类型的连续材料，其可以至少部分地包裹在从头部16排出的基质材料中。
根据需要，当增强件位于头部16内时、当增强件被传递到头部16时和/或当增强件从头部16排出时，增强件可以暴露于(例如，涂覆有)基质材料。基质材料、干燥增强件、和/或已经暴露于基质材料的增强件(例如，湿润的增强件)可以以本领域技术人员显而易见的任何方式输送到头部16中。
基质材料和增强件可以经由至少两种不同的操作模式从头部16排出。在第一操作模式中，当头部16由支撑件14移动以产生结构12的三维形状时，基质材料和增强件被从头部16挤出(例如，在压力和/或机械力下推动)。在第二操作模式中，至少增强件被从头部16拉出，使得在排出期间，在增强件中产生拉伸应力。在这种操作模式中，基质材料可以粘附到增强件且从而也可以与增强件一起从头部16拉出，并且/或者基质材料可以在压力下与拉出的增强件一起从头部16排出。在第二操作模式中，当基质材料被从头部16拉出时，增强件中产生的张力可以增加结构12的强度，同时还允许更大长度的无支撑材料具有更直的轨迹(即，张力可以克服重力以提供对于结构12的无支撑物支撑)。
增强件可以由于头部16移动远离锚定点18而从头部16拉出。特别地，在结构形成开始时，一段基质浸渍增强件可以从头部16拉出和/或推出、沉积到锚定点18上并固化，使得排出的材料粘附到锚定点18。此后，头部16可以移动远离锚定点18，并且该相对移动可以使得增强件从头部16拉出。应该注意的是，如果需要，可以辅助增强件穿过头部16的移动(例如，经由内部供给机构)。然而，增强件从头部16的排出速率可主要是头部16和锚固点18之间的相对运动的结果，使得在增强件内产生张力。可以设想，锚固点18可以移动远离头部16，而不是头部16移动远离锚定点18。
一个或多个固化增强器(例如，一个或多个光源、超声波发射器、激光器、加热器、催化剂分配器、微波发生器等)20可以安装在头部16附近(例如，在头部16内、头部16上和/或尾随头部16)，并且被配置成当从头部16排出基质材料时增强基质材料的固化速率和/或质量。可以控制固化增强器20以在结构12的形成期间选择性地将结构12的内表面和/或外表面暴露于能量(例如，光能、电磁辐射、振动、热、化学催化剂或硬化剂等)。能量可以提高在基质材料内发生的化学反应的速率、烧结材料、硬化材料、或以其他方式使材料在其从头部16排出时固化。
可以提供控制器22，并且控制器22与支撑件14、头部16以及任何数量和类型的固化增强器20通信地联接。控制器22可以实施有单个处理器或多个处理器，处理器包括用于控制一个或多个系统10和/或12的操作的装置。控制器22可以包括一个或多个通用或专用处理器或微处理器。控制器22还可以包括储存器或者与存储器关联用于储存数据，例如设计限制、性能特征、操作指令、基质特征、增强件特征、结构12的特征、以及系统10的每个部件的相应参数。各种其他已知电路可以与控制器22相关联，包括电源电路、信号调节电路、螺线管/马达驱动器电路、通信电路和其他适当的电路。此外，控制器22可以能够经由有线和/或无线传输与系统10的其他部件通信。
一个或多个映射可以存储在控制器22的存储器中并在结构12的制造期间使用。这些映射中的每一个可以包括呈查找表、图表和/或等式形式的数据集合。在所公开的实施例中，控制器22使用这些映射来确定固化增强器20、相关基质和/或相关增强件在结构12内不同位置处的所需特征。除此之外，这些特征可包括待在结构12内的特定位置处排出的增强件和/或基质的类型、数量、和/或配置、和/或所需固化的量、强度、形状和/或位置。然后，控制器22可以将支撑件14的操作(例如，头部16的位置和/或定向)和/或材料从头部16的排出(材料类型、所需的材料性能、材料的交联要求、排出速率等)与固化增强器20的操作关联，使得结构12以所需的方式生产。
在图2所示的实施例中，多种不同类型的发光固化增强器20连接到头部16(例如，围绕喷嘴尖端24)，并由控制器22调节。例如，第一固化增强器20a可以是UV光源；第二固化增强器20b可以是红外光源；第三固化增强器20c可以是蓝光光源，并且第四固化增强器20d可以产生位于另一种频谱中的光。这些固化增强器20中的每一个可以选择性地通电(例如，通过控制器22)至特定水平，从而在任何给定时间实现从头部16排出的特定基质材料的所需固化性质。
在一些实施例中，可以同时使用多种不同的固化增强器20，以产生固化能量混合源。例如，当排出较大直径、圆形横截面、多纤维和/或总体不透明的材料(例如，基于碳纤维的复合材料)时，所有固化增强器20可以由控制器22同时和/或以最大输出水平激活。然而，当排出较小直径、扁平横截面、单纤维和/或总体透明的材料(例如，基于玻璃纤维的复合材料)时，可以通过控制器22将仅仅一种或两种类型的固化增强器20激活至较低程度。在这些实施例中，可能需要使固化增强器20中一个或多个聚焦和/或瞄准，使得由这些源产生的能量以所需图案重叠在结构12上(图3中所示)。一个或多个可调节透镜26和/或其他装置可用于此目的。
在结构12远离头部16轴向生长超过预定长度之前，由活跃固化增强器20的任何组合产生的能量量可足以固化复合材料中的基质。在一个实施例中，在轴向生长长度等于基质涂覆增强件的外直径之前，结构12完全固化。
图3示出了可由固化增强器20产生的光能量的示例性图案，当基质从头部16排出时，固化增强器20可用于固化结构12内的基质材料。图3将在以下部分中更详细地讨论，以进一步示出所公开的概念。
工业适用性
所公开的系统可用于连续制造具有任何所需横截面形状、长度、密度和/或强度的复合结构。复合结构可包括任何数量的呈相同或不同类型、直径、形状、配置和组成的不同增强件，和/或任何数量和类型的不同基质。另外，所公开的系统可以实现与各种不同的喷嘴尖端24一起使用并且实现对各种排放材料的可调节固化。现在将详细描述系统10的操作。
在制造事件开始时，关于所需结构12的信息可以加载到系统10中(例如，加载到控制器22中，该控制器22负责调节支撑件14、头部16和/或一个或多个固化增强器20的操作)。该信息可以尤其包括尺寸(例如，直径、壁厚、长度等)、轮廓(例如，轨迹)、表面特征(例如，脊尺寸、位置、厚度、长度；凸缘尺寸、位置、厚度、长度等)、连接几何形状(例如，联接部、三通、接头等的位置和尺寸)、特定位置基质规定、特定位置增强件规定、所需固化速率、固化位置、固化形状、固化量等。应当注意，如果需要，该信息可以替代地或另外地在制造事件期间在不同时间和/或连续地加载到系统10中。
基于部件信息，特定喷嘴尖端24和/或固化增强器配置可以连接到头部16，并且一个或多个不同(例如，不同尺寸、形状和/或类型)的增强件和/或基质材料可被选择性地安装在系统10内和/或连续地供应到喷嘴尖端24中。例如，配置成排出总体透明的玻璃纤维材料扁平带的喷嘴尖端24或者配置成排出总体不透明的碳纤维圆形丝束的喷嘴尖端24可以连接到头部16。在一些实施例中，增强件还可以需要连接到拉动机器(未示出)和/或连接到安装固定装置(例如，连接到锚定点18)。基质材料的安装可以包括填充头部16和/或将挤出机(未示出)联接到头部16。然后，头部16可以在控制器22的调节下由支撑件14移动，以使得基质涂覆增强件抵靠对应锚固点18放置或者放置在对应锚固点18上。
然后，可以选择性地激活固化增强器20(例如，通过控制器22打开/关闭、瞄准、重叠和/或强度调节)，以使围绕增强件的基质材料硬化，从而将增强件粘合到锚定点18。参考上面提供的实施例，可能只需要以较低水平操作的固化增强器20a来充分固化总体透明的玻璃纤维扁平带，而可能需要以较高水平操作的固化增强器20b-d来充分固化总体不透明的碳纤维圆形丝束。
图3示出了在复合材料的排出期间可以在喷嘴尖端24的尖端端部周围产生的示例性能量图案。可以通过单独或同时地选择性地激活特定固化增强器20来产生这些图案，使得对应照明区域在某种程度上重叠。例如，第一照明区域28a可以具有大致圆形的形状，并且可以通过激活第一固化增强器20a而形成；第二照明区域28b也可以具有大致圆形的形状，并且可以通过激活第二固化增强器20b来形成；第三照明区域28c也可以具有大致圆形的形状，并且可以通过激活第三固化增强器20c而形成；并且第四照明区域28c也可以具有大致圆形的形状，并且可以通过激活第四固化增强器20d来形成。另外，可以通过同时激活固化增强器20a-d中的两个或多个来产生任何数量的不同混合照明区域28f。混合照明区域28f可以具有一系列不同的形状、尺寸和强度，这取决于同时激活和重叠的固化增强器20的数量和/或基于可调节透镜26的瞄准。
在一些实施例中，协调头部16与由固化增强器20产生的照明区域28的位置的角度对准可能是有益的。特别地，当头部16在材料排出期间由支撑件14移动时，排出材料可以仅从头部16的一侧(例如，从与头部16的轨迹相反的一侧)出离。如果该侧未与所需的照明区域28对准(例如，如果排出材料未通过所需的照明区域28)，则可能不会适当地发生排出材料的固化。因此，应注意确保排出材料穿过指定的照明区域28。
可以使用多种方法来确保排出材料穿过指定的照明区域28。在一个示例中，头部16可以旋转(例如，通过支撑件14)，使得排出材料与特定的照明区域28成角度地对准(例如，使得特定的固化增强器20或一组固化增强器20位于头部16的出离侧)。在另一个示例中，可以使用透镜26来瞄准由固化增强器20产生的光能，使得特定的照明区域28放置在排出材料上方。在又一个示例中，固化增强器20本身可以围绕位于在头部16的端面处的喷嘴尖端24移动(例如，通过相应的致动器绕中心轴线枢转)。如果需要，也可以实施其他方法。
然后，可以使用部件信息来控制系统10的操作。例如，可以从头部16(与基质材料一起)拉出和/或推出增强件，同时控制器22选择性地使支撑件14以期望的方式移动头部16，使得所得结构12的轴遵循期望的轨迹(例如空间自由无支撑3D轨迹)。另外，在从喷嘴尖端24排出材料期间，固化增强器20可以由控制器22选择性地激活和/或调节到特定位置和/或定向(例如，经由相应的致动器)，使得来自一个或多个固化增强器20的相应量能量被位于所需位置并呈所需形状的排出材料吸收。例如，控制器22可以基于从喷嘴尖端24排出的连续增强件的直径、形状、数量和不透明度中的至少一个来选择性地激活或调节一个或多个固化增强器20a-20d。一旦结构12已经生长到期望的长度时，结构12可以以任何期望的方式从头部16断开(例如，切断)。在一些实施例中，可以对特定于锚固过程的固化增强器20进行调节并且这些调节不同于在结构12的一般制造期间进行的调节。控制器22可以基于正在进行的制造过程的阶段而自动地实现这些不同的调节。
对于本领域技术人员显而易见的是，可以对所公开的系统和头部进行各种修改和改变。考虑到所公开的系统和头部的说明书和实践，其他实施例对于本领域技术人员来说是显而易见的。说明书和示例旨在仅被视为是示例性的，真实范围由所附权利要求及其等同物表示。

Claims (20)

1.一种用于连续制造系统的头部，包括：
喷嘴，其配置为排出用纤维增强的基质；以及
多个光源，其至少部分地围绕喷嘴并且被配置为增强所述基质的固化，其中，所述多个光源中的至少两个被配置生成处于不同频谱内的光。
2.根据权利要求1所述的头部，其中，所述不同频谱中的至少一个包括UV光。
3.根据权利要求2所述的头部，其中，所述不同频谱中的另一个包括红外光和蓝光中的至少一种。
4.根据权利要求1所述的头部，其中，所述多个光源在不同时间活跃以在所述头部的不同侧处产生单独照明区域。
5.根据权利要求4所述的头部，其中，所述多个光源选择性地同时活跃以产生至少一个重叠照明区域。
6.根据权利要求5所述的头部，其中，所述多个光源的激活与所述基质和纤维的排出协调。
7.根据权利要求6所述的头部，其中，所述多个光源仅在所述头部的所述基质和纤维出离自的一侧活跃。
8.根据权利要求1所述的头部，还包括至少一个透镜，所述透镜被配置为瞄准来自所述多个光源的光能。
9.根据权利要求1所述的头部，其中，所述纤维是连续的。
10.一种用于增材制造系统的头部，包括：
喷嘴，其配置为排出用纤维增强的基质；
UV光源，其邻近所述喷嘴；以及
至少一个额外光源，其邻近所述喷嘴，所述至少一个额外光源被配置成产生红外光和蓝光中的至少一种，
其中：
所述UV光源和所述至少一个额外光源在不同时间活跃以在所述头部的不同侧处产生单独照明区域；以及
所述UV光源和所述至少一个额外光源也选择性地同时活跃以产生至少一个重叠照明区域。
11.根据权利要求10所述的头部，其中，所述UV光源和所述至少一个额外光源仅在所述头部的所述基质和纤维出离自的一侧活跃。
12.一种增材制造系统，包括：
支撑件；
头部，其安装在所述支撑件上，包括：
喷嘴，其配置为排出用纤维增强的基质；以及
多个光源，其至少部分地围绕所述喷嘴并且被配置为增强所述基质的固化，其中，所述多个光源中的至少两个被配置为生成位于不同频谱内的光；以及
控制器，其被配置为调节所述支撑件和所述多个光源的操作。
13.根据权利要求12所述的增材制造系统，其中，所述不同频谱中的至少一个包括UV光。
14.根据权利要求13所述的增材制造系统，其中，所述不同频谱中的另一个包括红外光和蓝光中的至少一种。
15.根据权利要求12所述的增材制造系统，其中，所述控制器被配置为在不同时间选择性地激活所述多个光源以在所述头部的不同侧处产生单独照明区域。
16.根据权利要求15所述的增材制造系统，其中，所述控制器还被配置为选择性地同时激活所述多个光源以产生至少一个重叠照明区域。
17.根据权利要求16所述的增材制造系统，其中，所述控制器被配置为使所述多个光源的激活与所述基质和纤维的排出协调。
18.根据权利要求17所述的增材制造系统，其中，控制器被配置为将所述多个光源的特定组合定向在所述头部的所述基质和纤维出离自的一侧。
19.根据权利要求12所述的增材制造系统，还包括至少一个透镜，所述透镜被配置为瞄准来自所述多个光源的光能。
20.根据权利要求12所述的增材制造系统，其中，所述纤维是连续的。
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