KR100773307B1 - Preform for manufacturing a material having a plurality of voids and method of making the same - Google Patents

Abstract

Beaded preforms include a plurality of adjacently positioned beads to form a plurality of voids in the material being processed. Beaded preforms may include filaments (one strand of beads) and mats (two and three dimensional arrays of beads). The filaments and mats can be coated to be a tow and a laminate, which can then be assembled into a composite material. Preforms may be produced using novel apparatus and methods, and are known in the art for making porous structures comprising stress modulating structures in any material, including, for example, metals, plastics, ceramics, textiles, paper, and biological materials. Can be incorporated into the process.

Description

Preform for producing a material having a plurality of voids and a method for manufacturing the same {PREFORM FOR MANUFACTURING A MATERIAL HAVING A PLURALITY OF VOIDS AND METHOD OF MAKING THE SAME}

FIELD OF THE INVENTION The present invention relates to the design and manufacture of materials, and more particularly to preform constructions used to create voids, pores, or cavities in any material, in particular engineered materials. It relates to a preform component.

The present invention generally relates to the ability to create a plurality of voids organized in a given material, as well as the stresses that can be safely involved with respect to the bearing structure and the amount of material required for the structure. It relates to the ability to populate structures that provide improved trade-off between them.

In general, the voids have been formed in the material using a number of existing foaming techniques. These foaming techniques produce unorganized pores, ie, materials in which the pores are placed randomly as well as randomly positioned. Moreover, many of the pores in these materials are not closed, ie interconnected with adjacent pores.

Thus, existing processes may not create closed voids and / or voids in precisely organized positions within a given material. Current technology also has not made the voids exactly the desired size and substantially self-enclosed shape.

It is especially important in stress steering materials that the interconnected voids form tissues. The stress modifier material allows the force exerted on the structure to result primarily in compressive forces.

The aforementioned stress regulating materials have been developed in which the voids are symmetrically arranged, which results in substantially compressive stress of most of the stress applied to the material using the novel structure comprising the voids. Such novel structures are disclosed in US Pat. Nos. 5,615,528, 5,660,003, 5,816,009, which are jointly owned by Applicant, which are incorporated herein by reference. Each of these patents discloses the use of a plurality of uniform, symmetrically arranged voids throughout the base material that result in the majority of the added force resulting in compressive forces rather than tensile stresses.

NASA's work and other prestigious scientific societies have concluded that the more uniform and symmetrical the voids in a material, the greater the effective tensile strength of the material. As a result, manufacturers of foamed materials and other materials, where porosity is a major factor, have precisely sized and three-dimensional shapes in the material to optimize the material's effective tensile strength, allowing the material to have a certain size of pores at a given location. Or efforts have been made to find a commercial way to position the voids.

However, incorporating these voids into the material in a three-dimensional symmetrical arrangement using conventional manufacturing techniques has been a difficult and expensive task. It was still not possible using known material foaming techniques. Thus, the widespread use and storage of porous materials, including the stress adjusting materials disclosed in the aforementioned patents, has been difficult because it is difficult to incorporate the necessary voids in the material.

Accordingly, there is a need for materials, processes, and / or systems that facilitate the manufacture of materials having the desired shape to incorporate voids, including the stress adjusting materials of the aforementioned patents.

It is therefore an object of the present invention to provide a method and apparatus for creating voids (pores located in a predetermined arrangement) that are organized in any material. The voids created using this novel method and apparatus can be of any size, shape, space, and can also be interconnected or entirely closed respectively.

Moreover, the spacing of the voids in a particular material may be symmetrical and / or asymmetrical to obtain the desired material characteristics. Thus, in order to obtain a stress adjustment in accordance with the material disclosed in the aforementioned patent, the voids must be arranged in a special symmetrical structure.

Thus, any combination of voids, including a stress modulating material of the patent, which is arranged in a plurality of symmetries and results in the use of uniform voids, resulting in the majority of the forces added to the structure result in extrusion forces rather than tensile stresses. Forms of material can be made using the unique and novel parts and methods of the present invention.

Structures having preforms, such as voids, as well as manufacturing apparatuses and methods according to the invention, are also filed in the name of the applicant with the same as the present application, and the name of the invention is for producing a material having a plurality of voids. Preform, and a method of manufacturing the same, which is incorporated herein by reference in its entirety, which is incorporated by reference in its provisional patent application (U.S. Provisional Patent Application No. 60 / 291,904, filed on January 15, 2005).

According to a preferred embodiment of the present invention, the voids are incorporated into the material using one of the components or texturizing of the preform material or a combination thereof. The said void may be produced | generated in a material using a well-known manufacturing method.

It is therefore an object of the present invention to provide a constituent material for making a plurality of voids.

Another object of the present invention is to provide a method for imparting a plurality of voids to a material.

Thus, in one aspect of the invention, the bead type preform for forming a plurality of voids in the material to be processed includes a plurality of adjacently located beads.

According to another aspect of the present invention, a method of manufacturing a beaded preform for forming a plurality of voids in a material to be processed comprises a preform material out of a first opening to make an extruded preform material. Extruding and calendering the extruded preform material to form a plurality of adjacently located beads.

In another aspect of the invention, a method of making a coated bead preform for forming a plurality of voids in a material to be processed comprises the steps of: providing a die with a first flow of extruded coating material; Providing a molded body in the first flow, causing a beaded preform to be coated with the coating material, and extruding the first stream from the opening with the beaded preform to form a tow It includes.

According to another aspect of the invention, a method for making a material to be processed having a plurality of voids includes guiding a plurality of bead-shaped preforms with a first feed material, and a plurality of bead-shaped preforms with a first feed material. Coating with a material, and molding the coated preform into a predetermined shape.

In still another aspect of the present invention, a method of manufacturing an artificial structure including a plurality of voids forming a tissue by using a continuous casting device includes a bead-shaped preform comprising a plurality of adjacently placed beads in a first container. Guiding the matrix material and guiding the matrix material into a space having a predetermined spacing, and forming a product having a predetermined thickness substantially equal to the spacing.

According to another aspect of the present invention, a method for forming a composite in which a plurality of voids forming a tissue is arranged therein comprises: imparting a first void of a first array onto a first stack; Assembling the laminate with the second laminate, wherein openings directed to the first voids are formed in the first side of the first laminate.

In another aspect of the invention, a laminate assembled from a composite material comprises a fabric having a plurality of recesses on a first side, the recesses corresponding to a plurality of protrusions on a second side of the laminate. do.

According to another aspect of the invention, a method of manufacturing a processed material having a plurality of voids forming a tissue comprises the steps of guiding a bead shaped preform comprising a plurality of spaced beads in a continuous cast of molten material. It includes.

In still another aspect of the present invention, a method of manufacturing a processed material having a plurality of voids forming a tissue comprises the following process, namely a bead-shaped preform comprising adjacent bead strands.

Additive manufacturing, atomization manufacturing and layered manufacturing processes, including fusion deposition modeling, stereo-lithography, optical assembly, solid base (polishing) curing, plasma spray molding, sputtering, deposition,

Including die-die forging, open-die forging, coining, penetrating, hubbing, fullering and etching, roll forging, ring rolling, direct extrusion, indirect extrusion, hydrostatic extrusion and impact extrusion Deformation and forming processes, including bulk deformation

Sheet metal forming processes including shearing, bulging, rubber forming, high energy forming, superplastic forming, deep drawing, embossing,

Material removal processes including cutting, polishing, electric discharge machining, water spraying, abrasive spraying, chemical processing and electrochemical processing and polishing,

Permanent molds, including slush casting, pressure casting, insert molding, centrifugal casting and infiltration casting, vacuum casting, ceramic-molding casting, plaster-molding casting, shell mold casting and sand casting, gel-casting, injection molding, compression molding Casting processes including consumable molds, transfer molding, insert molding,

Particulate material processing process including sintering, cold equal pressing, hot equal pressing

Providing to any one of assembly and joining processes including friction stir welding, resistance welding, explosion welding, soldering and soldering, arc welding, laser welding.

These aspects will be more readily understood upon reading the accompanying drawings and the following detailed description of the invention.

1 shows a first closed cell structure of a stress regulating structure produced by a preform according to the invention, wherein all symbolic TRDs have voids in their respective centers,

FIG. 2 shows a second open cell structure of the stress adjusting structure produced by the preform according to the invention, with every other symbolic TRD removed; FIG.

FIG. 3 shows a third combined open cell, closed cell structure of a stress modulating structure produced by a preform according to the invention with symbolic TRDs having voids in their respective centers, FIG.

4 shows a fourth combined open cell, closed cell structure of a stress modulating structure produced by a preform according to the invention with symbolic TRDs having voids in their respective centers;

Figure 5a is a view showing a pearled thread resembling a preform according to the present invention,

5B is a view schematically showing a bead-type filament preform according to a first embodiment of the present invention,

6A is a schematic illustration of a beaded filament preform according to a first embodiment of the present invention having a single size of beads located at a first interval,

FIG. 6B is a view schematically showing a bead-type filament preform according to the first embodiment of the present invention in which beads of large size are disposed in spaces between beads of small size, and FIG.

FIG. 6C is a view schematically showing a bead-like filament preform according to the first embodiment of the present invention in which a bead of a large size is disposed adjacent to it in a space between beads of a small size;

FIG. 7A is a schematic illustration of a beaded filament preform in accordance with a first embodiment of the present invention in which the filaments are divided into groups of typical laminated materials and arranged horizontally; FIG.

FIG. 7B is a schematic illustration of a beaded filament preform according to a first embodiment of the present invention in which the filaments are divided into groups of typical laminated materials and arranged diagonally;

FIG. 7C schematically illustrates a beaded filament preform according to a first embodiment of the present invention in which the filaments are divided into groups of typical laminated materials and arranged horizontally while at the same time two different sizes of beads are used; ego,

FIG. 7D is a schematic view of the bead-like filament preform according to the first embodiment of the present invention similar to FIG. 7C except that the filaments are arranged in a diagonal direction, FIG.

8 is a schematic illustration of a beaded filament preform according to a first embodiment of the present invention, showing the filament beads prior to processing in a material having an elliptic shape and consequently forming spherical voids of a suitable shape. ego,

9 is a cross-sectional view showing a processed material produced by assembling a plurality of filaments with each other according to the first embodiment of the present invention;

10 is a cross-sectional view showing another processed material produced by assembling a plurality of filaments with each other according to the first embodiment of the present invention;

11A is a view showing a cylindrical tow using the filament preform according to the first embodiment of the present invention.

11B is a view showing a square column tow using the filament preform according to the first embodiment of the present invention.

12A is a view showing a laminate manufactured by assembling a plurality of tows shown in FIG. 11A,

12B is a view showing a laminate produced by assembling a plurality of tows shown in FIG. 11B,

FIG. 13A is a view of the plurality of tows shown in FIG. 11A assembled to form a fabric; FIG.

FIG. 13B illustrates a plurality of tows shown in FIG. 11B assembled to form a fabric; FIG.

FIG. 13C shows a plurality of tows and laminates assembled together to form a fabric, FIG.

13D is a view showing a plurality of laminates,

FIG. 14 shows beaded filaments and mats aligned for processing for laminate / fabric formation, FIG.

FIG. 15 shows a first extrusion / spinning process for producing a beaded filament preform according to the present invention;

FIG. 16 shows a first extrusion / spinning process for producing beaded filament preforms according to the invention, FIG.

FIG. 17 is a view showing a first extrusion process for producing a bead-shaped mat preform according to the present invention;

FIG. 18 is a view showing a second extrusion process for producing the bead-shaped mat preform according to the present invention;

19 shows a first extrusion process for producing a tow according to the invention,

20 shows a second extrusion process for producing a tow according to the invention,

21 shows a first extrusion process for producing a laminate using the preform according to the present invention,

22 shows a second extrusion process for producing a laminate using the preform according to the invention,

23 shows a preform according to the invention used to produce a predetermined material using a continuous casting method,

24 and 25 illustrate preforms according to the invention used to produce laminates or fabrics using extrusion methods;

FIG. 26 is a view showing a material having a grain according to a second embodiment of the present invention having a first dimple structure;

27 is a view showing a material having a grain according to a second embodiment of the present invention having a second dimple structure;

FIG. 28 is a view showing a material having a grain according to a second embodiment of the present invention having a third dimple structure;

FIG. 29 illustrates various structures that can be produced using preform materials in accordance with the first and second embodiments of the present invention.

Bead-shaped preforms as precursors to materials having structuring pores

The bead-shaped preform according to the invention is a component of a precursor which incorporates a predetermined material to form a predetermined symmetrical or asymmetrical positioning or tissue forming voids, for example, to produce a material having a tissue forming void. An example of such a material is a stress regulating structure to result in an added load primarily to compressive stress. Two-dimensional cross-sectional views of such three-dimensional stress control structures are shown in FIGS.

The preform may be sacrificial (ie, preliminary), permanent, or a combination thereof. In the case of a sacrificial preform, the bead material forming the voids is generally removed at some point after incorporation into the base material during further processing. In the case of permanent preforms, the bead material will remain in the void, although it may be deformed or reshaped in some way during the process.

The beads of the preform may be of any shape and size needed to produce the desired material to be processed, and may be hollow or solid and combinations thereof. In general, the shape of the beads is such that it can produce voids having a specific pore volume and / or shape after the process.

The bead shaped preform is preferably in one of two basic forms, filament and mat, one of which may be rigid or flexible. These preforms can be further assembled into tows and laminates by applying a coating to the filaments and the mat, respectively.

The filament 2 preform according to the invention is similar to the bead strand (see FIG. 5A) and comprises strands 4 of spaced beads 6 (see FIG. 5B). The spacing may be asymmetric, but is generally organized and / or symmetric with a pattern of spacing. Moreover, the beads can have the same size, random size or repeating pattern of beads of a particular shape as shown in FIGS. 6A-6C.

The mat 8 can be formed by assembling a plurality of beads in another way to form a two-dimensional array, but is a two-dimensional array of assembled filaments 2 as shown in FIGS. 7A-7D. As shown in the figure, the vertical and horizontal bead spacings are generally organized and provided at a predetermined distance and pattern.

8 shows a beaded filament having an elliptical bead. These beads are formed into such a shape that, when incorporated with a particular material, voids and even permanently, the beads themselves have a spherical shape after the process. The above-described process that benefits from this type of filament may be a casting process, where high pressure and / or compression rolling affect the shape of the preform, as a result of which the shape of the void is determined as the preform is sacrificial or not. do.

Mats and filaments can be assembled to form a fabric, resulting in, for example, the cross sections shown in FIGS. 9 and 10 with voids 12, 14 (see FIG. 9) and voids 16 (see FIG. 10). It will form a material having. As shown in FIG. 14, this fabric stack may comprise alternating layers of mat 8 and filaments 2 with surface material 11 covering the top and bottom.

Tow 18 (see FIGS. 11A-11B) is formed by coating filament 2 with a matrix material 3 (eg, a thermosetting resin) of generally some type. Similarly, laminate 20 is generally formed by coating a mat with a matrix material, or by assembling a plurality of tows 2 (see FIGS. 12A-12B), or a plurality of arrays arranged in a predetermined array. It can be prepared by coating a filament aggregate.

Since tows and laminates, as well as filaments and mats, may also include cutting and positioning guides (eg, recesses, protrusions), they are intermediate and final products in particular applications. It can be easily cut, arranged and assembled into a material.

The intermediate product and the final product can be made of a composite 22 of tow and laminates (FIGS. 13A-13D and 14). For example, a method of manufacturing a composite fabric includes a method of weaving, knitting, or assembling each other with a plurality of tows, a plurality of laminates, or a combination thereof.

Composites comprising fabrics can be continuous (eg, tape) or non-combustible, and can be made for intermediate products and finished products. For example, the composite can be made of slabs, blooms, billets, panels, boards and sheets (see FIG. 29).

One skilled in the art will understand that the void pattern of the material (eg, stress steering structure) is incorporated into the fabric by weaving, braiding, and knitting the tow so that the advantages of such a structure can be obtained at two different levels. . Moreover, the structure, the material of the beads and the coating can be composed of a stress adjusting structure (ie a pore structure) such that the advantages of the stress adjusting structure can be obtained at three levels.

Thus, there are various potential materials of the tow, laminates and fabrics of the present invention utilizing metals, plastics, ceramics and various alloys, mixtures and composites thereof. Alternative materials include semiconductors, textiles, papers, and biomaterials.

The voids formed from the components of the preform can be used in house devices for intelligent materials used in intelligent structures. In particular, sensors, actuators, MEMS, and other devices may be incorporated in the air gaps of structural elements of bridges or wings of aircraft, for example to provide information about the function of the element / bridge or to change its shape or its elements. It will induce a load on the structure for a change in the characteristics of (e.g., a change in the wing shape of the aircraft for further takeoff). To incorporate such a device into a finished product, the device may be used in place of one or more beads in a filament or mat or may be incorporated into one or more beads.

The preform according to the invention is produced using a conventional manufacturing method. Accordingly, Applicant has provided a comprehensive list, such as shown in Figures 15-18 which can be used to prepare the preform according to the invention. These methods include various casting, deformation and forming processes for metals; Blow molding, compression molding (cold / hot), transfer molding, cold molding, injection molding, reaction injection molding, thermoforming, rotational molding, foam molding for plastics; Pressure casting, slip casting, conformal pressing, plasma spray molding, roll pressing, injection molding, gel casting for ceramics; And inductive casting, filament winding, equivalent pressing for composites.

An example of producing a novel preform according to the invention is shown in FIG. 15 and described below.

Filament: As shown in FIGS. 15 and 16, the filament may be produced by the spinning process 31 forcing the extruded material through a die 32, which includes a plurality of small holes 34. The beads are then added by shaping rolling 36, or preferably by inline drawing 38 and by calendering operations on the filaments with embossing roller 40. Drawing can make filaments thinner and increase their tensile strength in further processes. The finished filaments are collected in the winding spool 39. Filaments can also be produced by using rotary compression, as shown in FIG.

Mat: The mat is generally undertaken as an extruded tape casting (preferably performed using filaments) to add beads to inline by calendering using an embossing roller as shown in FIGS. 17-18. As shown, the material is extruded out of the extruder die 42 to make a mat of material that does not include beads. From this, a two-dimensional array flows into the calendering operation of adding beads using the embossing roller 40. However, beaded filaments can be used to form the mat by organizing the plurality of filaments into a mesh or by aligning the plurality of filaments into a predetermined array as appropriate in an extruded matrix material. The latter process is similar to continuous preform casting (see below). The matrix material may comprise a reinforcement or may be a composite.

Tow: Tows are generally undertaken as beaded filaments and are generally formed in-line in an extrusion operation, for example by coating the filaments with an extruded matrix material as shown in FIGS. 19 and 20. This process is commonly used for wire and cable coating. The extruded coating material 43 is applied to the beaded filaments 2 in the die body 44. This filament is introduced into the die body through the core tube 46. The guide tip 48 aligns the beaded filament 2 within the opening 50 of the die 52. The uncured tow can then be overlapped (or otherwise organized) and fused, bonded or inline bonded to form a structure with other preforms, such as laminates and fabrics.

Laminates: Laminates are generally undertaken as mats (or filaments / toes) and are generally formed in-line of extrusion operations, as shown in FIGS. 21 and 22, for example by coating the mats with extruded matrix material. As with the tow, the coating material may also include a reinforcement, and may also be a composite of another type. The coating material may also be a material that is applied in multiple layers to be functionally graded and organized in the grade structure.

As with the tow, the uncured laminates can be overlapped and fused or otherwise joined to form structures such as composites, other preforms and fabrics. These combinations may be mechanically formed via intermediate laminated connectors or mechanical fasteners (eg, snap fits or tongues and recesses), or adhesives, fusion bonding and welding (eg, ultrasonic, microwave, radio wave welding). , Induction). It is desirable for the sacrificial preform to be generally removed during the joining process.

The plastic-matrix preform laminate can be melted and cured slightly on its surface. In addition to the heating, the superimposed metal-metrics preform laminate can be rolled to improve the hardening as well as the quality of the final product.

Laminates and fabrics according to the invention are produced using filaments and mats in, for example, an extrusion process as shown in FIG. 24, a casting process as shown in FIG. 23, and a continuous extrusion process as shown in FIG. 25. Can be.

Thus, all of the above-described processes for producing preforms according to the present invention can be continuous or batch processes, and can be automated to produce high quality and uniform continuous or discontinuous preforms.

Filaments, mats, tows, laminates and fabrics according to the present invention can be used to make materials comprising stress modifier materials in a variety of additional manufacturing processes. For convenience, the list of manufacturing processes in which the preform according to the invention provided by the applicant can be used is as follows.

Additive manufacturing:

Atomic manufacturing;

Layered manufacturing including fusion deposition modeling, stereo-lithography, optical assembly, solid base (polishing) curing, plasma spray molding, sputtering, deposition;

Deformation and Forming:

Including die-die forging, open-die forging, coining, penetrating, hubbing, fullering and edging, roll forging, ring rolling, direct extrusion, indirect extrusion, hydrostatic extrusion and impact extrusion Bulk deformation process;

Sheet metal forming processes including shearing, bulging, rubber forming, high energy forming, superplastic forming, deep drawing, embossing;

Material removal including cutting, polishing, electrical discharge machining, water spraying, abrasive spraying, chemical processing and electrochemical processing and polishing;

casting:

Permanent molds including slush casting, pressure casting, insert molding, centrifugal casting and infiltration casting;

Consumable molds including vacuum casting, ceramic-molding casting, plaster-molding casting, shell molding casting and sand casting;

Gel-casting, injection molding, compression molding, transfer molding, insert molding;

Particulate Material Processing:

Sintering, cold equal pressing, hot equal pressing;

Assembly and Joining Process:

Friction stir welding, resistance welding, explosion welding, soldering and soldering, arc welding, laser welding.

The example below addresses the use of preforms as used in a continuous manufacturing process.

Continuous manufacturing process with preform-continuous casting

The preform according to the invention is ideally suitable for producing materials which are processed using a continuous material manufacturing process, ie continuous (preform molded) casting, continuous extrusion manufacturing process. Continuous preform casting utilizes two substrate manufacturing processes—extrusion and continuous casting used to cast continuous tape material.

Typically, such manufacturing processes produce materials having a constant cross-sectional area of shape, including circular, rectangular, tubular, plates, sheets, and structural products. In the present invention, the processes are adapted to include a preform fixture for turning the filament and / or mat into proper alignment with the matrix material (optionally a reinforcement such as continuous fibers). The fixture can also be used to shape the preform / matrix combination.

The production flow of the continuous preform casting can be unobstructed from introducing the preform into the molten material for the output of the artificial product. Whatever base material (metal, plastic or ceramic) is employed, the initial feedstocks are fluids (or metals), molten metals, monomer solutions, slips and slurries. Since the ceramic is sintered and the metal is generally sagging, the post casting process changes with the choice of matrix material.

The description below relates to an example of a continuous casting process. In the continuous casting process, for example, as shown in FIG. 23, the continuous mat 8 (and / or filament) is fed to the tundish 60 of the casting device 5, where the molten material 59 and The mat flows out of the tundish through a water cooled continuous mold 62. The mold generally determines the thickness and / or profile as well as the length of the finished material and can be positioned vertically, horizontally or at an angle depending on the desired material flow.

The mat / material mixture flows down the exit rack 63 to cool. The cast undergoes an additional process to the final mold through various inline applications of heat and mechanical forces (eg, pinch rolling 64, reheat 66) to give it the desired shape, size, physical properties and surface quality. do. Such inline applications include pinch rolling, reheating / cooling, and the like. After the above-described process, the sizing area 67 makes the slab material to a certain size, where the cutting torch 65 (or other cutting device suitable for a particular cast material) cuts the slab into a plurality of debris. Used for.

Due to the stringency of both casting (e.g. temperature) and post casting processing (e.g. rolling), the size, shape, arrangement and composition of the bead-shaped preforms according to the invention involved in this process are desired in the final product. The arrangement may be structured or organized according to the expected degree of change resulting from the process to obtain an array of voids. For this reason it is desirable that the characteristics of the preform conform substantially to the technology of the continuous processing process in order to produce the desired product.

The preform can be organized for extreme (or bulk) deformation processes, but it is equally well adapted for near net shape casting or thin slab casting, for example.

Metals are known as materials used in continuous casting processes, but continuous casting of plastics and ceramics can be obtained through modification of the basic tape casting process. For example, a liquid resin material (always acrylic syrup) is injected between two horizontal and continuous belts separated by gaskets. This gasket holds the liquid resin and limits the thickness of the tape. Similar processes can be used for the production of metal and ceramic tapes, combination tapes that are all three types of base materials: mixtures or alloys of metals, plastics and ceramics. Laminates and fabrics according to the present invention can be readily produced by employing the above-described process using preform fixtures as a supplement or instead of gaskets.

The preform according to the invention can also be produced as a consumable pattern of mold casting. A pattern or copy of one or part of the product produced by casting is used to determine the shape and dimensions of the mold cavity. Although the matrix material of the pattern is consumable, this pattern comprises the beaded preform according to the invention, which may be sacrificial or permanent. Among the castings, the processes that can use the consumable preform pattern are lost foam and investment casting, described below.

In conventional lost foam casting, the pattern is also made of consumable polystyrene (EPS) beads. When molten metal is injected into the mold, it replaces the evaporating EPS pattern. Preforms having a polystyrene (PS) matrix incorporating beaded filaments and / or mats can be used in the process described above to form an artificial article. This pattern is undertaken with PS preform slabs.

PS preform slabs can be made by continuous preform casting or continuous extrusion processes. The slabs may be formed by introducing the blowing agent into the PS solution or melt and then suitably integral with the beaded filaments and / or mats to form a continuous tape. While the blowing agent inflates the tape to fill the gap between the belts or plates, the tape may be passed through between the belts or plates that maintain the desired gap to fix the tape's dimensions. The aforementioned PS continuous tape can be cooled and cut into slabs. The slabs may be extended in part or in full depending on the choice of subsequent casting procedure.

Beaded filaments and / or mats are aligned in the PS solution or melt to desirably mitigate the degree of expansion by creating the geometry of the pore array in the final product.

To increase yield, the slabs can be converted to EPS preform patterns in a heated mold or die to burn off excess material from the slabs to conform to the shape of the desired pattern. For example, the slabs can be expanded in the heated mold to conform to the shape of the mold cavity, or the excess slabs can be forged to the desired shape in the heated die. In order to further reduce the amount of work, the pattern shape can be cut from the slabs using conventional woodworking equipment, and, if necessary, such a shape can be glued to form the final pattern.

Squeezing casting is a combination of casting and forging. In this process, forging means pressing and pressing the uncured feedstock into a predetermined shape. In pressure casting, the casting preform feedstock according to the present invention is disposed below the preheated die. The heated upper die is then lowered to apply pressure from the beginning to the end of the curing of the feedstock. Using this process, complex shapes can be produced at pressures much lower than those typically required for hot or cold forging. Thus, the tows and laminates can be cured by heat and pressure, and at the same time form the final product while preserving the void space created by the beaded preform (although such preforms can be sacrificial in the process). Can be shaped by a die.

The thermo-mechanical processing of the above-described casting feedstock during pressing will produce forged microstructures with improved ductility over the original cast microstructures. In a similar embodiment of this process, the liquid (or thixotropic material) is forced around the preform pattern in the mold. Since a solid mass of matrix material is used and it is heated to a semisolid (liquid plus solid) state, the thixotropic material eliminates the need to introduce the correct amount of molten metal into the die.

 Because of the nature of thixotropic materials, they can be treated mechanically as solids, but can be molded at low pressures because they flow like liquids upon stirring or pressing. An additional advantage of this material is that there is no turbulence, thereby minimizing gas pick-up and trapping. Moreover, since the material is already partially solid, condensation and shrinkage and the associated undesirable porosity are reduced. For example, semi-solid metals are viscous and flow, allowing thin cast sections to fill quickly without ejecting and spraying the liquid metal normally occurring.

Pultrusion

Although continuous preform casting processes can be used to form intermediate and final products consisting of plastics, metals and ceramics, plastic resins are typically matrix materials used in drawing processes. It is a cost effective and automated process for the continuous production of composite materials having a constant cross-sectional area, such as round, rectangular, tubular, plates, sheets and structural products. However, recent technological innovations have also made it possible to draw out composites of varying cross-sectional areas.

The drawing process can be used to produce both laminates and fabrics comprising the preform according to the invention (see FIG. 24). Thus, a fixture 73 is provided in the drawing system to properly align the preform with the matrix material corresponding to the desired product profile and structure.

According to the present invention, the drawing process, as shown in FIGS. 24 and 25, generally involves a fiber supply system 69, a resin bath 74, a preform fixture / heating die 76, a synchronous puller 78 and a cut. Device 80 (eg, a torch, a saw, etc.). One or more continuous filament 2 (or mats and / or weaves) bundles are guided through a feed fixture 73 which aligns the preform with the matrix material and outlines the desired shape of the combination of components. The composite can then be pulled through one or more heating dies 76 (fixed or floating) for further shaping, consolidation and condensation of the matrix material and to remove sacrificial filaments, mats and / or squeezes. . Thereafter, the produced material is cooled and cut into predetermined lengths for further manufacture into intermediate and finished products.

Continuous Extrusion

Continuous extrusion may be used in conjunction with drawing (extrusion apparatus 31 shown in Figure 25) to construct a continuous process in which the preform is produced through extrusion and organized into a final product using the drawing process. Extrusion is the process of forcing a continuous stream of material into a forming tool (die) or into some other subsequent forming process to form filaments, mats and laminates according to the invention.

Thus, the laminate may be formed by either post extrusion coding of beaded filaments and mats using a matrix material and post extrusion addition of a fabric to the tape. In the latter case, the tape can be ablate through specific graining or selective laser burning in a pattern applied by, for example, calendaring.

Batch Processing

Batch processing techniques may also be used for the production of preforms in accordance with the present invention as well as artificial intermediates and consumer goods, including having stress adjusting structures. This batch process involves additional manufacturing (AM) and special manufacturing techniques. The former may be an independent batch process while the latter may also be a continuous process.

Additional fabrication (AM) gives the ability to incorporate the actual voids for the pore precursors into the fabric in a one step process. The additional fabrication is a family of processes that involves creating three-dimensional objects by placing layers of two-dimensional material on top of each other automatically under computer control. The geometrical complexity of the structure has the advantage that it hardly impacts the manufacturing process. This process family is now known as Rapid Prototyping and Solid Freeform Fabrication or Layered Manufacturing. These include purely additional processes such as selective laser sintering and laser metal deposition, and hybrid methods such as forming deposition, including both deposition and removal of materials.

The AM process regenerates the preforms of layer to layer according to an unobstructed sequence. For example, the fabric according to the invention can be produced as a layer comprising a series of alternating layers of solid mass and either bead (sacrificial or permanent) or real beads.

A good and powerful feature of AM used in conjunction with the present invention is its ability to impart changes in macrostructures and microstructures to products. Thus, this technique can be used to incorporate the actual voids and preform materials into the fabric and to create heterogeneous and hierarchical composites.

It is also possible to use AM technology using three-dimensional printing, which offers the potential for the production of intermediate and complete fabrics according to the invention to create functional parts and articles made of plastic, metal and ceramic powders.

Particle manufacturing techniques (powder metallurgy) mix fine powder materials (metals, plastics and ceramics) to compress (compress) them into the desired shape, and then heat them in a controlled atmosphere to bond the contact surfaces of the particles to obtain the desired characteristics. Sintering). The filaments and mats according to the invention of the appropriate size, shaped and positioned are enumerated above by enclosing the preform with powder material and compressing the compound into a "green" fabric for later sintering into the final artificial product. Can be incorporated into the process. One advantage of this process is that the assembled material can maintain its shape before and during sintering. During sintering, the “clean” fabric can be heated just below the melting point of the matrix material and just below the melting point of the liquid. As a result, the compact will not loosen its shape. Thus, the void space will be preserved because the compressed particles are only slightly melted and joined to form the final product. During sintering, of course any sacrificial preforms can be removed.

For high tolerance products, the sintered product can be compressed again, which generally allows the product to be made more accurate with a better surface finish. The voids can also be injected in an oil bath, for example. This process is very similar to the continuous casting described above except that the matrix material is powder and does not melt.

Particulate technology can be applied to form fabrics for use as consumable patterns for lost foaming and investment casting, as well as preforms for press casting. Particle technology is the basis of various ceramic and polymer resin processing technologies, including tape casting of ceramics and plastics as well.

The symmetry of the particular stress regulating structure and the simultaneous vertical arrangement of the voids are provided to enable the fabrication of the processed materials, parts, products and structures using a wide range of manufacturing processes described below. Among these processes, the choice of the best process for producing the particulate product is determined by the function of several basic considerations, including the product's geometric shape, material properties and economics.

Fine grained material as precursor to stress modulating structures with voids

The voids for the artificial structure including the stress modulating structure may also be provided by incorporating a texture onto the laminate. Examples of such fabrics are shown in FIGS. 26-28. As shown, dimples 78 are added on the material surface. Such dimples may be included over the entire thickness of the material, that is, one side of the material is provided with dimples (shallow openings) and the other side of the material is provided with corresponding projecting areas.

In general, in order to produce good symmetrical voids according to the invention using texturizing, the fabric pattern can be incorporated into one or both sides of the laminate, depending on the void array implemented in the final artificial product. Grain making can also give tape cutting and stacking guidance of the stack, so that the stack can be more easily assembled into composites and finished products (as with the tow and stack described above).

The fabric can be added to the laminate through imprinting and excising (ie, removal of material). In order to minimize the material requirements, it is used to impart the necessary fabrics on the laminate surface according to the invention. Imprinting redistributes the material of the laminate so that it is not wasted (waste due to ablation). Thus, the pore precursor at the laminate surface can either (1) compress (eg, by forging depression) of a localized material that redistributes the material out of plane, or (2) redistribute the laminate material within the plane (eg, By rolling forming).

According to a preferred embodiment, the thixotropic laminate material is used during imprinting of the fabric. The material is easily redistributed because the laminate is imprinted when the thin material is heated to a "clean" state. In a continuous casting or molding process, this is readily accomplished in the field during the casting of metals, plastics and ceramics. Thus, metals such as aluminum and iron (eg foil) can be inline imprinted later in the hot rolling sequence; The plastic can be inline imprinted, for example, during plastic film casting; And the ceramic can be inline printed during tape casting when the tape is in a clean unfired state.

In addition to ensuring material redistribution, it is independent of creating a grainy pattern when cutting the laminate, for example through selective laser combustion or chemical etching.

The advantage of grain making in tape casting to produce patterned laminates is to form monolithic composite structures comprising many layers (which can be, for example, composites of different bases to produce functionally graded products). In order to strengthen the tape using heat, pressure and holding time. This advantage can be augmented by drawing and graining of the uncured tape as the tape casting line continues while the tape is still heated.

Composites formed from grained laminates are generally well formed using mechanical and adhesive connections as well as welding in general. It can be compressed to obtain hardening, but is particularly suitable for grained metals. On the other hand, the engraved ceramic laminate must be sintered.

Textured plastic laminates can also be welded using microwave, ultrasonic, radio, or inductive techniques. Induction welding uses the heat generated by the metal filler in the plastic that moves through the magnetic field to heat the plastic material.

Although the system of the present invention has been described with reference to the above-described manufacturing materials, processes, and systems, it will be apparent to those skilled in the art that other materials, processes, and systems not specifically mentioned herein may be used.

While the present invention has been described with reference to preferred embodiments, numerous changes in structure may be employed without departing from the true spirit of the invention as defined in the appended claims.

Claims (85)

A bead type preform for forming a plurality of voids in a material to be processed, comprising a plurality of adjacently placed beads. The bead-shaped preform according to claim 1, wherein the beads are spaced apart by a predetermined distance. The bead-shaped preform according to claim 1, wherein the beads are sized after incorporation into the final material. The bead-shaped preform according to claim 1, wherein the plurality of beads are arranged along strands forming a filament. 5. The bead-shaped preform according to claim 4, further comprising a coating applied to the filament. 5. The beaded preform according to claim 4, wherein the plurality of filaments are interwoven to form a fabric. The bead-shaped preform according to claim 4, wherein the plurality of filaments are assembled to form a casting feedstock. The bead-shaped preform according to claim 4, wherein the filament is substantially continuous. The bead-shaped preform according to claim 4, wherein the filament is discontinuous. The bead-shaped preform according to claim 2, wherein the plurality of spaced beads are arranged along a plurality of strands forming a plurality of filaments. The bead-shaped preform according to claim 10, further comprising a coating applied to the filament. 12. The bead-shaped preform according to claim 11, wherein the filaments are coated with the coating to be arranged in a two-dimensional array to form a laminate. 11. The beaded form of claim 10, wherein the filament comprises a first group of filaments having a plurality of first beads of a first size and a second group of filaments having a plurality of second beads of a second size Preform. 11. The bead-shaped preform according to claim 10, wherein each of the filaments includes a guide for arranging the filaments. 15. The bead-shaped preform according to claim 14, wherein the guide comprises a cutting guide. The bead preform according to claim 1, wherein the plurality of beads are arranged on a grid forming a mat. 17. The beaded preform of claim 16 wherein the mat comprises a lamination guide for proper assembly with a second mat. The bead-shaped preform according to claim 16, wherein the mat includes a cutting guide. 17. The bead-shaped preform according to claim 16, further comprising a coating applied to the mat forming the laminate. 20. The beaded preform of claim 19 wherein said laminate is substantially continuous. 20. The bead-shaped preform of claim 19, wherein the laminate is discontinuous. 20. The bead-shaped preform according to claim 19, wherein the plurality of laminates are arranged to form a casting feedstock. 20. The bead-shaped preform of claim 19, wherein the plurality of laminates are combined to form a composite. The bead-shaped preform of claim 23, wherein the composite comprises a fabric. 20. The beaded preform of claim 19 wherein the coating comprises a reinforcing material. 20. The bead-shaped preform according to claim 19, wherein each of the laminates includes holes for facilitating the flow of material between the laminates. The bead type preform according to claim 1, wherein the bead type preform is rigid. The bead preform according to claim 1, wherein the bead preform is flexible. The bead-shaped preform of claim 1, wherein the plurality of beads are of various sizes. The bead-shaped preform of claim 1, wherein the plurality of beads are of substantially similar size. The bead-shaped preform according to claim 1, wherein the plurality of beads have a specific shape. 32. The beaded preform as claimed in claim 31 wherein the shape comprises a geometric shape. 33. The bead preform as claimed in claim 32 wherein the geometric shape is spherical. The bead-shaped preform according to claim 1, wherein the plurality of beads are substantially hollow. The bead preform according to claim 1, wherein the plurality of beads are substantially solid. The bead preform of claim 1, wherein the plurality of beads comprises a mixture of substantially solid and hollow beads. The bead-shaped preform according to claim 1, wherein one of the beads includes a predetermined device. The bead-shaped preform of claim 1, wherein any one of the beads comprises a sensor. The bead preform of claim 1, wherein any one of the beads comprises a monitoring device. The bead preform according to claim 1, wherein any one of the beads comprises an actuator. A method of manufacturing a bead type preform for forming a plurality of voids in a material to be processed, Extruding the preform material out of the first opening to produce an extruded preform material; Calendaring the extruded preform material to form a plurality of adjacently located beads along the drawn material. 42. The method of claim 41 wherein the method comprises drawing the extruded material to produce a drawn material prior to calendering the extruded material. 40. The method of claim 39 wherein the material is heated prior to extruding from the first opening. 44. The method of claim 43 wherein the material is heated to a dissolution temperature. 41. The method of claim 40 wherein the material is cooled after being extruded from the first opening. 40. The method of claim 39, wherein the result of the method is a filament comprising strands of adjacently located beads. 40. The method of claim 39, wherein the method produces a two-dimensional array of adjacently located beads. A method of making a coated bead shaped preform for forming a plurality of voids in a material to be processed, Providing a first flow of extrusion coating material to the die; Providing the bead-shaped preform in the first flow to cover the coating material; And extruding the first flow from the opening with the beaded preform to form a tow. 49. The method of claim 48 wherein the bead shaped preform comprises a filament. 49. The method of claim 48, wherein the beaded preform comprises a two-dimensional array of adjacently located beads. 49. The method of claim 48 wherein a reinforcing material is provided in the first stream before the first stream is extruded out of the opening. As a method of manufacturing a material to be processed having a plurality of voids, Guiding one or more preforms to a supply of first material, each of the one or more preforms comprising a plurality of beads spaced apart from each other at predetermined intervals along the strand; Coating said first material on said at least one preform; Shaping the coated preform into a predetermined shape; And hardening the shape. 53. The method of claim 52, wherein the voids are structured. 53. The method of claim 52, wherein the pores are symmetrically organized. 53. The method of claim 52, wherein the voids are asymmetrically textured. 53. The method of claim 52, wherein the pores are organized in a random arrangement. 53. The processed material of claim 52, wherein the curing removes one or more bead-shaped preforms such that the bead is a processed material that includes a plurality of voids at a location previously present. Manufacturing method. 53. The method of claim 52, wherein the bead comprises a second material different from the first material. 53. The method of claim 52, further comprising cutting the processed material to a particular length after curing. A method of manufacturing a processed structure consisting of a plurality of voids forming a structure using a continuous casting device, Guiding a preform comprising a plurality of beads spaced from each other at predetermined intervals along the strand to a matrix material contained in a first container; Directing the matrix material into spaces at predetermined intervals, And the material to be processed comprises a plurality of voids forming a structure in which the material is processed to have a predetermined thickness equal to the gap. 61. The method of claim 60, wherein the space is formed by a die. 61. The plurality of voids of claim 60, wherein the space comprises a gap between a first conveyor belt running in a first direction and a second conveyor belt running in the first direction. A method of making a structure to be processed. As a method for forming a composite in which a plurality of voids forming a tissue are arranged therein, Imparting a first void of a first array on a first stack, wherein an opening for the first void is formed on a first side of the first stack; Imparting a second void of a second array on a second stack, wherein an opening for the second void is formed on a second side of the second stack; Aligning said first opening of said first void of said first laminate with a corresponding second opening of said second void of said second laminate; Assembling the first laminate with the second laminate such that the first void and the corresponding second void are in communication with a plurality of voids forming a tissue arranged therein. Method for forming a complex. 64. The method of claim 63, wherein the plurality of first stacks are assembled with the plurality of second stacks. 64. The plurality of voids of claim 63, wherein the first voids of the first array comprise voids of a first group having a similar first size and voids of a second group having a similar second size. A method for forming a composite arranged therein. 66. The method of claim 65, wherein the first void of the first array and the second void of the second array of the first stack are corresponding first group of pores having a similar first size, and the second stack. And a corresponding second group of pores having a similar second size in said second array of said second pores of the sieve. 64. The method of claim 63, wherein the recess is formed by imprinting at least one of the first laminate and the second laminate to form a composite with a plurality of voids forming a tissue arranged therein. Way. 67. The method of claim 67, wherein imprinting comprises calendering the stack with an embossing roller. 64. The structured plurality of voids of claim 63, wherein the recess is imparted on the stack by removing a portion of the material forming at least one of the first stack and the second stack. Method for forming a complex. 70. The method of claim 69, wherein the removal of the material is via laser combustion. 70. The method of claim 69, wherein the removal of the material is via chemical etching. 66. The structure of claim 63, wherein a plurality of voids forming a tissue are arranged therein, wherein the recess is imparted to at least one of the first stack and the second stack in a periodic manner. Method for forming a complex. 64. The composite of claim 63, further comprising imparting a second void of a second array on the second side of the first stack to form a composite having internally arranged a plurality of voids therein. How to. A laminate assembled from a composite material, the laminate comprising a fabric having a plurality of recesses on a first side, the recesses corresponding to a plurality of protrusions on a second side of the laminate. sieve. 75. The laminate of claim 74, wherein the recess and the corresponding protrusion are symmetrically positioned along the laminate. 75. The laminate of claim 74, wherein the recess and corresponding protrusions are of various sizes. 75. The laminate of claim 74, wherein the recess is of similar size. 75. The laminate of claim 74, wherein the protrusions are of similar size. 75. The laminate of claim 74, wherein the laminate comprises a continuous tape. 75. The laminate of claim 74, wherein one of the recesses contains a monitoring device. 81. The laminate of claim 80, wherein the monitoring device comprises a sensor. 81. The laminate of claim 80, wherein said monitoring device comprises an actuator. 75. The laminate of claim 74, wherein the recess comprises a curved shape. A method of manufacturing a material to be processed having a plurality of voids forming a tissue, Guiding a bead-shaped preform comprising a plurality of spaced beads in a continuous cast of molten material. A method of manufacturing a material to be processed having a plurality of voids forming a tissue, Providing to a predetermined process a bead-shaped preform comprising adjacently located bead strands, the predetermined process comprising: As an additive manufacturing, including atomic manufacturing, and layering manufacturing, the layering manufacturing includes fusion deposition modeling, stereo-lithography, optical assembly, solid base (polishing) curing, plasma spray molding, Additional fabrication including sputtering, deposition, Including die-die forging, open-die forging, coining, drilling, hubbing, fullering and edging, roll forging, ring rolling, direct extrusion, indirect extrusion, hydrostatic extrusion and impact extrusion Deformation and molding, including bulk deformation processes Sheet metal forming processes including shearing, bulging, rubber forming, high energy forming, superplastic forming, deep drawing, embossing, Material removal including cutting, polishing, electrical discharge machining, water spraying, abrasive spraying, chemical processing and electrochemical processing and polishing, As a casting comprising permanent mold, consumable mold, gel-casting, injection molding, compression molding, transfer molding, and insert molding, the permanent mold includes slush casting, pressure casting, insert molding, centrifugal casting and infiltration casting. The consumable mold may include a casting including vacuum casting, ceramic-molding casting, plaster-molding casting, shell molding casting and sand casting, Particulate material processing including sintering, cold equal pressing, and hot equal pressing; and Assembly and joining processes including friction stir welding, resistance welding, explosion welding, soldering and soldering, arc welding, laser welding Which is one of them, a process for producing a processed material having a plurality of voids forming a tissue.

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