CN110114219A - 具有光洁度跟随器的增材制造系统 - Google Patents

具有光洁度跟随器的增材制造系统 Download PDF

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Publication number
CN110114219A
CN110114219A CN201780080414.1A CN201780080414A CN110114219A CN 110114219 A CN110114219 A CN 110114219A CN 201780080414 A CN201780080414 A CN 201780080414A CN 110114219 A CN110114219 A CN 110114219A
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China
Prior art keywords
matrix
material manufacturing
manufacturing system
increasing material
follower
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CN201780080414.1A
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English (en)
Inventor
肯尼斯·泰勒
赖安·C·斯托科特
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Cc3d Ltd
CC3D LLC
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Cc3d Ltd
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Publication of CN110114219A publication Critical patent/CN110114219A/zh
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    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/10—Formation of a green body
    • B22F10/12—Formation of a green body by photopolymerisation, e.g. stereolithography [SLA] or digital light processing [DLP]
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    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/05—Filamentary, e.g. strands
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明公开了一种增材制造系统。增材制造系统可包括基质贮存器，流体连接到基质贮存器的主喷嘴，以及可操作地连接到基质贮存器和主喷嘴中的至少一个的主固化增强器。主固化增强器可以配置成将固化能量导向主喷嘴的尖端。增材制造系统还可包括辅助喷嘴，配置成将辅助喷嘴安装在主喷嘴的尾侧的臂，以及从基质贮存器延伸到辅助喷嘴的通道。

Description

具有光洁度跟随器的增材制造系统
相关申请
本专利申请基于并且要求于2017年1月24日递交的申请号为No.62/449,899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，更具体地，涉及一种具有光洁度跟随器的增材制造系统。
背景技术
挤出制造是用于生产连续结构的已知工艺。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。离开模具时，材料固化并硬化成最终形式。在一些应用中，UV光和/或超声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，具有直的或弯曲的轮廓，一致的横截面形状，和优异的表面光洁度。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工艺。在拉挤成型制造期间，单独的纤维股线、股线穗带和/或编织的织物用液体基质(例如，热固性树脂或加热的热塑性塑料)涂覆或浸渍，并被牵拉通过固定模具，在所述模具处液体基质固化并且硬化成最终形式。与挤出制造一样，UV光和/或超声振动在一些拉挤成型应用中用于当液体基质离开模具时加速液体基质固化。由拉挤成型制造工艺生产的结构具有许多与挤压结构相同的属性，以及由于集成纤维而增加的强度。虽然拉挤成型制造可以是连续制造高强度结构的有效方式，所得结构可能缺少某些应用所需的形式(形状、尺寸和/或精度)和/或表面光洁度。
所公开的系统旨在解决现有技术中的上面提出的问题中的一个或多个和/或其他问题。
发明内容
在一个方面，本公开涉及用于增材制造系统的跟随器。跟随器可包括基质入口通道和连接到基质入口通道的远端的喷嘴。跟随器还可包括位于喷嘴下游的固化增强器，以及设置在喷嘴和固化增强器之间的刮板叶片。
在另一方面，本发明涉及一种增材制造系统。增材制造系统可包括基质贮存器，流体连接到基质贮存器的主喷嘴，以及可操作地连接到基质贮存器和主喷嘴中的至少一个的主固化增强器。主固化增强器可以配置成将固化能量导向主喷嘴的尖端。增材制造系统还可包括辅助喷嘴，配置成将辅助喷嘴安装在主喷嘴的尾侧的臂，以及从基质贮存器延伸到辅助喷嘴的通道。
在又一方面，本发明涉及另一种增材制造系统。该增材制造系统可包括可移动的支撑件，连接到可移动的支撑件并配置成排出基质润湿的加强件的打印头，以及连接到打印头后面的尾部的跟随器。跟随器可包括：喷嘴，其配置为仅排出基质；以及位于喷嘴的与打印头相反的一侧的固化增强器。跟随器还可包括设置在喷嘴和固化增强器之间的刮板叶片。
附图说明
图1是示例性公开的制造系统的示意图；
图2是可以与图1的制造系统一起使用的示例性公开的头部的示意图；以及
图3是可以与图2的头部结合使用的示例性公开的跟随器的示意图。
具体实施方式
图1示出了示例性系统10，其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可以包括至少支撑件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，可以设想，支撑件14可以替代地是架空龙门架或混合龙门架/臂，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被示出为能够进行多轴运动，可以设想，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，并且可以包括协作以向头部16移动和/或供应动力或材料的组件。
头部16可以被配置为接收或以其他方式容纳基质。基质可包括可固化的任何类型的材料(例如，液体树脂，诸如零挥发性有机化合物树脂；粉末金属；等)。示例性基质包括热固性材料、单部分或多部分环氧树脂、聚酯树脂、阳离子环氧树脂、丙烯酸酯化环氧树脂、聚氨酯、酯、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，例如通过经由相应的导管(未示出)流体连接到头部16的外部装置(例如，挤出机或其他类型的泵(未示出))，头部16内的基质可以被加压。然而，在另一个实施例中，基质压力可以通过类似类型的装置完全在头部16内部产生。在其他实施方案中，基质可以通过头部重力进料和/或在头部16内混合。在一些情况下，头部16内的基质可能需要保持冷却和/或黑暗，以抑制过早固化；而在其他情况下，由于同样的原因，基质可能需要保持温暖。在任一种情况下，头部16可以是特殊配置的(例如，绝缘的、冷冻的和/或加温的)，以满足这些需求。
基质可用于涂覆、包裹或以其他方式至少部分地围绕任何数量的连续加强件(例如，单独的纤维、丝束、粗纱、带和/或材料片)，并且与加强件一起，构成复合结构12的至少一部分(例如，壁)。加强件可以储存在头部内(例如，在单独的内部线轴上(未示出))或以其他方式穿过头部16(例如，从外部线轴进料)。当同时使用多个加强件时，加强件可以是相同类型，并且具有相同的直径和截面形状(例如，圆形、方形、扁平等)，或者是具有不同直径和/或截面形状的不同类型。加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“加强件”意味着包括结构和非结构二者类型的连续材料，其可以至少部分地包裹在从头部16排出的基质中。
加强件可以暴露于(例如，涂覆有)基质，同时加强件在头部16内，而加强件被传递到头部16(例如，作为预浸材料)，和/或根据需要，加强件从头部16排出。基质、干燥加强件、和/或已经暴露于基质的加强件(例如，润湿的加强件)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。
可以经由至少两种不同的操作模式，从头部16排出基质和加强件。在第一操作模式中，当头部16由支撑件14移动以产生三维形状的结构12时，基质和加强件从头部16挤出(例如，在压力和/或机械力下推动)。在第二操作模式中，至少从头部16拉出加强件，使得在排出期间，在加强件中产生拉伸应力。在这种操作模式中，基质可以粘附到加强件上，从而也可以与加强件一起从头部16拉出，和/或基质可以在压力下与拉出的加强件一起从头部16中排出。在第二操作模式中，在从头部16拉出基质的情况下，加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，张力可以抵抗重力作用，以为结构12提供独立支撑)。
由于头部16远离锚固点18移动，可以从头部16拉出加强件。特别地，在结构形成开始时，基质浸渍的加强件可以被从头部16拉动和/或推动一段长度，沉积到锚固点18上并固化，使得排出的材料粘附到锚固点18。此后，头部16可以远离锚固点18移动，并且相对运动可以使得加强件从头部拉动。应该注意的是，如果需要，可以辅助加强件通过头部16的运动(例如，通过内部进料机构)。然而，来自头部16的加强件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，使得在加强件内产生张力。可以设想，替代头部16远离锚固点18移动或者除了头部16远离锚固点18移动之外，锚固点18可以远离头部16移动。
一个或多个固化增强器(例如，一个或多个光源、超声发射器、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)，并且被配置成当基质从头部16排出时，增强基质的固化速率和/或品质。在结构12的形成期间，可以控制固化增强器20，以选择性地将结构12的内部和/或外部表面暴露于能量(例如，光能、电磁辐射、振动、热、化学催化剂或硬化剂等)。能量可以增加在基质内发生的化学反应的速率、使材料烧结、使材料硬化、或者另外使材料在其从头部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可以实施单个处理器或多个处理器，其包括用于控制系统10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还可以包括用于存储数据的存储器或与存储器相关，数据例如设计限制、性能特征、操作指令、基质特性、加强特性、结构12的特征、以及系统10的每个组件的相应参数。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能够经由有线和/或无线传输与系统10的其他组件通信。
一个或多个映射可以存储在控制器22的存储器中，并且在结构12的制造期间使用。这些映射中的每一个可以包括模型、查找表、图形和/或方程形式的数据集合。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/或结构12内不同位置处的相关加强件的所需特性。这些特征除其他以外可包括在结构12内的特定位置排出的加强件和/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可以关联支撑件14的操作(例如，头部16的位置和/或取向)和/或通过固化增强器20的操作从头部16排出材料(材料类型、所需的材料性能、材料的交联要求、排出速率等)，使得结构12以所需的方式生产。
在图2中详细公开了示例性头部16。头部16除其他以外可以包括一个或多个喷嘴24，所述喷嘴24流体连接到基质贮存器26的下端。任意数量的加强件(表示为如图2中的R)可以容纳在贮存器26的相反的上端处，在发生至少一些基质浸渍(基质在图2中表示为M)之处轴向穿过贮存器26，并且经由任意数目的分离喷嘴24从头部16排出。在所公开的实施例中，使用具有直轴向或会聚尖端的单个主喷嘴24。然而，在多喷嘴应用中，每个主喷嘴24的尖端具有发散形状，以便于将不同的基质涂覆的纤维聚结成复合材料的带或片，这会是有帮助的。
如图2和3所示，头部16可包括跟随器28，其通过枢转臂29连接到头部16的尾侧(例如，主喷嘴24的尾侧)。跟随器28可以是组件的组装件，其协作以产生结构12上的所需表面纹理。这些组件除其他以外尤其可以包括(例如，经由主喷嘴24)与基质贮存器26流体连接的通道30，以及可操作地连接到通道30的远端的至少一个辅助喷嘴32。通道30可以在内部设置有来自头部16的基质(和/或来自另一个源头的不同基质)；并且(一个或多个)辅助喷嘴32，可配置成朝向结构12排出基质，使得基质填充结构12的外表面内的空隙和/或粘附到结构12的外表面。刮板34可与(一个或多个)辅助喷嘴32相关联，并且配置成在从(一个或多个)辅助喷嘴32排出之后并且在通过一个或多个下游固化增强器20固化之前，擦拭基质并从而使基质平滑。
(一个或多个)辅助喷嘴32可被配置成将基质的外部环形层或膜施加到结构12的外表面。例如，每个辅助喷嘴32可包括位于刮板34的上游叶片34a和下游叶片34b之间的一个或多个孔口36，其被配置成将基质喷射或以其他方式排出到结构12的外表面上。下游叶片34b可以与结构12的外表面间隔开所需的距离，并且被配置成擦拭由孔口36所施加的基质，从而将基质压入具有所需和相对恒定厚度的平滑层(例如，在工程公差范围内恒定)。上游叶片34a可以沿着结构12的外表面行进(例如，以直接或近直接接触)，并且被配置成阻止基质传递到更上游的位置。在某些实施例中，可以省略上游叶片34a。如果需要，刮板34的上游叶片34a和下游叶片34b中的一者或两者可以是位置可调节的。
如上所述，头部16可包括固化增强器20，其用于在复合材料从主喷嘴24排出时，至少部分地固化复合材料。在所公开的实施例中，这些固化增强器20直接安装到头部的尖端(例如，到基质贮存器26的下部外表面)。并且还如上所述，附加的下游固化增强器20可以与跟随器28相关联，以至少部分地固化通过(一个或多个)辅助喷嘴32施加到结构12的附加基质。这些固化增强器20可安装在跟随器28的罩38内。罩38可向外张开，并向下游延伸，以将来自附加下游固化加强器20的能量向内朝向结构12反射。
如图3所示，跟随器28的(一个或多个)辅助喷嘴32可包括独特的特征，其配合以适应多维打印表面和/或产生多面结构12。例如，(一个或多个)辅助喷嘴32的孔口36可以通过多个铰接件40彼此连接，这允许孔口36移出直线关系。特别地，铰接件40可以允许相对于彼此枢转、升高和/或降低孔口36。当头部16相对于结构12的打印表面(例如，参见图2)轴向行进时，孔口36的升高/降低可以允许制造C形、V形和/或S形截面的结构12的外基质壳。
一个或多个致动器42(例如，线性和/或旋转致动器)可以与铰接件40相关联，并且被配置为当由控制器22选择性地激励时，自动地对孔口36的布置进行调节。根据需要，这些调节可以包括相对枢转铰接件40和孔36的所产生的升高和降低。例如，控制器22可以基于存储在存储器中的结构12的规格和/或与由支撑件14引起的头部16的移动协调，来选择性地激励一个或多个致动器42。在一个实施例中，可以实施调整以创建结构12的特定表面。在另一个实施例中，可以实施调节，以在不规则打印表面的顶部上排出材料。
如果需要，可以预期(一个或者多个)辅助喷嘴32可以附加地或替代地仅基于与打印表面的相互作用(例如，不使用任何致动器42)来移动。例如，孔口36可以被偏置(例如，经由弹簧或液压)到基线位置，并且当在不平坦表面上打印时，可以移动远离基线位置。
在一个实施例中，图3的刮板34包括围绕孔口36的柔性外膜。膜可以填充有智能流体(例如，磁流变流体)，当智能流体被激励时(例如，当暴露于磁场或电压电势时)，粘度增加并且甚至可以变成固体。控制器22可选择性地去激励流体，以在(一个或多个)致动器42的运动期间使得膜松弛，并且此后重新激励流体，使得膜在由于(一个或多个)致动器42的运动引起的新配置中再次变得刚性。以这种方式，膜可有助于在结构12的制造期间，提供一致的轮廓控制。
如果需要，可以预期附加功能可以包括在跟随器28内。例如，振动和/或震荡引发构件(未示出)可以嵌入在跟随器28内和/或其附近。该构件可以起到减少气泡和/或帮助扩散由主要和/或辅助喷嘴24、32排出的基质的作用。
工业适用性
所公开的系统可用于连续制造具有任何所需截面尺寸、形状、长度、密度和/或强度的复合结构。复合结构可包括相同或不同类型、直径、形状、配置和组成的任何数量的不同加强件，每个加强件涂覆有通常的基质。另外，所公开的头部和跟随器可以允许协同制造具有高公差表面光洁度规格的复杂结构。现在将详细描述系统10的操作。
在制造事件开始时，可以将关于期望结构12的信息加载到系统10中(例如，加载到负责调节支撑件14和/或头部16的操作的控制器22中)。该信息除其他以外可以包括尺寸(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)和光洁度、连接几何形状(例如，联轴器、三通、接头等的位置和尺寸)、特定位置的基质规定、特定位置的加固规定等。应该注意，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。基于组件信息，可以选择性地安装和/或连续地将一个或多个不同的加强件和/或基质提供到系统10中。
可以通过使加强件向下通过基质贮存器26，然后，将加强件穿过存在的任何喷嘴24，来执行加强件的安装。基质的安装可包括在头部16内填充贮存器26和/或将挤出机(未示出)联接到头部16。
然后，可以在控制器22的调节下，通过支撑件14移动头部16，以使涂覆基质的加强件靠着相应的锚固点18或在相应的锚固点18上放置。头部16和/或跟随器28内的固化增强器20可以被选择性地激活，以使加强件周围的基质硬化，从而将加强件结合到锚固点18。
然后，可以使用组件信息来控制系统10的操作。例如，可以从头部16(与基质一起)拉动和/或推动加强件，而支撑件14在固化期间以期望的方式选择性地移动头部16，使得所得结构12的轴线遵循期望的轨迹(例如，自由空间、无支撑的3D轨迹)。当单独的加强件被拉动通过头部16时，加强件可以通过(一个或多个)主喷嘴24，并且在跟随器28下或者通过跟随器28。辅助喷嘴32、下游固化增强器20、(一个或多个)致动器42和/或在刮板34的膜内的智能流体可以由控制器22选择性地激励，使得具有所需表面光洁度和轮廓的外层或表皮被施加到结构12并固化。一旦结构12已经生长到期望的长度，结构12可以以任何期望的方式从头部16断开(例如，切断)。
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变化。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示例性的，真实范围由所附权利要求及其等同物指示。

Claims (20)

1.一种用于增材制造系统的跟随器，包括：
基质入口通道；
喷嘴，其连接到基质入口通道的远端；
位于喷嘴下游的固化增强器；和
刮板叶片，其设置在喷嘴和固化增强器之间。
2.根据权利要求1所述的跟随器，其中：
刮板叶片是第一叶片；并且
跟随器还包括设置在喷嘴上游的第二叶片。
3.根据权利要求1所述的跟随器，其中，所述刮板叶片包括：
柔性外膜；和
设置在柔性外膜内的智能流体。
4.根据权利要求1所述的跟随器，其中，所述喷嘴包括多个孔口。
5.根据权利要求4所述的跟随器，其中，所述多个孔口通过至少一个铰接件以链的形式连接在一起。
6.根据权利要求5所述的跟随器，还包括致动器，所述致动器被配置成移动所述链。
7.根据权利要求1所述的跟随器，还包括围绕所述固化增强器向外张开的罩。
8.根据权利要求1所述的跟随器，还包括枢转臂，所述枢转臂被配置成将所述喷嘴连接到打印头的尾侧。
9.一种增材制造系统，包括：
基质贮存器；
主喷嘴，其流体连接到基质贮存器；
主固化增强器，其可操作地连接到基质贮存器和主喷嘴中的至少一个，主固化增强器配置成将固化能量导向主喷嘴的尖端引导；
辅助喷嘴；
臂，其被配置成将辅助喷嘴安装在主喷嘴的尾侧；和
通道，其从基质贮存器延伸到辅助喷嘴。
10.根据权利要求9所述的增材制造系统，还包括位于所述辅助喷嘴下游的辅助固化增强器。
11.根据权利要求10所述的增材制造系统，还包括设置在所述辅助喷嘴和所述辅助固化增强器之间的刮板叶片。
12.根据权利要求11所述的增材制造系统，其中：
所述刮板叶片是第一叶片；并且
增材制造系统还包括设置在辅助喷嘴上游的第二叶片。
13.根据权利要求11所述的增材制造系统，其中，所述刮板叶片包括：
柔性外膜；和
设置在柔性外膜内的智能流体。
14.根据权利要求10所述的增材制造系统，还包括罩，所述罩围绕所述辅助固化增强器向外张开。
15.根据权利要求9所述的增材制造系统，其中，所述辅助喷嘴包括多个孔口。
16.根据权利要求15所述的增材制造系统，其中，所述多个孔口通过至少一个铰接件以链的形式连接在一起。
17.根据权利要求16所述的增材制造系统，还包括致动器，所述致动器配置成移动所述链。
18.根据权利要求9所述的增材制造系统，其中，所述臂配置成使所述辅助喷嘴相对于所述主喷嘴枢转。
19.根据权利要求9所述的增材制造系统，其中：
主喷嘴配置成排出基质润湿的加强件；并且
辅助喷嘴配置成仅排出基质。
20.一种增材制造系统，包括：
可移动的支撑件；
打印头，其连接到可移动的支撑件，并且配置成排出基质润湿的加强件；和
跟随器，其连接到打印头后面的尾部，跟随器包括：
喷嘴，其配置为仅排出基质；
位于喷嘴的与打印头相反的一侧的固化增强器；以及
设置在喷嘴和固化增强器之间的刮板叶片。
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