CN111873359A - 一种连续纤维芯状复合线材的制备方法及3d打印头 - Google Patents

一种连续纤维芯状复合线材的制备方法及3d打印头 Download PDF

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CN111873359A
CN111873359A CN202010502067.0A CN202010502067A CN111873359A CN 111873359 A CN111873359 A CN 111873359A CN 202010502067 A CN202010502067 A CN 202010502067A CN 111873359 A CN111873359 A CN 111873359A
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韩民峰
张晓军
贾玲玉
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Sting3d Technology Co ltd
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Abstract

一种连续纤维芯状复合线材的制备方法及3D打印头，属3D打印材料技术领域。通过预处理去除外连续纤维表面物质，再将连续纤维浸润在介质溶液中，最后由聚合物包裹经挤出机挤出制成芯层为连续纤维、皮层为聚合物的复合线材。上述连续纤维和聚合物之间相容性好，线材强度高。采用制备的复合线材和打印头，使用常规打印机就可完成连续纤维的3D打印，打印工艺简单，制件成本低。并可以根据不同的连续纤维含量进行调整或更换打印头，以适应不同尺寸的纤维束，具有实用性强、适应范围广的优点。

Description

一种连续纤维芯状复合线材的制备方法及3D打印头
技术领域
本发明涉及3D打印材料技术领域，特别是一种含有连续纤维的复合线材的制备方法和打印设备。
背景技术
皮芯复合结构的3D打印线材是在连续纤维外包裹热塑性树脂或热固性树脂等基体材料形成的二相或多相复合材料，与传统单一的打印材料相比，复合结构的打印线材具有强度高、耐疲劳性好等特点，制成的构件有良好的韧性和耐冲击、耐磨损的性能。
目前，使用复合连续纤维的3D打印方式有两种，一种是将热固性树脂或热塑性树脂在打印头中熔融，使增强纤维浸渍在其中并直接由打印头挤出，固化成型后得3D打印构件；这种方式需要连续长纤维与熔融树脂界面之间保持良好的相容性，并且长纤维要有序排列，否则无规则排列的长纤维降低打印件的强度。第二种方法是采用双头并进，一个打印喷头输送长纤维进行铺层，另一个打印喷头熔融树脂材料并包裹长纤维后堆积成型。中国专利介绍了一种连续纤维增强热塑性树脂基复合材料3D打印方法及打印头，它包括分别设有螺旋齿环的熔融腔与挤出头，熔融腔与挤出头可绕轴线反向旋转，纤维束与熔融的热塑性树脂在反向旋转的搅拌作用下均匀共混，共混体以螺旋状密实缠紧成圆柱丝束，并从挤出头挤出，固化后在打印平台上堆积复合材料模型，从而达到增强模型强度的目的。但是双头打印的3D打印机价格昂贵，而且打印头结构复杂，两者稍不同步就很难保证连续纤维与热塑性聚合物在打印过程中同步挤出。
发明内容
本发明所要解决的技术问题是克服已有技术之缺陷，提供一种连续纤维芯状复合线材的制备方法，通过预处理、浸润、融合成型等步骤将连续纤维和聚合物融合为复合线材，使用复合线材通过常规的3D打印技术即可进行打印。
本发明所述技术问题是以下述技术方案实现的：
一种连续纤维芯状复合线材的制备方法，它包括如下步骤，
a.预处理：将市售的连续纤维浸渍在丙酮溶液中去除外表面物质，经过氢氧化钠溶液清洗，用高浓度酒精高温熏蒸，制成连续纤维；
b.浸润：将所得的连续纤维浸润在介质溶液中，使纤维丝表面充分包裹介质溶液，浸润后在烘箱蒸干，形成处理后的连续纤维；
c.融合制线材：加热聚合物成熔融状态，在挤出机构中用熔融的聚合物包裹步骤b制得的连续纤维并挤出，制成芯层为连续纤维、皮层为聚合物的复合线材。
上述连续纤维芯状复合线材的制备方法，所述连续纤维包括碳纤维、玻璃纤维或金属纤维中的一种；所述步骤b中的介质溶液是按质量百分比份数计的磺化聚对苯二甲酸盐10-40份、淀粉3-20份、NaOH溶液5-10份和蒸馏水50-80份，搅拌均匀，加热溶解形成介质溶液。
上述连续纤维芯状复合线材的制备方法，所述步骤c中的聚合物包括聚偏氟乙烯或聚乳酸。
上述连续纤维芯状复合线材的制备方法，所述挤出机构包括螺杆挤出机、挤出部和模头，所述模头内部设置模腔，螺杆挤出机的底端连接挤出部，挤出部设置在模腔内；所述挤出部为中空的圆环形结构，圆环内侧开有一圈狭缝形成挤出口，连续纤维垂直穿过挤出口；聚合物加热形成熔融状态，在螺杆挤出机的作用下进入挤出部，由挤出口流入模腔；处理后的连续纤维从模头的一端进入模腔经聚合物包裹，从另一端连续挤出成为复合线材。
一种使用连续纤维芯状复合线材的打印头，所述打印头包括相互连通的进料部和打印模头，进料部为内部中空的圆柱状结构，中空部分为料腔，打印模头为圆锥形，前端设置喷嘴；进料部外壁上设置加热套和溢流仓，所述溢流仓套接在进料部外壁，溢流仓包裹的进料部腔壁上开有若干溢流道，溢流道连通料腔和溢流仓。
上述连续纤维芯状复合线材的打印头，所述打印头的料腔内加载复合线材，经过加热套加热，复合线材中的聚合物部分熔融，随着线材不断向下移动，多余的聚合物在挤压力的作用下，通过溢流道向上溢出至溢流仓内；连续纤维和剩余的聚合物通过料腔进入打印模头，由喷嘴挤出堆积固化成型。
上述连续纤维芯状复合线材的打印头，所述加热套为两个，分别设置在溢流仓的上方和下方。
上述连续纤维芯状复合线材的打印头，所述溢流道倾斜向上排列，倾斜角度为30°-75°。
本发明在制备复合线材的过程中首先将连续纤维进行预处理并通过介质溶液浸润，再用处理后的纤维和聚合物融合制备复合线材，浸润后的连续纤维长丝与聚合物的界面具有良好的融合性，增强两者之间的界面结合力，使融合成的复合线材均匀挤出，同时纤维在纵向上均匀分布，有效提高线材的强度。
打印头采用的溢流仓和溢流道，能够精准控制聚合物与连续纤维丝的含量，使打印构件的纤维含量高、力学性能好；同时保证连续纤维与聚合物同步挤出，使连续纤维丝在三维结构中有序排列，提高打印件强度，避免多余的聚合物堆积在喷嘴处，造成打印不畅，影响打印件质量。
采用制备的复合线材和本发明的打印头，使用常规打印机就可完成连续纤维的3D打印，打印工艺简单，打印件的制作成本低。打印时可以根据不同的连续纤维含量进行调整或更换打印头，以适应规格为1K-12K(K为千根)的不同尺寸的纤维束，具有很强的实用性，适应范围广。
附图说明
图1是本发明制备工艺的示意图；
图2是本发明挤出机构的结构示意图；
图3是本发明挤出机构的A-A剖视图；
图4是本发明打印头的结构示意图；
图5是本发明打印头的剖视图。
图中各标号清单为：1、连续纤维，2、浸润池，3、烘箱，4、挤出机构，5、牵引机，6、螺杆挤出机，7、模头，8、聚合物，9、线材，10、挤出部，11、挤出口，12、进料部，13、打印模头，14、喷嘴，15、加热套，16、溢流仓，17、溢流道。
具体实施方式
下面结合附图对本发明作进一步详细说明。
本发明包括含有连续纤维的皮芯复合线材及其制造工艺和使用复合线材的3D打印头，所述皮芯复合线材的芯层是连续纤维、皮层是热塑性树脂的聚合物，其中连续纤维包括具有一定长度的连续的碳纤维、玻璃纤维或金属纤维中的一种。
如图1所示，连续纤维芯状复合线材的制备设备包括顺序连接的预处理池、浸润池2、烘箱3、挤出机构4、牵引机5，制备过程具体工艺步骤如下：
a预处理：将市售的连续纤维浸渍在丙酮溶液中，用于溶解并去除纤维表面的热固性溶剂和粘结剂等物质；再用质量浓度为25％-30％的NaOH溶液清洗纤维，清洗后用浓度为95％上的酒精高温熏蒸，进一步去除连续纤维表面的水分和杂质。
由于市售的连续纤维表面涂有一层保护胶，预处理的过程是将碳纤维的保护层及杂质去除，为后续浸润、融合打下基础。高浓度的氢氧化钠溶液不仅有中和丙酮的作用，还能够使连续纤维表面形成细微凹凸，有利于后续步骤中聚合物和连续纤维有效结合。
b浸润：将预处理后的连续纤维1浸泡在长条形的浸润池2中，浸润池中装有介质溶液。连续纤维充分、完全地浸泡在介质溶液中，并沿浸润池长度方向缓慢移动，使介质能充分包裹在每根纤维丝的表面。所述浸润池的长度为2-3m，连续纤维在浸润池中的牵引速度为0.5-1m/s。浸润后的连续纤维在60℃-150℃的烘箱3内蒸干，形成处理后的连续纤维。
所述介质溶液是按质量百分比份数计的磺化的聚对苯二甲酸盐10-40份、淀粉3-20份、浓度为5％-10％(w/w)的NaOH 5-10份分别加入到50-80份蒸馏水中搅拌均匀，加热溶解形成介质溶液。所述磺化的聚对苯二甲酸盐是由磺基对苯二甲酸乙二脂和磺基对苯二甲酸丁二脂聚合而成。
c融合制线材：处理后的连续纤维进入挤出机构4；加热聚合物成熔融状态，所述聚合物为热塑性树脂，它包括聚偏氟乙烯(PVDF)或聚乳酸(PLA)。熔融的聚合物通过螺杆挤出机6压入模头7，在模头7内聚合物将连续纤维包裹在中间并挤出，形成芯层为连续纤维、皮层为聚合物的复合线材9；线材直径为0.6mm-1.75mm。
制成的线材由牵引机5引导，最后收卷成线材成品。牵引机拉力稳定保证线材平直、均匀。
融合过程中，连续纤维完全浸润在熔融的聚合物中并融合为一体，两相之间形成良好的界面微观结构，界面强度显著提高。形成皮芯结构的复合线材，解决了纤维丝容易断裂、聚合物强度差的问题，两者结合大大提升了线材的强度。
如图2、3所示，所述挤出机构4包括螺杆挤出机6、挤出部10和模头7，所述模头内部设置模腔，模腔一端为连续纤维的进入端，另一端为制成线材的出口端。螺杆挤出机的底端连接挤出部10，挤出部设置在模腔内；所述挤出部的上部中间是实心两侧是中空的管状结构，挤出部下部中空的圆环形结构，圆环内侧开有一圈狭缝形成挤出口11，连续纤维垂直于挤出口。聚合物加热形成熔融状态，在螺杆挤出机6的作用下熔融的聚合物沿两侧的管状结构进入挤出部，充满圆环形结构后从挤出口流入模腔。处理后的连续纤维从模头7的一端进入经聚合物包裹，从另一端连续挤出成为复合线材9。圆环形的挤出口可以增大熔融聚合物与纤维丝的接触面积，使每一根纤维丝上都充分浸润在聚合物中，同时使纤维包裹在聚合物的中间，防止线材中纤维偏移，从而影响线材的质量。
d打印：将制成的线材加载到打印头内，经过加热套加热，线材在移动过程中表面的聚合物熔融，连续纤维和剩余的聚合物从喷嘴挤出，熔融堆积成型，冷却后成为3D打印件。常规3D打印机配合本发明的打印头，装载复合线材，打印过程中只需要调整设置中的速度参数和挤出量参数，采用常规的打印切片软件，即可实现使用常规单头打印机直接进行连续纤维的3D打印，成本低、操作简单。
如图4、图5所示，所述打印头包括进料部12和打印模头13，进料部12设置在打印头的上部，其为内部中空的圆柱状结构，进料部顶端为进料口，进料部中间为料腔；打印头下部为圆锥形的打印模头13。料腔内径为2.0mm，进料部外壁分别设置上、下两个加热套15和溢流仓16；两个加热套分别设置在溢流仓的上方和下方，用于加热料腔内的线材。上加热套用于加热线材，促进聚合物熔融，能够降低挤出阻力起到润滑作用；下加热套进一步加热线材，保证挤出时聚合物呈熔融态。所述溢流仓16为中空结构，套接在进料部外壁。溢流仓包裹的进料部壁上开有若干溢流道17，溢流道连通料腔和溢流仓16。溢流道倾斜向上排列，倾斜角度为30°-75°，溢流道孔径0.5-1.0mm。所述打印模头13底端为喷嘴14，喷嘴直径为0.6-0.9mm。
加载到打印头的线材9从进料口进入料腔，通过上加热套的加热，外层聚合物在高温下逐渐变软、形成熔融状态。随着线材不断向下移动，聚合物不能与连续纤维同量挤出，多余的聚合物在挤压力的作用下，通过溢流道17向上溢出并储存在溢流仓16内。经过下加热套进一步加热，连续纤维和熔融聚合物通过料腔进入打印模头13，由喷嘴14挤出至打印台。通过溢流仓和进料部之间的溢流道，可以使多余的聚合物溢出，控制挤出聚合物的量，能够实现根据打印件的要求精准控制挤出线材的直径，同时使聚合物和连续纤维同步挤出，保证打印件质量。
打印实施例
取6K的碳纤维(直径0.6mm)经过预处理，在介质溶液内浸润，经过100℃烘箱内蒸干成处理后的碳纤维。将处理后的碳纤维进入挤出机构，在碳纤维的表面融合聚乳酸，形成复合线材，线材直径1.6mm。
所述介质溶液为磺化的聚对苯二甲酸盐30份、淀粉15份、浓度为10％的NaOH 5份、蒸馏水60份，混合加热溶解形成。
使用常规3D打印机，根据打印件要求配置打印头。根据聚乳酸的熔融特性设置加热温度，加热套开始升温至设定温度。复合线材经齿轮挤压进入料腔，在上加热套形成的加热区内聚乳酸变化成熔融态，碳纤维在挤压力和聚乳酸熔融的润滑作用下进入下一层加热区，聚乳酸进一步加热成熔融态；最后线材通过直径为0.8mm的喷嘴挤出，至打印平台，冷却后固化成实体轨迹，根据输入打印数控数据，最终在打印平台上形成具有碳纤维的增强构件。

Claims (8)

1.一种连续纤维芯状复合线材的制备方法，其特征在于，它包括如下步骤，
a.预处理：将市售的连续纤维浸渍在丙酮溶液中去除外表面物质，经过氢氧化钠溶液清洗，用高浓度酒精高温熏蒸，制成连续纤维；
b.浸润：将所得的连续纤维浸润在介质溶液中，使纤维丝表面充分包裹介质溶液，浸润后在烘箱蒸干，形成处理后的连续纤维；
c.融合制线材：加热聚合物成熔融状态，在挤出机构中用熔融的聚合物包裹步骤b制得的连续纤维并挤出，制成芯层为连续纤维、皮层为聚合物的复合线材。
2.根据权利要求1所述的连续纤维芯状复合线材的制备方法，其特征在于，所述连续纤维包括碳纤维、玻璃纤维或金属纤维中的一种；所述步骤b中的介质溶液是按质量百分比份数计的磺化聚对苯二甲酸盐10-40份、淀粉3-20份、NaOH溶液5-10份和蒸馏水50-80份，搅拌均匀，加热溶解形成介质溶液。
3.根据权利要求2所述的连续纤维芯状复合线材的制备方法，其特征在于，所述步骤c中的聚合物包括聚偏氟乙烯或聚乳酸。
4.根据权利要求3所述的连续纤维芯状复合线材的制备方法，其特征在于，所述挤出机构包括螺杆挤出机(6)、挤出部(10)和模头(7)，所述模头内部设置模腔，螺杆挤出机的底端连接挤出部(10)，挤出部设置在模腔内；所述挤出部为中空的圆环形结构，圆环内侧开有一圈狭缝形成挤出口(11)，连续纤维垂直穿过挤出口；聚合物加热形成熔融状态，在螺杆挤出机(6)的作用下进入挤出部，由挤出口流入模腔；处理后的连续纤维从模头(7)的一端进入模腔经聚合物包裹，从另一端连续挤出成为复合线材。
5.一种使用权利要求1所述的连续纤维芯状复合线材的打印头，其特征在于，所述打印头包括相互连通的进料部(12)和打印模头(13)，进料部(12)为内部中空的圆柱状结构，中空部分为料腔，打印模头(13)为圆锥形，前端设置喷嘴(14)；进料部外壁上设置加热套(15)和溢流仓(16)，所述溢流仓套接在进料部外壁，溢流仓包裹的进料部腔壁上开有若干溢流道(17)，溢流道连通料腔和溢流仓(16)。
6.根据权利要求5所述的连续纤维芯状复合线材的打印头，其特征在于，所述打印头的料腔内加载复合线材，经过加热套(15)加热，复合线材中的聚合物部分熔融，随着线材不断向下移动，多余的聚合物在挤压力的作用下，通过溢流道(17)向上溢出至溢流仓(16)内；连续纤维和剩余的聚合物通过料腔进入打印模头(13)，由喷嘴(14)挤出堆积固化成型。
7.根据权利要求5所述的连续纤维芯状复合线材的打印头，其特征在于，所述加热套(15)为两个，分别设置在溢流仓(16)的上方和下方。
8.根据权利要求5所述的连续纤维芯状复合线材的打印头，其特征在于，所述溢流道(17)倾斜向上排列，倾斜角度为30°-75°。
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CN114247889A (zh) * 2021-12-03 2022-03-29 深圳市众德祥科技有限公司 一种覆膜3d打印线材、覆膜挤出机及其制备方法
CN114193799A (zh) * 2021-12-10 2022-03-18 永高股份有限公司 一种纤维复合管成型设备的保温机构
CN114193799B (zh) * 2021-12-10 2024-05-24 公元股份有限公司 一种纤维复合管成型设备的保温机构
CN114454513A (zh) * 2021-12-28 2022-05-10 南京航空航天大学 一种连续纤维增强热塑性树脂基复合材料丝材成形装置
CN114874605A (zh) * 2022-05-09 2022-08-09 上海大学 一种连续碳纤维增强热固性树脂预浸丝及其制备方法和应用
CN114874605B (zh) * 2022-05-09 2024-05-14 上海大学 一种连续碳纤维增强热固性树脂预浸丝及其制备方法和应用
CN115351291A (zh) * 2022-09-02 2022-11-18 西安交通大学 一种基于金属丝连续纤维3d打印工艺的电子元件制备方法
CN115416133A (zh) * 2022-09-13 2022-12-02 河南工程学院 利用异形钢纤维的水泥基材料3d打印装置及打印方法
CN115416133B (zh) * 2022-09-13 2023-11-03 河南工程学院 利用异形钢纤维的水泥基材料3d打印装置及打印方法

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