CN109927263A - 长纤维增强热塑性长丝 - Google Patents

长纤维增强热塑性长丝 Download PDF

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CN109927263A
CN109927263A CN201811425255.7A CN201811425255A CN109927263A CN 109927263 A CN109927263 A CN 109927263A CN 201811425255 A CN201811425255 A CN 201811425255A CN 109927263 A CN109927263 A CN 109927263A
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method described
extrudate
thermoplastic
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M·西莫宁
L·C·桑切斯奎诺恩斯
W·R·罗杰斯
R·杰尔杰伊
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GM Global Technology Operations LLC
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    • B29C48/265—Support structures or bases for apparatus, e.g. frames
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    • B29C48/266—Means for allowing relative movements between the apparatus parts, e.g. for twisting the extruded article or for moving the die along a surface to be coated
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    • B29C48/25—Component parts, details or accessories; Auxiliary operations
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    • B29C48/395—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders
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    • B29C48/78—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling
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    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
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Abstract

一种制造长纤维增强热塑性长丝的方法，包括将纤维材料和热塑性材料的混合物置于挤出机装置的料斗中，并将该混合物引入到挤出机中并通过拉伸流动模头以保持较长的纤维长度。从拉伸流动模头中，使混合物通过拉延模以产生长纤维增强长丝。

Description

长纤维增强热塑性长丝
技术领域
与示例性实施例相一致的装置涉及一种制造3D打印所使用的材料的方法。更具体地，与示例性实施例相一致的装置涉及一种制造长纤维增强热塑性长丝的方法。
背景技术
本部分中的陈述仅提供与本发明相关的背景信息，并且构成或不构成现有技术。
在产品开发的原型设计中，3D打印被认为是在零件进入开发制造阶段之前创建零件的快速，有效的手段。
虽然在测试零件的形状和适合性以确保任何产品在绿色生产之前不需要进行设计和工程调整的方面，3D打印是一种可行的技术，但使用该技术也存在缺点。
这些缺点包括可用于制造零件的材料种类有限，以及零件的物理特性是否能提供与其预期应用相关的有用信息的问题。
在传统的3D打印中，所选择的材料是热塑性塑料，因为其可以沉积在熔融层中以形成最终部件。然而，由热塑性材料制成的部件具有微孔隙率和显著各向异性的趋势，这种趋势会限制部件的功能性和机械性能。开发更简单的工具或工艺来改善这些存在于3D打印所使用的热塑性材料中的功能的及机械的缺陷将是有用的。
发明内容
通过提供制造3D打印所使用的材料的方法，一个或多个示例性实施例解决上述问题。更具体地，与示例性实施例相一致的设备涉及一种制造长纤维增强热塑性长丝的方法，在其它应用中该长丝可用于3D打印。
根据示例性实施例的一个方面，制造用于3D打印的长纤维增强热塑性长丝的方法包括将含纤维的材料与热塑性材料的混合物置于挤出机装置的料斗中。该示例性实施例的另一方面包括将该含纤维的材料与热塑性材料的混合物引入到挤出机装置中。仍然根据该示例性实施例的另一方面包括使该含纤维的材料与热塑性材料的混合物通过拉伸流动模头。该示例性实施例的另一方面包括通过至少一个成型模头挤出该含纤维的材料与热塑性材料的混合物以产生长纤维长丝挤出物。
并且该示例性实施例的另一方面，其中该挤出机装置是单螺杆挤出机。并且另一方面，其中该挤出机装置是低压缩和低剪切挤出机。并且再一方面包括在与该热塑性材料混合之前切碎该含纤维的材料。
仍然根据该示例性实施例的另一个方面，其中该热塑性材料是颗粒形式。根据示例性实施例的另一方面，其中该含纤维的材料是切碎的增强尼龙。并且示例性实施例的另一方面包括通过第二拉伸模头从至少一个成型模头中拉出该长纤维长丝挤出物。
本示例性实施例的再一方面，其中，所述的至少一个成型模头还包括第一挤出物直径，并且该第二拉伸模头具有小于该第一挤出物直径的第二挤出物直径。并且该示例性实施例的另一方面包括通过至少一个模头在挤出之后冷却该长纤维长丝挤出物。并且另一方面包括用于3D打印的长纤维增强热塑性长丝，该长丝具有0.3mm至10mm的平均纤维长度，该长丝使用与示例性实施例相一致的制造长纤维增强热塑性长丝的方法来制造。
通过参考以下描述和附图，本发明的其它特征、方面和优点将变得显而易见，其中相同的附图标记表示相同的部件、元件或特征。
附图说明
通过参考在下文中描述的附图，将更好地理解本示例性实施例，其中：
图1A是根据示例性实施例的系统组件和工艺的图示；
图1B是根据示例性实施例的挤出装置的图示；
图1C是根据示例性实施例的方面的拉伸流动模头的图示；
图2是根据示例性实施例的制造用于3D打印的长纤维增强热塑性长丝的方法的流程图图示；以及
图3是纤维增强材料中增强纤维的长度与机械性能之间的关系的图示。
具体实施方式
以下描述本质上仅是示例性的，并不旨在限制本发明，应用或其用途。
图1A提供了根据示例性实施例的挤出机装置10和制造长纤维热塑性长丝的方法的示意图。用于这种方法的原料14通常由热塑性聚合物和长增强纤维组成。该原料14可能是单独的组分或者该热塑性聚合物可能已经含有长增强纤维(一种热塑性复合材料)。通过料斗12或如重量式计量进料器的更先进进料系统将原料14送入到挤出机装置10中。然后将该材料在挤出机中均化，目的是使纤维断裂最小化。然后，材料通过挤出机装置10末端的模头24形成，目的也是使纤维断裂最小化。然后通过模头24中的一个或多个孔从挤出机装置10中挤出和/或拉出挤出物30。在一个或多个可选的拉延模40之前和/或之后，受控制的加热/冷却设备35在挤出物30离开挤出机设备10之后控制其温度。将该方法生产的单根长丝或多根长丝45收集在卷轴上。
原料14是热塑性聚合物和增强纤维的组合物。这种材料可以是含有热塑性聚合物和增强纤维的预组合材料，或者是单独的聚合物和纤维，亦或者是聚合物和纤维的组合。该预组合材料的可能形式可以是但不限于切碎的废料(例如，片状或颗粒状)或长纤维颗粒(例如一定长度的拉挤物，推压物或颗粒，并且纤维长度约为5-25mm)。混合物14的热塑性聚合物以颗粒，树脂，微粒，滚花，片材和/或粉末的形式提供。纤维的可能形式包括连续的或切碎的未使用过的(原始制造)，或回收的(例如，后处理/消费后，从聚合物基质中提取的)。
废料可以包括诸如但不限于在原始部件制造过程中生产的模制热塑性塑料或纤维增强塑料(FRP)部件或装饰件等物品。原始的FRP材料可以包括连续的(例如，编织的，有饰带镶缀的或单向的)或离散的(例如，长的或短的)热塑性基质中的纤维。通过粉碎和/或研磨工艺加工废料(未示出)以产生小尺寸的材料(例如，碎片～5-25mm)以便送入到挤出机。该碎片由聚合物和纤维组成。
材料可以由热塑性聚合物和增强纤维组成。热塑性聚合物(基质)可以包括但不限于：聚酰胺(PA)，聚醚醚酮(PEEK)，聚醚酮(PEK)，聚苯硫醚(PPS)，聚醚砜(PES)，热塑性聚氨酯(TPU)，聚丙烯(PP)，其共聚物，及其组合。增强纤维可以包括但不限于：碳纤维，玻璃纤维，玄武岩纤维，对位芳族聚酰胺纤维，间位芳族聚酰胺纤维，聚乙烯纤维，及其组合。纤维填充量可以为10重量％至最多60重量％，更具体为15至50重量％，更具体为20至45重量％。
图1B提供了根据示例性实施例的用于制造3D打印所使用的长纤维热塑性复合长丝的挤出机装置10的附加部件的示意图。挤出机装置10目的在于减轻纤维断裂/磨损。用于限制纤维断裂的示例性挤出机类型可以包括但不限于低剪切或低压缩类型。此外，它可以采用单螺杆，切向双螺杆，非啮合双螺杆，锥形双螺杆或往复式单螺杆(巴斯捏合机)设计。调整每个螺钉的具体设计以使纤维磨损最小化。来自挤出机装置10的挤出物30的进料可以是连续的，或者挤出机装置10可以是往复式的，其中熔融材料的装料在挤出机装置10的末端建立并且当达到特定的装料量时通过出口模头24推出。根据示例性实施例的诸方面的挤出机装置10是单螺杆挤出机装置或任何类型的低压缩、低剪切挤出机装置，其不会使原料14内的纤维材料的长度在很大程度上减小。挤出机装置10可以结合现有技术用于混合均化或熔化材料，所述的现有技术可以执行这些功能，同时使纤维断裂最小化(例如，巴斯捏合机)。
挤出机装置10包括将热量产生到挤出机装置10中的加热元件16和监测挤出机装置10的温度的热电偶18。挤出螺杆20设置在挤出机装置10的料筒22内，并且被配置为使得含纤维的材料和热塑性材料的原料混合物14通过料筒22从材料进料斗12被推到料筒22的相反端的至少一个成型模头24中。料筒22和/或挤出螺杆20可以具有收缩或扩张的特征以操纵材料并引起加热和均质化，同时使纤维断裂最小化。
当挤出螺杆20由发动机和带传动系统26驱动时，混合物14在被加热元件16加热的同时被推动通过料筒22，这使得混合物14熔化成为熔融的纤维热塑性复合材料28。含有长增强纤维的熔融热塑性复合材料28最终被迫通过至少一个模头24以形成长纤维长丝挤出物30。所述的至少一个成型模头24是一种使纤维断裂最小化的类型，例如，拉伸流动模头(例如，图1C)。与具有更短和更陡的角度的简单板模头(未示出)相比，拉伸流动模头24可以具有渐变角25以减少纤维断裂。所述的至少一个模头24可以包含单个或多个孔口，用于产生单条或多条挤出物长丝。
根据示例性实施例的诸方面，长纤维长丝挤出物30可以从位于挤出机末端的至少一个成型模头24中通过一个或多个旋转拉延模40拉出，其中所述的至少一个成型模头24具有第一挤出物直径，第二拉延模具有小于第一挤出物直径的第二挤出物直径。使用来自第一成型模头24的拉延模进行将长纤维长丝挤出物30拉至更小直径的操作以进一步对齐挤出物30内的长丝。此外，拉延模40或一系列拉延模都可以使挤出物30固结以降低孔隙率。
在离开挤出机装置10之后，可再次拉伸挤出物30以进一步将直径减小至用于3D打印的所需直径，通常为3.0mm或1.5mm。成型模头24和拉延模40的设计还可以促进长丝直径的连续范围。拉伸过程可以包括在挤出机装置之后附加的加热和/或冷却。拉伸有许多优点。首先，可以增加该至少一个成型模头24的直径，这降低了挤出材料所需的压力和能量。此外，较大的模头直径减少了纤维上的剪切，从而减少了纤维断裂。拉伸长丝还增加了其机械性能，例如强度、刚度、失效应变，使其更适于处理和送入到3D打印机。应当理解，设计挤出机装置10的部件的主要目的是优化每个部件以减少纤维断裂。
现参照图2，提供了根据示例性实施例的制造长纤维增强热塑性长丝的方法的流程图50的图示。该方法开始于将含纤维的材料和热塑性材料的混合物置于挤出机装置的料斗中的方框55。接下来，在方框60处，该方法继续将含纤维的材料和热塑性材料的混合物引入到挤出机装置中，目的在于减轻纤维断裂/磨损。在方框65处，该过程继续将含纤维的材料和热塑性材料的熔融混合物通过拉伸流动模头挤出，并且在方框70处，通过旋转拉延模拉伸长丝以产生长纤维长丝。
使用低压缩，低剪切挤出机装置和拉伸流动模头24的组合允许挤出物30和长纤维增强热塑性长丝45中的长纤维的保留，得到了比典型的短纤维增强3D打印长丝更高的机械性能。
参照图3，提供了纤维长度对机械性能的影响的图示100。随着纤维长度的增加，机械性能，即抗冲击性105，强度110和模量115都得到改善。长纤维热塑性长丝中的纤维是不连续的，并且平均纤维长度可以为0.3至10mm，更具体地为1至5mm，或甚至更优选为2.0至3mm。3D打印长丝的更高机械性能会转化为使用3D打印长丝生产的部件的更高机械性能。
本发明的描述本质上仅是示例性的，并且旨在使不脱离本发明的基本概念的变形落入本发明的范围内。不应将这些变形视为脱离本发明的精神和范围。

Claims (10)

1.一种制造长纤维增强热塑性长丝的方法，包括：
将含纤维的材料和热塑性材料的混合物置于挤出机装置的料斗中；
将所述的含纤维的材料和热塑性材料的混合物引入到所述的挤出机装置中；
使所述的含纤维的材料和热塑性材料的混合物通过所述的挤出机装置；以及
通过拉伸流动模头挤出所述的含纤维的材料和热塑性材料的混合物，以产生长纤维长丝挤出物。
2.根据权利要求1所述的方法，其中所述挤出机装置是单螺杆挤出机。
3.根据权利要求1所述的方法，其中所述挤出机装置是低压缩及低剪切挤出机。
4.根据权利要求1所述的方法，进一步包括在与所述热塑性材料混合之前切碎所述含纤维的材料。
5.根据权利要求1所述的方法，其中所述热塑性材料是颗粒形式。
6.根据权利要求1所述的方法，其中所述含纤维的材料是切碎的可循环使用的模制热塑性材料。
7.根据权利要求1所述的方法，其中所述纤维材料是切碎的增强尼龙。
8.根据权利要求1所述的方法，进一步包括通过第二拉延模从所述至少一个成型模头中拉出所述长纤维长丝挤出物。
9.根据权利要求8所述的方法，其中所述至少一个成型模头进一步包括第一挤出物直径，并且所述第二拉延模具有小于所述第一挤出物直径的第二挤出物直径。
10.根据权利要求1所述的方法，进一步包括通过所述至少一个模头在挤出之后冷却所述长纤维长丝挤出物。
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