EP4240701A1 - Ensemble d'extrusion de verre et procédé d'extrusion de verre pour la fabrication directe de produits semi-finis compacts, tridimensionnels et géométriquement définis, et composants constitués de verre - Google Patents

Ensemble d'extrusion de verre et procédé d'extrusion de verre pour la fabrication directe de produits semi-finis compacts, tridimensionnels et géométriquement définis, et composants constitués de verre

Info

Publication number
EP4240701A1
EP4240701A1 EP21811243.1A EP21811243A EP4240701A1 EP 4240701 A1 EP4240701 A1 EP 4240701A1 EP 21811243 A EP21811243 A EP 21811243A EP 4240701 A1 EP4240701 A1 EP 4240701A1
Authority
EP
European Patent Office
Prior art keywords
glass
nozzle
laser
platform
extrusion
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP21811243.1A
Other languages
German (de)
English (en)
Inventor
Jens Bliedtner
Anne-Marie SCHWAGER
Jens Kobelke
Jan Dellith
Andreas Hopf
Volker Reichel
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ernst-Abbe-Hochschule Jena
Leibniz Institut fuer Photonische Technologien eV
Original Assignee
Ernst-Abbe-Hochschule Jena
Leibniz Institut fuer Photonische Technologien eV
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ernst-Abbe-Hochschule Jena, Leibniz Institut fuer Photonische Technologien eV filed Critical Ernst-Abbe-Hochschule Jena
Publication of EP4240701A1 publication Critical patent/EP4240701A1/fr
Pending legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE 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
    • B33Y10/00Processes of additive manufacturing
    • 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
    • B29C64/10Processes of additive manufacturing
    • B29C64/106Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • 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]
    • 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
    • B29C64/295Heating elements
    • 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
    • B29C64/30Auxiliary operations or equipment
    • B29C64/386Data acquisition or data processing for additive manufacturing
    • B29C64/393Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE 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
    • B33Y30/00Apparatus for additive manufacturing; Details thereof or accessories therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE 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
    • B33Y50/00Data acquisition or data processing for additive manufacturing
    • B33Y50/02Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • CCHEMISTRY; METALLURGY
    • C03GLASS; MINERAL OR SLAG WOOL
    • C03BMANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B19/00Other methods of shaping glass
    • C03B19/02Other methods of shaping glass by casting molten glass, e.g. injection moulding
    • C03B19/025Other methods of shaping glass by casting molten glass, e.g. injection moulding by injection moulding, e.g. extrusion
    • CCHEMISTRY; METALLURGY
    • C03GLASS; MINERAL OR SLAG WOOL
    • C03BMANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B37/00Manufacture or treatment of flakes, fibres, or filaments from softened glass, minerals, or slags
    • C03B37/01Manufacture of glass fibres or filaments
    • C03B37/012Manufacture of preforms for drawing fibres or filaments
    • C03B37/01265Manufacture of preforms for drawing fibres or filaments starting entirely or partially from molten glass, e.g. by dipping a preform in a melt
    • C03B37/01274Manufacture of preforms for drawing fibres or filaments starting entirely or partially from molten glass, e.g. by dipping a preform in a melt by extrusion or drawing
    • CCHEMISTRY; METALLURGY
    • C03GLASS; MINERAL OR SLAG WOOL
    • C03BMANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B2201/00Type of glass produced
    • C03B2201/06Doped silica-based glasses
    • C03B2201/30Doped silica-based glasses doped with metals, e.g. Ga, Sn, Sb, Pb or Bi
    • C03B2201/32Doped silica-based glasses doped with metals, e.g. Ga, Sn, Sb, Pb or Bi doped with aluminium
    • CCHEMISTRY; METALLURGY
    • C03GLASS; MINERAL OR SLAG WOOL
    • C03BMANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B2203/00Fibre product details, e.g. structure, shape
    • C03B2203/42Photonic crystal fibres, e.g. fibres using the photonic bandgap PBG effect, microstructured or holey optical fibres

Definitions

  • the invention relates to a glass extrusion arrangement and a generative glass extrusion process for the direct production of compact, three-dimensional and geometrically defined semi-finished products and components made of glass using at least one continuously supplied, commercially available and optionally coated glass fiber, the fiber material being both low-melting glass systems (Tg ⁇ 1000 °C, such as fibers for image transmission) as well as higher-melting glass systems (Tg >> 1000°C, such as pure or modified silica glass) can be used.
  • Tg ⁇ 1000 °C such as fibers for image transmission
  • Tg >> 1000°C such as pure or modified silica glass
  • Generative (additive) manufacturing processes represent a way of creating three-dimensional objects / components that differ significantly from classic removing / machining manufacturing processes, such as turning, drilling, milling, sawing or planing, in that a component is created by joining and Material quantities are joined together, which among other things leads to significantly greater freedom of form.
  • One form of assembling and assembling is the selective positioning of discrete amounts of material against and on top of each other to create a component in layers.
  • quantities of material are dispensed from an extruder in a fluid state onto a carrier, on which they then cool and solidify, which is why these 2D or 3D printing processes are referred to as extrusion processes.
  • a suitable device for a plastics extrusion process for producing three-dimensional objects is disclosed in DE 690 33 809 T2.
  • This device comprises a heatable extruder with a heatable nozzle that can be moved in the x, y, and z direction relative to a carrier plate on which the component is built.
  • the starting material is fed to the extruder in the form of a plastic rod or a flexible plastic strand, heated to its melting point in the extruder and discharged as a free-flowing fluid through a nozzle.
  • a controlled resistance heater is provided which is connected to a thermocouple to heat the feedstock just above the melting point.
  • a supplementary electrical heating device which heats the nozzle in a temperature-controlled manner.
  • the volume rate of the delivered fluid is controlled by the feed of the flexible strand.
  • Effective on/off fluid delivery can be achieved simply by stopping the feed motors.
  • the Düsseldorf Institute of Technology (KIT) is currently developing a special stereolithography process (SLA process) to print glass bodies.
  • SLA process stereolithography process
  • the green body In order to generate a pure glass component, the green body must be debound and sintered in a second process. This process removes the photopolymer, which acted as a binder, and the glass particles form a solid bond (also known as sintering).
  • Glass rods are used as filaments, which are melted using a CO 2 laser.
  • a three-dimensional body is created on the construction platform by moving a construction platform in the x-y-z direction and simultaneously laying down / applying the melted glass rod (technical approach of the Laser Center Hanover).
  • a suspension of pyrogenic silica and tetraethylene glycol dimethyl ether is extruded in layers through a nozzle onto the construction platform.
  • the Massachusetts Institute of Technology has developed a material extrusion printer for optically transparent glasses.
  • the extrudate is present as a glass melt in a melting furnace.
  • This melting furnace is arranged above the processing area and the melt is extruded in layers from the melting furnace through a heated nozzle as a glass strand onto the construction platform under pressure.
  • the process chamber has a processing temperature of approx. 550°C.
  • the process chamber is slowly cooled to avoid stress-induced glass breakage.
  • the Micron 3D company has a device structure that is analogous to that at MIT.
  • layer thicknesses of 100 ⁇ m can be achieved through special adjustments to the nozzle design, with typical extrusion materials being borosilicate glass or soda-lime glass.
  • a disadvantage of this extrusion process for glass is that a melting furnace is required to melt the extrudate.
  • This melting step is very energy- and time-consuming and therefore very cost-intensive.
  • the furnace must be thermally stable, which is particularly critical for high-melting glass types.
  • the melting furnace must be thermally decoupled from the actual processing area in order to avoid temperature gradients (which lead to undesirable tension and thus reduced mechanical stability of the extruded component) and the associated process fluctuations.
  • Another disadvantage is that due to the processing temperatures of approx. 550° C. in the process chamber and over 1000° C. in the melting furnace, the movement units have to be designed for extreme conditions, which involves a certain amount of effort and corresponding costs.
  • the extrusion volume is dependent on the capacity of the melting furnace, which is also disadvantageous.
  • a method is known from WO 2019/079 704 A1, for example, in which bulk metal glasses are treated with the aid of a laser.
  • coated glass fibers or glass strands cannot be used for glass extrusion in 3D printing techniques using the technical solution according to the teaching of WO 2019/079704 A1.
  • WO 2015/065 936 A1 discloses a method in which quartz glass can be produced additively by melting quartz glass fibers using a CO 2 laser source. In this process, combined laser heads focus laser radiation onto the glass fiber to melt it, using a three-axis system to move the printing surface and glass substrate.
  • WO 2015/065 936 A1 discloses a method in which quartz glass can be produced additively by melting quartz glass fibers using a CO 2 laser source.
  • combined laser heads focus laser radiation onto the glass fiber to melt it, using a three-axis system to move the printing surface and glass substrate.
  • direct extrusion of coated glass fibers or glass strands cannot be made possible by the technical solution according to the teaching of WO 2015/065 936 A1.
  • WO 2015/120 430 A1 teaches a method for the production of vitrified three-dimensional quartz glass molded parts, based among other things on the method of selective laser beam sintering with material-specific scan and parameter concepts.
  • WO 2015/077 262 A1 discloses the 3D printing of glass using the SLE (Selective Laser Etching) method. This procedure is a two-step, subtractive 3D process.
  • ultra-short pulsed laser radiation is focused. This happens on a micrometer-sized volume inside transparent materials.
  • the laser radiation is only absorbed in the focus by multi-photon processes. The material heats up briefly and strongly, then cools down quickly and changes locally and permanently. There are no microcracks.
  • the exposed workpiece is removed from the laser exposure system and developed in a wet-chemical etching bath.
  • the laser-modified glass is dissolved very selectively, with this etching process starting on the outside and then working its way inwards along the modification in order to create the inner structures.
  • WO 2016/198 148 A1 discloses the production of 3D-printed components with ultrasonically controlled microscale structure, with in situ manipulation of the discontinuous fiber structure during the printing process within a 3D-printed polymer composite architecture, which is a novel method for the immediate alignment of Microscale glass fibers in a selectively cured photocurable resin system.
  • Ultrasonic forces are used to align the fibers in the desired 3D architecture.
  • a switchable, focused laser module is mounted on a support of a three-axis 3D printing table over an ultrasonic alignment device containing a mixture of photocurable resin and discontinuous glass fiber reinforcement 14 ⁇ m in diameter (50 ⁇ m in length).
  • US 2017/0283297 A1 discloses a method for 3D printing of objects/components in which materials are deposited from walls by multiple print heads, while the print heads are moved along the 3D coordinates of the walls, where the operations of filling the material into the printheads, melting the material in the printheads and metering the melted material through an opening in each of the printheads are carried out simultaneously while the printheads are moved along the 3D coordinates so that the object / component is built.
  • DE 10 2018 109 131 A1 discloses a device for producing a three-dimensional object made of glass or glass ceramic, in particular by means of additive manufacturing technology, comprising at least the following components:
  • a print table for separating the print material, with the heating zone being placed between the print head and the print table and the print head and print table moving relative to each other in the x, y and z directions and the device having at least one of the following components:
  • the temperature in the heating zone is adjusted in such a way that the printing material has a viscosity in the range from 104 dPas to 107.6 dPas a device for cleaning the surface of the printing material before it enters the print head and/or - a device for treating the surface of the print material before it enters the printhead.
  • the object of the present invention is to specify a glass extrusion arrangement and a glass extrusion method for the direct production of compact, three-dimensional and geometrically defined semi-finished products and components made of glass, which avoids the disadvantages of the prior art mentioned above and in particular an extrusion of coated glass fibers or glass fiber strands with the
  • the aim of the additive production of high-quality 3-dimensional glass components is made possible, whereby the extrusion should be able to be switched on and off quickly and, as glass fiber material, both low-melting glass systems (Tg ⁇ 1000°C) and higher-melting glass systems (Tg>> 1000°C, such as pure or modified silica glass) can be used.
  • the essence of the invention is that a single-stage, continuous process using a glass extrusion system enables the direct production of compact, 3-dimensional and geometrically defined semi-finished products and components made of glass using a continuously supplied, commercially available and optionally coated glass fiber.
  • Low-melting glass systems (Tg ⁇ 1000°C, e.g. fibers for image transmission, such as oxidic crown or flint glasses) as well as higher-melting systems (Tg >> 1000°C, For example, from differently modified silica glass, such as photonic crystal fibers) are processed.
  • the glass extrusion arrangement comprises the following subsystems: - a peripheral mirror system, which is designed according to the technical teaching of DE 10 2009 021 448 B3, - a switchable, heatable nozzle, which is designed according to the technical teaching of DE 10 2016 125 166 A1 and which one Carrier plate / platform is spatially assigned, these two elements to each other in 3 axes (X, Y and Z axis) can be positioned, and - a transport system.
  • the switchable, heatable nozzle can be moved in the x, y and z direction relative to the carrier plate/platform on which the glass component is built.
  • the support plate/platform can also be movable in relation to the nozzle in the directions x, y and z, or there is also the further alternative possibility that both the nozzle and the support plate/platform can be moved in order to y and z direction to be adjustable.
  • the starting material is continuously fed to the switchable, heatable nozzle by means of the transport system through the peripheral mirror system in the form of a commercially available and optionally coated glass fiber, with the peripheral mirror system (CO 2 - or other lasers radiating for heating, alternatively also flame-based and mechanical Heating possible) preheating of the glass fiber and complete removal of any existing sheathing from the glass fiber takes place and in the nozzle (with the function of an extrusion unit) the final heating of the glass fiber to its softening range takes place, so that a free-flowing fluid made of glass is discharged via the outlet opening of the movable, heatable nozzle.
  • the peripheral mirror system CO 2 - or other lasers radiating for heating, alternatively also flame-based and mechanical Heating possible
  • At least one controlled laser is provided for heating, with a thermocouple monitoring the heating temperature during heating so that the glass fiber heated by the laser radiation is present in the nozzle as a free-flowing fluid above its softening point.
  • the volume rate of the delivered fluid glass is controlled by the feed of the glass fiber through the transport system with adjustable feed motors.
  • Precise control of the temperature to which the glass fiber is heated in the switchable nozzle in the softening region also aids in controlling the flow of the fluid glass being dispensed.
  • the peripheral mirror system according to DE 10 2009 021 448 B3 comprises at least one controlled laser (e.g. CO 2 laser) and a peripheral mirror with a peripheral mirror system axis and an optical system which couples a beam of laser light perpendicular to the peripheral mirror system axis into the peripheral mirror in such a way that that, after multiple reflections, it impinges on the glass fiber to be treated, whose axis runs in the same direction inside the peripheral mirror as the axis of the peripheral mirror system.
  • controlled laser e.g. CO 2 laser
  • This subsystem of the glass extrusion arrangement (in the form of the peripheral mirror system) is operated by coupling the laser beam bundle into the peripheral mirror for a predetermined processing time, with the glass fiber, the peripheral mirror and/or the optical system being held relatively still or moved relative to one another.
  • the switchable, heatable nozzle as a subsystem of the glass extrusion arrangement is already known per se from a device according to the technical teaching of DE 10 2016 125 166 A1 for the generative production of a three-dimensional object from a material that can be solidified by cooling and has a temperature-dependent viscosity, containing a heatable Platform as a carrier on which the three-dimensional object / component is produced in layers, and a nozzle with a nozzle opening for extrusion of the molten glass fiber (fluid), whereby the heated platform and the switchable, heated nozzle are three-dimensional in relation to each other in x, y and z direction with a feed rate are movable.
  • the temperature of the fluid and its viscosity can be specified by the laser-heated nozzle, with the energetic radiation, e.g. CO 2 laser radiation or other laser radiation, causing a controllable energy input with a specified radiation intensity over a specified emission time into the nozzle and with simultaneously controlled ejection of the fluid, in that a partial volume of the fluid in the nozzle is heated to a passage temperature that is higher than the specified temperature, at which the viscosity of the partial volume is so low that the partial volume, when subjected to a specified pressure, passes through the nozzle opening .
  • the energetic radiation e.g. CO 2 laser radiation or other laser radiation
  • the nozzle in the glass extrusion arrangement according to the present invention is supplied with a commercially available glass fiber which has already been preheated by the peripheral mirror system and has been freed from its possibly existing coating.
  • the actual melting process takes place in the switchable, heatable nozzle (fiber extrusion unit).
  • the switchable, heatable nozzle fiber extrusion unit
  • several laser sources are advantageously arranged around them. The energetic irradiation of the nozzle heats it up and at the same time melts the glass of the preheated glass fiber to be extruded.
  • the rapid switching of the laser and the associated dosing of the energy input into the switchable, heatable nozzle allows the viscosity of the material in the softening area to be set in a defined manner by the last temperature increase for the extrusion.
  • the beam guidance from the energy source(s) to the coupling point at the peripheral mirror and at the switchable nozzle can be realized in different ways.
  • the energy beam can be guided to the desired position.
  • the focus diameter and the associated intensity can be defined.
  • the focus diameter and thus the intensity can be varied and adjusted by regulating the laser power and varying the distance between the starting material and the energy source/optical components or between the energy source and the optical components. This makes it possible to define which volume is to be melted and which should be available for the construction process (3D printing).
  • the slice layer height is decisive for the dimensions of the stair step geometry and thus significantly determines the dimensional accuracy and surface quality.
  • each layer edge structure can be adjusted and manufactured depending on the required specifications.
  • each material has an absorption coefficient depending on the wavelength used and independent of the focus. This coefficient indicates how much energy can be absorbed by the material in relation to the output power. This absorbed energy is converted into heat and heats the material up to the required processing temperature. This makes it possible to switch between low-temperature and high-temperature glasses with little effort.
  • the switchable, heatable nozzle can be part of an extrusion unit, which can be designed as a single or multiple chamber system. At least one switchable, heatable nozzle is then arranged on each of these chambers.
  • a glass fiber with a different starting material or a glass fiber with the same starting material but with different doping properties can be melted through each nozzle of each of the individual process chambers.
  • this makes it possible to produce gradient workpieces that do not only consist of two components. From this, new design options and bases for three-dimensional components can be generated and derived. Because each chamber can be filled individually, composite structures can also be manufactured.
  • stepped or graduated transitions can be generated.
  • volume and cross-section can also be defined via the movement kinematics of the switchable, heatable nozzle or the heatable carrier plate.
  • the processing speed (as known from the prior art) depends on the heating power and the material feed.
  • new glass of the glass fiber must be thermally converted to the state of plastic deformability and flowability by the peripheral mirror system and the subsequent switchable nozzle and can only then be applied to the heatable carrier plate. The time required for this determines the maximum processing speed.
  • cooling also plays a role, which is understood to be a spontaneous process.
  • the currently known arrangements and methods do not allow rapid adjustment of the heating output, since the periphery and the components used are not designed for this.
  • Process temperatures that are required in a timely manner can also be set.
  • the entire construction process can be made more efficient and effective compared to conventional methods.
  • glass fibers which are used in fiber optics or telecommunications, for example, serve as the starting material for the glass extrusion process for 3D glass printing.
  • the glass fibers exist in the most varied variations (size, length, material) on the market.
  • the glass fibers can be ordered wound up to a length of several kilometers. This almost endless supply of starting material means that the glass 3D printing process can be completed without interruptions. Time-consuming refilling, as with a melting furnace, is no longer necessary.
  • Standard glass fibers typically have a diameter of 125 ⁇ m. Due to these small dimensions, very high levels of detail can be achieved during extrusion. In this way, optical elements such as lenses could be constructed with true contours.
  • thicker glass fibers e.g. 300 ⁇ m
  • Commercially available glass fibers have a protective plastic sheath. Depending on where it is used / where it is laid, this plastic coating has certain properties.
  • the result of this pre-treatment of the peripheral mirror system is a glass fiber that is cleaned and at the same time preheated for the switchable nozzle, which is used for the glass extrusion process for 3D glass printing.
  • the jacket material a wide variety of laser types can be used for the glass extrusion process.
  • the basic requirement is the absorption of the wavelength in the plastic jacket.
  • specially manufactured glass fibers can be used directly from the fiber drawing tower for the glass extrusion process.
  • Various material variations can be set here.
  • the laser energy and the clock frequency of the laser beam sources must be adjustable via a distance control (between the dosing element and the build platform). The greater the distance between platform and outlet nozzle the more volume has to be melted.
  • the distance sensor transmits a value to the control and regulation unit, which regulates the laser sources (energy, cycle time).
  • Active temperature monitoring at the plastification site controls the energy input into the starting material. This allows fluctuations in the system to be detected and compensated for.
  • a defined cooling can be implemented, for example, by means of a flow controller-controlled blowing cooling
  • the laser power can be adjusted efficiently so that the desired volume is optimally melted. Heat dissipation into the holding system can also be monitored and minimized if necessary.
  • a control-detection unit e.g. In this way, a statement about the removal of the cladding layer can be generated.
  • the advantage of this technical solution in the form of the glass extrusion arrangement and the glass extrusion process is that, starting from a wide variety of glass fibers, they can be used in a variety of ways for 3D glass printing due to the targeted interaction of the peripheral mirror system and switchable nozzle.
  • the following fiber systems can be processed: a) undoped quartz glass
  • Another advantage of the glass extrusion arrangement and the glass extrusion process is that the development and use of special fibers and dopings in the form of “printing fibers” that are adapted to the respective printing process is possible, which are taken directly from a fiber drawing tower and introduced into the arrangement and there can be edited with the method.
  • FIG. 2 a schematic detailed representation of a section of the glass extrusion arrangement according to FIG switchable, heatable nozzle, which is spatially assigned to a carrier plate,
  • Fig. 6a - h exemplary cross-sectional representations of various uncoated or coated gas fibers
  • Fig. 8a, b two exemplary cross-sectional representations of components with a support structure in the form of an axicon (a) and a concave perforated mirror (b)
  • a structured special optical fiber e.g. a photonic crystal fiber
  • the glass extrusion arrangement shown in Figures 1 and 2 for the direct extrusion of a coated glass fiber (7) for the production of compact, three-dimensional and geometrically defined semi-finished products or components (9) comprises:
  • a material feed unit (1) as material reserve and preheating unit for heating the coated glass fiber (7) by inductive heating or IR radiation,
  • a laser in the example a CO 2 laser with a wavelength of 10.6 ⁇ m
  • a peripheral mirror (62) as a stripping and preheating system system
  • a switchable nozzle (4) for 3D glass printing in the exemplary embodiment consisting of molybdenum), which indirectly via an optical system in the form of lenses, e.g. via two lasers (63) in the example a CO 2 laser radiation (with a Beam power in the kilowatt range) is heated (see Fig.
  • the nozzle (4) is in the immediate vicinity of a heated platform (42) and on their Outlet opening (41) that discharges the fluid glass (91) and deposits it on the platform (42) in two or three dimensions (with a thickness in the range from 100 ⁇ m to several 100 ⁇ m [- each depending on the material flow, which can be selected individually by the Laser power is set, and the specified traversing speed], during which the nozzle (4) and the platform (42) are moved relative to one another in the x, y and z direction in a definable manner with the traversing speed, so that the corresponding 3D - Component (9) can arise as intended, and
  • the switchable nozzle (4) is arranged in a process chamber (5) surrounding the heatable platform (42), the platform (42) being positionable in 3 axes (X, Y and Z) by a movement unit. However, it is also within the scope of the invention that the platform (42) can be positioned in 5 axes by a movement unit (not shown in the figures).
  • a gas flow controller can be provided (also not shown in the figure), which can direct cooling air to the heated platform (42) in a controlled manner.
  • the peripheral mirror system (3) is arranged outside of the process chamber (5), with the coated glass fiber (7) to be extruded passing through the transport system (2) from the material feed unit (1) through the peripheral mirror system (3) via the inlet opening (51) of the Process chamber (5) is introduced into the switchable nozzle (4) for extrusion via the outlet opening (41).
  • These subsystems can be controlled and operated simultaneously with precisely controlled parameters by a control and regulation unit in order to use the glass extrusion system to directly produce compact, 3-dimensional and geometrically defined semi-finished products and components (9) made of glass using a continuously supplied, commercially available and to enable optionally sheathed (coating) glass fiber.
  • one or more lasers (61) are used to strip the coated glass fiber (7) (see FIG. 2), in which the continuously fed glass fiber (7) is irradiated radially and thus a sufficiently high Energy is introduced in order to completely remove the cladding of the glass fiber (7) in the form of the organic coating (e.g. in the form of acrylate) from this in order to arrive at a cladding-free glass fiber (8) which is continuously fed into the switchable, heatable nozzle ( 4) is introduced to melt.
  • a detection system ensures the removal of the organic emissions that arise during this stripping (not shown in FIGS. 1 and 2).
  • the material feed unit (1) is advantageously applied to heat the glass fibers (7, 8) by inductive heating or IR radiation.
  • the switchable nozzle (4) is heated indirectly via laser beams from at least one laser (63), in the example from two lasers (63) for CO 2 laser radiation, so that the stripped glass fiber (8) in this is melted.
  • the nozzle (4) can be switched quickly by means of the laser-generated temperature control, the desired glass viscosity is set in a targeted manner, monitored by sensors and constantly adjusted to the desired value in the control loop (not shown in FIGS. 1 and 2). Temperature is readjusted, and it is also possible to switch the material flow of the glass fiber (8) melted to the fluid glass (91) on and off for 3D printing on the heatable platform (42).
  • the transport system (2) conveys the 125 ⁇ m standard glass fiber continuously into the peripheral mirror system (3) and the stripped glass fiber (8) into the following switchable nozzle (4) so that the still coated glass fiber (7) can be removed from the material feed unit (1). uninterrupted to the place of extrusion at the outlet opening (41) of the switchable nozzle (4) and fluid glass (91) is always ready for the 3D glass printing process.
  • the thermal shock resistance (TWB) of the respective Observe the type of glass, for example when using undoped or Al-doped SiO 2 as follows:
  • a special optical fiber e.g. in the form of a photonic crystal fiber with cavities of different sizes (e.g. bandgap fibers, anti-resonant fibers, evanescent sensor fibers with large internal cavities) can be produced from this preform in an adapted fiber drawing process.
  • cavities of different sizes e.g. bandgap fibers, anti-resonant fibers, evanescent sensor fibers with large internal cavities
  • an already established coated glass fiber (7) made of high-melting glass is used as the starting material (although low-melting glasses could also be used).
  • the diameter of the fiber (7) used in this exemplary embodiment is typically 250 ⁇ m (however, the nozzle geometry and the extrusion parameters can also be adapted for other fiber dimensions).
  • the glass fiber (7) is continuously unwound from a drum by means of the controlled fiber transport system (2) (designed as a roller capstan) and fed to the glass extrusion arrangement explained in the first exemplary embodiment at a defined feed speed.
  • the fiber coating is first removed without leaving any residue.
  • laser radiation is homogenized in the peripheral mirror by multiple reflections and the glass fiber is thereby irradiated peripherally.
  • the coated glass fiber (7) is heated to temperatures of approx. 400 - 600°C and the coating is thereby removed without leaving any residue.
  • the fiber material is also preheated as an offset temperature for the subsequent extrusion step.
  • the stripped and preheated glass fiber (8) is now fed to the switchable nozzle (4).
  • the nozzle (4) is heated indirectly by means of energetic radiation, in this exemplary embodiment CO 2 laser radiation, and heats the fiber (8) made of high-melting glass until it has reached the required viscosity.
  • a laser (63) with a beam power in the medium kilowatt range is used for this purpose, which is sufficient to heat the fiber (8) to temperatures of T>1000°C.
  • the material flow can be varied or stopped via the individually selectable laser power.
  • the layer thickness of the deposited fluid glass (91) can be precisely controlled and varied over a wide range from D ⁇ 100 ⁇ m to several 100 ⁇ m. Analogously, the structural width of the fluid glass (91) can also be varied.
  • the thermal shock resistance (TWB) of the respective glass type is taken into account, for example when using borosilicate glasses of this exemplary embodiment as follows:
  • the component (9) is built up as a 3D shaped body with typical dimensions of 20 mm to 50 mm in diameter or height and variably realizable structures via the sequential deposition of individual layers.
  • the component (9) is then mechanically separated from the platform (42) and removed from the process chamber (5).
  • the outer surface is smoothed using a laser polish and then slowly cooled down in a separate, temperature-controlled oven.
  • the glass fiber with the sheathing (7) is fed in analogously to the first and the second exemplary embodiment.
  • the glass fiber with the casing (7) is stripped by one or more mechanical cutters, which remove the casing from the glass fiber (7) with as little residue as possible by means of a peeling process.
  • the stripped and preheated glass fiber (8) is then fed to the switchable nozzle (4).
  • the nozzle (4) is heated directly or indirectly by means of energetic radiation and heats the fiber (8) until the required viscosity is reached.
  • a laser system (63) with a beam power in the medium kilowatt range is used, which is sufficient to heat the 3D printing fiber to temperatures of T>1000°C.
  • the material flow of the fluid glass (91) can be varied or stopped via the individually selectable laser power.
  • the layer thickness of the on the heated platform (42) preheating temperature is selected individually depending on the type of glass in order to reduce thermally induced stresses due to high To avoid cooling rates) deposited material can be precisely controlled and varied over a wide range from D ⁇ 100 microns to several 100 microns.
  • the structure width of the material can be varied analogously.
  • the component is built up as a 3D shaped body with typical dimensions of 20 mm to 50 mm in height and variably realizable structures by sequentially depositing individual layers from the fluid glass (91).
  • support structures (100) are also built up in the resulting cavities and walls during the layered construction on the platform (42) (shown in Figures 8a and 8b) .
  • the support structures (100) can be produced from different preform structures (see FIG. 6) of the same type or different materials.
  • the separation process can also take place chemically.
  • the 3D shaped body (93) is placed in a KOH bath, as a result of which the dissimilar material, which has a significantly higher etching rate than the 3D shaped body (93), separates from it.
  • the additively manufactured 3D shaped body (93) is subjected to a grinding and/or polishing process.
  • the coated fiber (7) is fed in and the cladding is removed in the same way as in exemplary embodiments 1, 2 or 3.
  • At least two switchable nozzles 4a and 4b are used in the fourth exemplary embodiment (shown in FIG. 3).
  • Both nozzles (4a and 4b) transport two fibers made of different glass materials with two different properties (91a and 91b).
  • Both nozzles (4a and 4b) can work simultaneously or sequentially, the component platform (42) and the two nozzles (4a and 4b) being moved relative to one another in the x, y and z direction by a drive system not shown in FIG.
  • a gradient component (9a; 9b) is built on the construction platform (42) with two different refractive indices n1 and n2.
  • Any graduated glass with different properties can be produced with this arrangement.
  • Extruder arrangement [(switchable nozzle (4)] for the direct and indirect laser beam melting of a glass fiber without a coating (8) in the glass extrusion arrangement
  • the glass fiber is fed without sheathing (8) to the switchable nozzle (4) via take-off rollers of the transport system (2).
  • the glass fiber (8) is transferred coaxially into the molten area in a very short time by a laser ring mirror, so that the viscosity of the material of the glass fiber (8) drops abruptly in that viscosity-temperature range (approx. 1-3 dPas) where the material is converted into a good flowable state.
  • the softened and free-flowing volume of material can thus pass through the nozzle (4) very quickly and be deposited on the platform (not shown in FIG. 4).
  • a pulsed CO 2 laser is preferably used for the partial melting process. With pulse lengths in the ps-ms range of the radiation from the laser (63), a very metered supply of fluid glass (91) can thus take place.
  • the glass fiber without a jacket (8) is conveyed into a heating container of the switchable nozzle (4) in the form of an enlarged material storage reservoir.
  • the introduced glass volume is brought to a pre-extrusion temperature by a heating source, preferably heating strips (52) in the form of resistance-heated strips (see FIG. 5).
  • a heating source preferably heating strips (52) in the form of resistance-heated strips (see FIG. 5).
  • a typical preheating range can be between 400 °C and 1,500 °C.
  • the glass volume has a viscosity between 4 - 10 dPas, for example.
  • the radiation from the laser (63) now applies a defined laser energy to a radiation converter (72).
  • the radiation converter (72) has a very good transmission of the optical radiation into thermal energy in order to bring the provided glass volume very quickly into a viscosity-temperature range (approx. 1-3 dPas) where the material [the fluid glass ( 91)] is converted into a readily flowable state.
  • a switchable nozzle (4) in this embodiment with a variable nozzle diameter (41), can the diameter of the fluid glass (91) can be adjusted accordingly in a range from 200 ⁇ m to several millimeters.
  • the arrangement shown in FIG. 7 for the online-monitored and online-controlled outlet of fluid glass (91) as part of the overall glass extrusion arrangement has a temperature measuring device (70) in the area at the outlet opening (41) of the switchable nozzle (4), preferably a pyrometer.
  • the temperature of the fluid glass (91) is measured online with this pyrometer.
  • the measured, calibrated temperature signal is used to determine the viscosity of the fluid glass (91) in order to control the outlet of the fluid glass (91) in a controlled operation.
  • the power of the lasers (63) and the two fiber feed devices (73) of the transport system (2) are controlled as a function of the measured temperature.
  • This control circuit ensures that a homogeneous flow of glass can be ensured throughout the entire construction process.
  • a disadvantage of additive manufacturing can be the relatively long processing times when dealing with large-volume or simple geometric shapes. This disadvantage is overcome by the hybrid production concept with an arrangement as shown in FIG. 9, for example.
  • the starting point is the provision of a prefabricated blank, semi-finished product or finished component (94a).
  • the Areas (94b) that have a more complicated shape and can only be produced to a limited extent or not at all by conventional separating processes such as milling and grinding are built up layer by layer by the first switchable nozzle (4a).
  • Such typical contours include, for example, internal contours, undercuts, thin webs, contours with a high aspect ratio (the ratio of height to width) or special free-form surfaces.
  • the processing sequence includes the following steps:
  • the component (94) is cooled with a temperature-time function known to those skilled in the art, also referred to as fine cooling.
  • connection areas (joining zones) (95) can be partially heated to the required process temperature by a laser beam (64). In this case, the heating of the entire component volume (94a) in the process chamber can be omitted.
  • the joining zone (95) shown in FIG. 9 represents a peripheral area of the component (94a), which is quasi-simultaneously through the Beam deflection between the maximum areas (64a) and (64b) is heated.
  • glass transition solders are used to solve this problem.
  • a second switchable nozzle (4b) is additionally used for this purpose, which discharges a second glass strand with a glass transition solder.
  • a zone with glass transition solder (94c) is now applied between the component (94a) and the area (94b) to be produced additively using (4b)
  • components (94) made of different materials can also be connected.
  • a material combination of a glass ceramic (94a) and a silica glass (94b) is also possible.
  • a metal-glass composite can also be built up with the available glass transition solders.
  • the arrangement according to FIG. 9 makes it possible to combine the advantages of subtractive manufacturing (grinding, lapping, polishing) and additive manufacturing.
  • prepared semi-finished products can be used as components (94a), which are finished after the additive process stage by form grinding and polishing to form the complete component (94).
  • you can Components are inserted into the extrusion system after the complete subtractive process stage in order to build up or add additional contour elements or to repair component defects.
  • the advantage of the provided technical solutions of the glass extrusion arrangement and the glass extrusion process is that by means of the method using the glass extrusion arrangement, both standard glass fiber systems with a complete or partial sheathing and standard glass fiber systems without sheathing are converted into semi-finished products and components of all kinds using 3D glass printing so that these products can be put to a wide variety of uses or further processing.
  • the glass extrusion arrangement and the glass extrusion process are particularly interesting for the production of modified glass fibers (e.g. for image transmission), of components or semi-finished products made of glass.
  • the process for example, commercially available and optionally coated glass fibers are fed in continuously.
  • the process can also be used to process both low-melting glass systems (Tg ⁇ 1000°C, e.g. for glass fibers for image transmission) and higher-melting systems (Tg >> 1000°C).
  • the glass extrusion arrangement and the method using this arrangement can be used for different, fusible fiber systems (in addition to the most diverse types of glass fibers, such as undoped or doped quartz glass fibers, soft glass fibers).
  • the scope of the invention is not tied to starting materials in the same way as other methods which can only use special starting materials.

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Abstract

L'invention concerne un ensemble d'extrusion de verre comprenant un système de miroir périphérique (3), une buse chauffante commutable (4) ayant une ouverture de sortie (41) et un système de transport (2). La buse (4) est située dans une chambre de traitement qui entoure une plateforme chauffante (42). La buse (4) et la plateforme (42) peuvent être positionnées dans trois axes l'une par rapport à l'autre par une unité de déplacement. Le système de miroir périphérique (3) est situé à l'extérieur de la chambre de traitement (5). Pour l'extrusion, la fibre de verre (7, 8) à extruder peut être introduite en continu par une unité d'alimentation en matériau (1) dans la buse (4) au moyen du système de transport (2), à travers le système de miroir périphérique (3), par le biais d'une ouverture d'entrée (51) de la chambre de traitement (5). Dans le but de chauffer, la buse (4) peut être irradiée en utilisant au moins un laser commandé (63). Dans l'état de fonctionnement, un thermocouple surveille la température de chauffage pendant le chauffage de la buse (4), de sorte que la fibre de verre chauffée par la lumière laser soit au-dessus de son point de fusion sous la forme d'un fluide coulant dans la buse (4) et peut s'écouler hors de l'ouverture de sortie (41) vers la plateforme (42). Les sous-systèmes peuvent être commandés/actionnés simultanément et précisément par une unité de régulation en boucle ouverte et en boucle fermée et par cet ensemble d'extrusion de verre utilisé de la manière prévue.
EP21811243.1A 2020-11-06 2021-10-29 Ensemble d'extrusion de verre et procédé d'extrusion de verre pour la fabrication directe de produits semi-finis compacts, tridimensionnels et géométriquement définis, et composants constitués de verre Pending EP4240701A1 (fr)

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DE102020129314.3A DE102020129314A1 (de) 2020-11-06 2020-11-06 Glasextrusionsanordnung und Glasextrusionsverfahren zur direkten Herstellung kompakter, dreidimensionaler sowie geometrisch definierter Halbzeuge und Bauteile aus Glas
PCT/DE2021/100866 WO2022096061A1 (fr) 2020-11-06 2021-10-29 Ensemble d'extrusion de verre et procédé d'extrusion de verre pour la fabrication directe de produits semi-finis compacts, tridimensionnels et géométriquement définis, et composants constitués de verre

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CN115042295A (zh) * 2022-06-20 2022-09-13 中建西部建设西南有限公司 3d打印混凝土状态调节挤出系统及其控制方法
CN115745396A (zh) * 2022-10-23 2023-03-07 武汉鑫友泰光电科技有限公司 一种石英玻璃纤维拉丝装置

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US5121329A (en) 1989-10-30 1992-06-09 Stratasys, Inc. Apparatus and method for creating three-dimensional objects
DE102009021448B3 (de) 2009-05-13 2010-07-22 Fachhochschule Jena Vorrichtung und Verfahren zur Umfangsbearbeitung eines Materialstranges mittels Laser
HUE055012T2 (hu) 2013-10-30 2021-10-28 Branch Tech Inc Épületek és egyéb szerkezetek adalékainak gyártása
US20160297104A1 (en) 2013-11-19 2016-10-13 Guill Tool & Engineering Coextruded, multilayer and multicomponent 3d printing inputs field
US20160354896A1 (en) 2014-02-10 2016-12-08 President And Fellows Of Harvard College 3d-printed polishing pad for chemical-mechanical planarization (cmp)
DE102015007317A1 (de) 2015-06-11 2016-12-15 Florian Eichenhofer Verfahren zur Verstärkung einer Grundstruktur
RU2618235C1 (ru) 2016-04-04 2017-05-03 Ануар Райханович Кулмагамбетов Способ трехмерной печати зданий (варианты) и устройство для его осуществления
DE102016125166A1 (de) 2016-12-21 2018-06-21 Ernst-Abbe-Hochschule Jena Verfahren und Vorrichtung zum generativen Herstellen eines dreidimensionalen Objektes aus einem durch Abkühlung verfestigbaren Material mit einer temperaturabhängigen Viskosität
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DE102018109131A1 (de) 2018-04-17 2019-10-17 Schott Ag Additiver Fertigungsprozess und Vorrichtung zur Herstellung von transparenten dreidimensionalen Körpern aus anorganischen Materialien

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