CN111132836A - 用于连续制造复合结构的系统、打印头和压实器 - Google Patents

用于连续制造复合结构的系统、打印头和压实器 Download PDF

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CN111132836A
CN111132836A CN201880028271.4A CN201880028271A CN111132836A CN 111132836 A CN111132836 A CN 111132836A CN 201880028271 A CN201880028271 A CN 201880028271A CN 111132836 A CN111132836 A CN 111132836A
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compactor
piston
sensor
printhead
nozzle
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特雷弗·大卫·巴格
肯尼思·莱尔·泰勒
C·H·汉布林
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Continuous Composite Materials Co Ltd
CC3D LLC
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Continuous Composite Materials Co Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/20Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/205Means for applying layers
    • B29C64/209Heads; Nozzles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/10Formation of a green body
    • B22F10/18Formation of a green body by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF]
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
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    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B22F12/00Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50Means for feeding of material, e.g. heads
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B22F12/50Means for feeding of material, e.g. heads
    • B22F12/53Nozzles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C64/00Additive 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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    • B29C64/118Processes 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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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/30Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/38Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
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Abstract

公开了一种用于增材制造打印头的压实器。该压实器可以包括可与增材制造打印头连接的壳体。该压实器还可以包括压实轮和至少一个弹簧,该至少一个弹簧置于壳体中并且被配置成对压实轮施加轴向力。该压实器还可以包括活塞,该活塞可移动以调节壳体与压实轮之间的距离。

Description

用于连续制造复合结构的系统、打印头和压实器
相关申请
本申请基于在2017年12月29日递交的美国临时申请No.62/611,922并且要求该美国临时申请的优先权权益,该美国临时申请的内容通过引用明确地并入在本文中。
技术领域
本公开总体上涉及制造系统、打印头和压实器,更具体地涉及用于增材制造打印头和系统的压实器。
背景技术
挤压制造是用于生产连续结构的已知工艺。在挤压制造期间,液体基质(例如热固性树脂或加热的热塑性塑料)被推动通过具有所需横截面形状和尺寸的模具。该材料在离开模具后固化并硬化为最终形式。在一些应用中,在液体基质离开模具时,使用紫外光和/或超声波振动加速液体基质的固化。由挤压制造工艺生产的结构可以具有任何连续长度,具有直线或曲线轮廓、一致的横截面形状和光滑的表面抛光。尽管挤压制造法可以是一种用于连续制造结构的高效方式,但形成的结构会缺乏一些应用所需的强度。
拉挤制造是用于生产高强度结构的已知工艺。在拉挤制造期间,单独的纤维束、多股编织物和/或机织物涂有或以其它方式浸渍有液体基质(例如热固性树脂或加热的热塑性塑料)并被拉动通过静止的模具,在此,液体基质固化并硬化为最终形式。与挤压制造一样,在一些应用中使用紫外光和/或超声波振动加速流体基质在其离开模具时的固化。由拉挤制造工艺生产的结构具有许多与挤压型结构相同的属性,并且由于集成纤维而具有提高的强度。尽管可以使用拉挤制造法连续制造高强度结构,但形成的结构会缺乏一些应用所需的形式(形状、尺寸、精度和/或表面纹理)。此外,常规的拉挤制造法可能在制造过程中缺乏对固化的精确控制和动态改变复合材料中的材料的能力。此外,拉挤型结构内集成的图案和形状的多样性会受到限制,从而限制形成的结构的可用特性。
最近开发出连续纤维3D打印法(又称CF3DTM)以解决挤压制造和拉挤制造的缺点。CF3D涉及使用嵌入在从可移动打印头排出的基质内的连续纤维。该基质可以是传统的热塑性塑料、粉末状金属、液体树脂(例如,紫外线固化性和/或两组分树脂)、或其中任意一种和其它已知基质的组合。当退出打印头时,头戴式固化增强器(例如,紫外光、超声波发射器、热源、催化剂供给等)被激活以启动和/或完成基质的固化。这种固化几乎立即发生,允许在自由空间制作无支撑的结构。当纤维(特别是连续纤维)被嵌入在该结构内时,可以使该结构的强度倍增超过基质相关的强度。在2016年12月6日颁发给泰勒的美国专利9,511,543中公开了该技术的示例。
尽管与不使用连续纤维强化的制造工艺相比,CF3DTM提供了增加的强度,但是可以对现有系统的结构和/或操作进行改进。所公开的增材制造系统和打印头独特地被配置成提供这些改进和/或解决现有技术的其它问题。
所公开的系统旨在解决上文提出的一个或多个问题和/或现有技术的其它问题。
发明内容
在一方面,本公开涉及一种用于增材制造打印头的压实器。所述压实器可以包括可与所述增材制造打印头连接的壳体。所述压实器还可以包括压实轮和至少一个弹簧,所述至少一个弹簧置于所述壳体中并且被配置成对所述压实轮施加轴向力。所述压实器还可以包括活塞,所述活塞可移动以调节所述壳体和所述压实轮之间的距离。
在另一方面,本公开涉及一种用于增材制造系统的打印头。所述打印头可以包括:基质储存器,所述基质储存器被配置成保持一定量的基质;和喷嘴,所述喷嘴与所述基质储存器的端部连接。所述打印头还可以包括:固化增强器,所述固化增强器被配置成将从所述喷嘴排出的复合材料暴露于固化能量;和压实器,所述压实器位于所述喷嘴和所述固化增强器之间。所述压实器可以被配置成将复合材料在暴露于固化能量之前压实。所述压实器可以具有壳体、压实轮和至少一个弹簧,所述至少一个弹簧置于所述壳体中并且被配置成对所述压实轮施加轴向力。所述压实器也可以具有活塞,所述活塞可移动以调节所述壳体和所述压实轮之间的距离。
在另一方面,本公开涉及一种用于增材制造复合结构的系统。所述系统可以包括:喷嘴,所述喷嘴被配置成排出至少部分地涂覆有基质的连续强化物;支架,所述支架被配置成在排出期间移动所述喷嘴;和压实器,所述压实器与所述喷嘴操作性连接并且可调节以改变对从所述喷嘴排出的所述涂覆有基质的连续强化物施加的压实力。所述系统还可以包括:固化增强器,所述固化增强器被配置成使所述基质暴露于固化能量;和刮刀,所述刮刀被安装在所述压实器和所述固化增强器之间。所述系统还可以包括:传感器,所述传感器被安装在所述喷嘴的与所述压实器相对的一侧并且被配置成生成指示所述复合结构的表面特性的信号;和控制器,所述控制器被配置成基于所述信号选择性地引起对所述压实器的调整。
附图说明
图1为示例性公开的增材制造系统的图解说明;和
图2和图3分别为可以与图1的系统结合使用的示例性公开的打印头的横截面侧视图和端视图说明。
具体实施方式
图1示出示例性系统10,该系统10可用于连续制造具有任意所需横截面形状(例如圆形、矩形或多边形)的复合结构12。系统10可以包括至少一个支架14和头部16。头部16可以与支架14联接并且通过支架14移动。在所公开的图1的实施方式中,支架14为能够在制作结构12期间使头部16沿多个方向移动的机械臂,从而形成的结构12的纵轴(例如,轨迹)是三维的。支架14可以替选地实施为高架起重机架或混合起重机架/臂,其也能够在制作结构12期间使头部16沿多个方向移动。尽管支架14被示出为能够进行6轴移动,但是设想也可以利用能够以相同或不同方式移动头部16的任何其它类型的支架14。在一些实施方式中,驱动部可以将头部16与支架14机械联接,并且包括配合用于移动头部16的部分和/或向头部16供电的部件。
头部16可以被配置成接收或以其它方式包含基质材料。该基质材料可以包括任何类型的可固化基质材料(例如,液体树脂(诸如零挥发性有机复合树脂)、粉末状金属等)。示例性树脂包括:热固性树脂、单组分或多组分环氧树脂、聚酯树脂、阳离子环氧树脂、丙烯酸酯化的环氧树脂、氨基甲酸酯类树酯、酯类物质、热塑性塑料、感光树脂、聚环氧化物、硫醇、烯烃、噻吩等。在一个实施方式中,头部16内的基质材料可以被加压,例如通过借助相应导管(未示出)与头部16流体连接的外部设备(例如,通过挤压机或另一类型的泵-未示出)。然而,在另一个实施方式中,该压力可以完全在头部16的内部由相似类型的设备产生。在另外的其它实施方式中,基质材料可以通过重力被进给到头部16中和/或通过头部16。例如,基质材料可以被进给到头部16中,并且连同一个或多个连续强化物一起被推出或拉出头部16。在一些实例中,头部16内的基质材料可能需要保持冷却和/或黑暗,以抑制过早固化或在排出后以其它方式获得期望的固化速率。在其它实例中,出于类似原因,基质材料可能需要保温。在任一情况下,头部16可以被特殊配置(例如,绝缘型、温度控制型、屏蔽型等)以满足这些需求。
基质材料可用于涂覆任意数量的连续强化物(例如,单独的纤维、丝束(tow)、粗纱、短袜和/或多片连续材料),并与强化物一起构成复合结构12的一部分(例如,壁部)。强化物可以被储存在头部16内(例如,在一个或多个单独的内部卷轴(未示出)上)或以其它方式通过头部16(例如,从一个或多个外部卷轴17(仅在图2中示出)进给)。当同时使用多个强化物时,这些强化物可以为相同的材料成分且具有相同的尺寸和横截面形状(例如,圆形、正方形、矩形等),或者为不同的材料成分、具有不同的尺寸和/或横截面形状。强化物可以包括例如碳纤维、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“强化物”意在涵盖结构型和非结构型连续材料,这些材料至少部分地被装在从头部16排出的基质材料中。
当强化物在头部16内部时、当将强化物被传递到头部16时、和/或当将强化物被从头部16排出时,可以使强化物暴露于(例如,至少部分地涂有)基质材料。可以采用对于本领域技术人员显而易见的任何方式将基质材料、干燥的强化物、和/或已暴露于基质材料的强化物输送到头部16中。在一些实施方式中,在基质材料涂覆连续强化物之前和/或之后,可以将填充材料(例如短纤维)与基质材料混合。
一个或多个固化增强器(例如,紫外光、超声波发射器、激光器、加热器、催化剂分配器等)18可以被安装在头部16附近(例如,在头部16内、在头部16上、或与头部16相邻)并且被配置成在基质材料从头部16排出时提高基质材料的固化速率和/或质量。每个固化增强器18可以被控制成在形成结构12期间使结构12的部分选择性地暴露于能量(例如,紫外光、电磁辐射、振动、热、化学催化剂等)。该能量可以在材料从头部16排出时提高发生在基质材料内的化学反应速率、烧结材料、硬化材料、或以其它方式引起材料固化。在所描述的实施方式中,固化增强器18包括围绕头部16的中心轴均匀分布的多个LED(例如,6个不同的LED)。然而,可设想出于所公开的目的,可以可替选地利用和/或以另一种方式布置(例如不均匀分布)任意数量的LED或其它能量源。由固化增强器18产生的能量的量可足以在结构12远离头部16轴向增长超过预定长度之前固化基质材料。在一个实施方式中,在轴向增长长度变为等于涂有基质的强化物的外径之前,结构12完全被固化。在另一个实施方式中,在轴向增长长度变为等于涂有基质的强化物的外径之前,只有结构12的外壳被固化。
基质材料和/或强化物可以通过至少两种不同的操作模式从头部16排出。在第一种操作模式中,当头部16由支架14移动以在结构12的纵轴内生成三维轨迹时,基质材料和/或强化物被从头部16挤出(例如,在压力和/或机械力下推出)。在第二种操作模式中,至少将强化物被从头部16拉出,从而在排出期间在强化物中产生拉伸应力。在这种操作模式中,基质材料可以粘附到强化物,从而伴随强化物一起也被从头部16拉出,和/或基质材料可以在压力下伴随拉出的强化物一起被从头部16排出。在第二种操作模式中,在基质材料与强化物被从头部16拉出的情况下,在强化物内形成的张力可以提高结构12的强度(例如,通过调整强化物、抑制屈曲、压缩基质、保证分布的强化物负荷等),同时也允许无支撑的结构12的长度更大以具有更直的轨迹。即,在基质材料固化后保留在强化物中的张力可以抵消重力(例如,直接地和/或间接地通过创造与重力相反的力矩)以为结构12提供支撑。
由于头部16移动远离锚定点20,因此可以将强化物从头部16拉出。特别地,在结构形成开始时,可以将一段浸渍有基质的强化物从头部16拉出和/或推出、沉积到锚定点20上并固化,使得排出的材料粘附(或以其它方式联接)到锚定点20。此后,头部16可以移动远离锚定点20,并且相对运动可以导致强化物从头部16拉出。应当注意,如果需要,则可以辅助强化物移动通过头部16(例如,借助内部头部机构)。然而,强化物从头部16的排出速率可以主要为头部16和锚定点20之间的相对运动的结果,从而在强化物内产生张力。可设想,代替或除了使头部16移动远离锚定点20,可以使锚定点20移动远离头部16。
可以设置控制器22并且使其与支架14、头部16和任意数量的固化增强器18通信联接。每个控制器22可以实施为被配置成控制系统10的操作的单个处理器或多个处理器。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还可以包括存储器或与存储器相关联,该存储器用于存储数据,诸如例如系统10的每个部件的设计限制、性能特性、操作指令、工具路径和相应参数。各种其它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、螺线管驱动电路、通信电路和其它合适电路。此外,控制器22可以借助有线传输和/或无线传输与系统10的其它部件通信。
一个或多个映射(map)可以被存储在控制器22的存储器中并且在制作结构12期间被使用。这些映射中的每一个可以包括以查询表、图线和/或等式形式的数据集合。在所公开的实施方式中,这些映射可以被控制器22用来确定产生结构12的期望尺寸、形状和/或轮廓所需的头部16的运动,并与这些运动协调地调整固化增强器18(和/或系统10的其它部件)的操作。
在图2中详细地公开示例性头部16。除了别的之外,头部16可以包括基质储存器24和喷嘴26,该喷嘴26可拆卸地与基质储存器24流体连接。在本示例中,喷嘴26为单路径喷嘴,该单路径喷嘴被配置成排出具有大致圆形横截面的复合材料。然而,头部16的配置可以允许喷嘴26被另一喷嘴(未示出)换出,该另一喷嘴排出具有不同形状(例如,管状横截面、线性横截面、矩形横截面、三角形横截面等)的复合材料。
除了固化增强器18、基质储存器24和喷嘴26之外,头部16还可以包括压实器36。压实器36可以被配置成将涂有基质的强化物在从喷嘴26排出之后且在通过固化增强器18固化之前(和/或期间)压实。
压实器36可以包括压实轮38,借助弹簧40使该压实轮38向涂有基质的强化物偏置。弹簧40可以置于壳体42中并且被配置成借助一个或多个活塞44对压实轮38施加轴向力,该一个或多个活塞44至少部分地延伸到壳体42中。在所公开的实施方式中,压实轮38一般为圆柱形的,相对的端部均放有一个活塞44。每个活塞44可以借助相应的轴承46与压实轮38连接。
在所公开的实施方式中,由弹簧40施加在压实轮38上(随后施加在结构12上)的压实力是可变的。例如,活塞44可以具有在弹簧40和压实轮38之间测量的可调有效长度Le。在所公开的示例中,可通过活塞44与轴承46的螺纹连接调节Le。具体地,可以将活塞44从轴承46(从相关联的轴承壳体)拧出以使Le更长。相反,可以将活塞44进一步拧入轴承46中以使Le更短。当Le变长时,弹簧40可以被压缩更大的量,导致将压实轮38更用力推向湿的强化物的偏置力更大。当Le变短时,弹簧40可以被压缩更小的量,导致将压实轮38更用力推向湿的强化物的偏置力更小。可以根据需要手动地或自动地(例如,借助相关联的致动器,诸如可选的电机48)转动(例如,拧入或拧出)活塞44。
可设想,如果需要,则可以使用其它类型和/或布置的致动器(例如,液压致动器、螺线管等)自动调节Le。例如,相同或附加的螺纹活塞44可以在壳体42内位于弹簧40的相对端。这些活塞将起作用以选择性地将弹簧40推出壳体42并推向压实轮38。
在一些应用中,对于固化的或部分固化的基质材料来说可能的是堆积在压实轮38上。出于该原因,在这些应用中可以将刮刀50附着到压实器36。刮刀50可以实施为刀片,该刀片具有紧邻压实轮38放置(例如在切线取向上)的凿刻尖端52。凿刻尖端52的位置可以是可调节的(例如,相对于喷嘴26的轴线轴向地和/或径向地),从而改变压实轮38上可允许的堆积厚度。在所描述的示例中,通过一个或多个固定螺钉54手动地改变该位置。然而,可设想,其它手动和/或自动调节手段可以为可用的。也可设想,如果需要,则可以用遮光罩或擦拭器增强或替换刮刀50,以减少或抑制树脂在压实轮38上的初始堆积。
在一些实施方式中,压实器36的压实力可以基于在头部16的前(例如,相对于头部16的行进方向)沿检测到的结构12的参数而自动地调节(例如,借助Le的调节)。可以借助一个或多个传感器56检测该参数。传感器56可以是本领域已知的用于检测复合表面的参数的任何类型的传感器。该参数可以包括例如位置、取向、形状、尺寸、材料类型、硬度、量、在头部16相对的一侧的支架的类型等。在所公开的实施方式中,传感器56为激光雷达传感器和雷达传感器之一。然而可设想,可以附加地或可替选地利用另一种类型的传感器(例如,照相机、电流传感器、超声波传感器、红外线传感器、立体光学类型传感器等)检测结构12的参数并生成相应信号。该信号可以被传递到控制器22,该控制器22可以响应地生成相应命令以调节Le和在压实轮38在结构12的先前检测区域上移动时由压实轮38施加的相关压实力。
例如,当检测到结构12的易碎的(直径小的且脆弱的)和/或无支撑的区域时,控制器22可以响应地减小Le。在另一示例中,当检测到突起或过大的表面粗糙度时,控制器22可以响应地增大Le
工业实用性
所公开的系统和打印头可以用于连续制造具有任意所需横截面形状和长度的复合结构。复合结构可以包括类型相同或不同且直径相同或不同的任意数量的不同纤维,和成分相同或不同的任意数量的不同基质。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,加载到负责调整支架14和/或头部16的操作的控制器22中)。除了别的之外,该信息可以包括:尺寸(例如直径、壁厚、长度等)、轮廓(例如轨迹)、表面特征(例如脊部尺寸、位置、厚度、长度;凸缘尺寸、位置、厚度、长度;等)、连接几何结构(例如联轴器、三通、接头等的位置和尺寸)、期望纺织图案、纺织过渡位置等。应该注意,如果需要,则可以替选地或附加地在制造事件过程中在不同时间和/或连续地将该信息加载到系统10中。基于部件信息,可以将一种或多种不同的强化物和/或基质材料选择性地安装和/或连续地供应到系统10中。
为了安装强化物,单独的纤维、丝束和/或丝带可以通过基质储存器24和喷嘴26。在一些实施方式中,强化物还可能需要与拉丝机(未示出)和/或与安装固定装置(例如与锚定点20)连接。基质材料的安装可以包括填充头部16(例如储存器24)和/或将挤出机(未示出)与头部16联接。
然后可以使用部件信息控制系统10的操作。例如,可以将强化物连同基质材料一起从头部16拉出和/或推出。支架14也可以选择性地以期望方式移动头部16和/或锚定点20,使得形成的结构12的轴线遵循期望的三维轨迹。可以在操作期间调节固化增强器18以提供期望的固化条件。一旦结构12增长到期望长度,就可以将结构12从系统10分离。
在头部16的操作期间,控制器可以连续地或周期性地监控正在制造的结构12的表面。例如,控制器22可以将由来自传感器56的信号表示的表面特性(例如,尺寸、形状、位置、粗糙度、压实度等)与期望特性进行比较。然后控制器22可以基于该比较选择性地调节Le(例如,借助电机48的激活)。
对于本领域技术人员来说将显而易见的是,可以对所公开的系统和打印头进行各种修改和变更。通过考虑所公开的系统和打印头的说明书和实践,其它实施方式对于本领域技术人员来说将显而易见。意图将说明书和示例仅视为示例性的,其中真实范围由所附权利要求及其等同方案来指示。

Claims (20)

1.一种用于增材制造打印头的压实器,所述压实器包括:
壳体,所述壳体能够与所述增材制造打印头连接;
压实轮;
至少一个弹簧,所述至少一个弹簧置于所述壳体中并且被配置成对所述压实轮施加轴向力;和
活塞,所述活塞可移动以调节所述壳体与所述压实轮之间的距离。
2.根据权利要求1所述的压实器,其中,所述活塞与所述压实轮螺纹式连接。
3.根据权利要求2所述的压实器,其中,所述活塞与所述压实轮的轴承螺纹式连接。
4.根据权利要求1所述的压实器,其中,所述活塞位于所述至少一个弹簧和所述压实轮之间。
5.根据权利要求1所述的压实器,其中,所述活塞位于所述壳体和所述至少一个弹簧之间。
6.根据权利要求1所述的压实器,还包括致动器,所述致动器被配置成自动地移动所述活塞。
7.根据权利要求1所述的压实器,其中,所述压实轮位于所述增材制造打印头的尾侧。
8.根据权利要求7所述的压实器,还包括刮刀,所述刮刀在所述压实轮的尾侧被安装到所述壳体。
9.根据权利要求1所述的压实器,其中:
所述压实轮为圆柱形;
所述至少一个弹簧包括位于所述压实轮的第一端的第一弹簧、和位于所述压实轮的第二端的第二弹簧;
所述活塞为与所述第一弹簧相关联的第一活塞;并且
所述压实器包括与所述第二弹簧相关联的第二活塞。
10.一种用于增材制造系统的打印头,包括:
基质储存器,所述基质储存器被配置成保持一定量的基质;
喷嘴,所述喷嘴与所述基质储存器的端部连接;
固化增强器,所述固化增强器被配置成将从所述喷嘴排出的复合材料暴露于固化能量;和
压实器,所述压实器位于所述喷嘴和所述固化增强器之间并且被配置成将所述复合材料在暴露于所述固化能量之前压实,所述压实器包括:
壳体;
压实轮;
至少一个弹簧,所述至少一个弹簧置于所述壳体中并且被配置成对所述压实轮施加轴向力;和
活塞,所述活塞可移动以调节所述壳体和所述压实轮之间的距离。
11.根据权利要求10所述的打印头,还包括致动器,所述致动器被配置成选择性地旋转所述活塞。
12.根据权利要求10所述的打印头,还包括刮刀,所述刮刀在所述压实轮和所述固化增强器之间被安装到所述壳体。
13.根据权利要求10所述的打印头,还包括传感器,所述传感器被安装在所述喷嘴的与所述压实器相对的前侧并且被配置成生成指示正在由所述复合材料形成的结构的表面状况的信号。
14.根据权利要求13所述的打印头,其中,所述活塞基于所述信号能够自动移动。
15.根据权利要求13所述的打印头,其中,所述表面状况包括位置、取向、形状、尺寸、材料类型、硬度、量和支架类型中的至少一个。
16.根据权利要求13所述的打印头,其中,所述传感器为激光雷达传感器、雷达传感器、照相机、电流传感器、超声波传感器、红外线传感器和立体光学类型传感器中的一个。
17.一种用于增材制造复合结构的系统,包括:
喷嘴,所述喷嘴被配置成排出至少部分地涂覆有基质的连续强化物;
支架,所述支架被配置成在排出期间移动所述喷嘴;
压实器,所述压实器与所述喷嘴操作性连接并且可调节以改变对从所述喷嘴排出的所述涂覆有基质的连续强化物施加的压实力;
固化增强器,所述固化增强器被配置成使所述基质暴露于固化能量;
刮刀,所述刮刀被安装在所述压实器和所述固化增强器之间;
传感器,所述传感器被安装在所述喷嘴的与所述压实器相对的一侧并且被配置成生成指示所述复合结构的表面特性的信号;和
控制器,所述控制器被配置成基于所述信号选择性地引起对所述压实器的调整。
18.根据权利要求17所述的系统,其中,所述表面状况包括位置、取向、形状、尺寸、材料类型、硬度、量和支架类型中的至少一个。
19.根据权利要求17所述的系统,其中,所述传感器为激光雷达传感器、雷达传感器、照相机、电流传感器、超声波传感器、红外线传感器和立体光学类型传感器中的一个。
20.根据权利要求17所述的系统,其中,所述压实器包括:
压实轮;
弹簧,所述弹簧使所述压实轮向所述涂覆有基质的连续强化物偏置;
活塞,所述活塞可移动以影响所述弹簧的力;和
致动器,所述致动器由所述控制器选择性地激励以移动所述活塞。
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