WO2023216421A1 - 用于增材制造丝材的流道可自动抬升熔融浸渍装置 - Google Patents

用于增材制造丝材的流道可自动抬升熔融浸渍装置 Download PDF

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WO2023216421A1
WO2023216421A1 PCT/CN2022/107550 CN2022107550W WO2023216421A1 WO 2023216421 A1 WO2023216421 A1 WO 2023216421A1 CN 2022107550 W CN2022107550 W CN 2022107550W WO 2023216421 A1 WO2023216421 A1 WO 2023216421A1
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Prior art keywords
flow channel
resin
impregnation
riser
additive manufacturing
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English (en)
French (fr)
Inventor
单忠德
宋文哲
王靖轩
范聪泽
郑菁桦
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Nanjing University of Aeronautics and Astronautics
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Nanjing University of Aeronautics and Astronautics
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Priority to US18/572,780 priority Critical patent/US12576557B2/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/06—Making preforms by moulding the material
    • B29B11/10—Extrusion moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
    • B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
    • B29B15/14—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length of filaments or wires
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive 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
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/118—Processes 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]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive 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
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/205—Means for applying layers
    • B29C64/209—Heads; Nozzles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive 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
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/307—Handling of material to be used in additive manufacturing
    • B29C64/314—Preparation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE 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
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE 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
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/10—Pre-treatment
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the invention belongs to the field of continuous fiber-reinforced thermoplastic resin-based composite materials, and specifically relates to a composite material wire melting and impregnating device that can automatically lift the flow channel for additive manufacturing.
  • thermoplastic resins As a new type of high-performance material, continuous fiber resin-based composite materials are currently widely used in aerospace, wind power generation, rail transportation and other fields, and also have broad application prospects in the civilian field. With the progress of research on new high-performance thermoplastic resins, their performance has become comparable to traditional thermosetting resins, and they have become the focus of recent research and applications because of their environmental friendliness and good biocompatibility.
  • the material characteristics of thermoplastic composite materials make them almost perfectly suitable for the FDM process in 3D printing. However, the poor in-situ impregnation effect, large pore content of printed parts, and poor combination of fibers and resin greatly limit the application and development of this technology.
  • pre-impregnated filament for 3D printing can achieve complete coating of resin, which greatly improves the forming quality and strength of 3D printed components.
  • the traditional solution impregnation method reduces the resin content and cannot achieve effective bonding during the 3D printing process.
  • the melt impregnation method is mainly used for filament forming.
  • problems such as wire breakage and blockage are prone to occur during the impregnation process.
  • it is necessary to realize convenient control of the filament diameter. Therefore, designing an impregnation device that facilitates filament replacement and can quickly adjust the filament forming size has become a focus and difficulty in this field.
  • impregnation devices for preparing continuous fiber-reinforced thermoplastic resin composite materials are as follows:
  • the patent application with publication number CN204674042U discloses a melt impregnation die system, including a melt diversion device and a glass fiber impregnation device located below it.
  • the device itself is detachable, making it easy to replace the guide rollers and tension shafts in the frame, speeding up the disassembly and installation, improving the fusion effect of glass fiber and polypropylene melt, and overall improving production efficiency.
  • the publication number is CN 102848489 A.
  • the patent application discloses a melt impregnation machine head and method for continuous long fiber reinforced thermoplastic resin molding.
  • the machine head is equipped with a melt distribution channel and an impregnation channel to match the length of each bundle.
  • the melt pressure and flow rate of fiber bundle contact remain consistent, ensuring a balanced impregnation effect between each continuous long fiber.
  • there is no lifting device, and high-temperature operation is required to deal with broken wire problems, which is prone to safety accidents, and it is impossible to prepare variable-diameter wire.
  • the present invention discloses a composite material wire melting and impregnating device that can automatically lift the flow channel for additive manufacturing, realize the automatic lifting of the flow channel, and facilitate the treatment and replacement of broken wires while maintaining a high temperature and a molten resin state. Fiber greatly improves production continuity and production efficiency.
  • Composite material filament melt impregnation device with automatically lifting runner for additive manufacturing including mechanical lifting device, heating device, curved resin impregnation runner, guide wire block, single-screw extruder, replaceable combined die nozzle, Resin riser;
  • the mechanical lifting device uses multiple sets of screw guide motors that operate in coordination and synchronization to realize the automatic lifting and lowering functions of the flow channel;
  • the heating device includes a heating resistor outside the screw extruder barrel, and multiple sets of heating to control the impregnation temperature up and down the flow channel.
  • the wire guide block is located at the fiber inlet at the front end of the runner to adjust the angle of the fiber entering the impregnation runner to reduce wear;
  • the curved resin impregnation runner consists of a trapezoidal narrow runner that fits up and down.
  • the pressure block of the tank forms an S-shaped curved runner; the screw extruder is located on the side of the impregnation runner to evenly transport molten resin into the runner; the replaceable combined die nozzle is located at the rear of the impregnation runner; the resin riser is located below the replaceable die nozzle .
  • the mechanical lifting device is equipped with at least four screw guide motors that are aligned, distributed, and operated in a coordinated and synchronous manner.
  • the lower part of the guide rail is connected to the working platform to ensure stability during the operation.
  • the upper part of the curved flow channel is connected by the ball screw and the connecting block.
  • the half part is connected to the guide rail, and the motor drives the screw to rotate to realize the automatic lifting, lowering and stabilization of the flow channel.
  • the temperature change range of the heating device is set according to the type of thermoplastic resin.
  • the upper heating block of the flow channel is evenly distributed on the upper cover plate, and the lower heating block of the flow channel is evenly distributed with the lower bottom plate and the lower W-shaped pressing block to ensure that the temperature in the flow channel is stable.
  • the guide block is located at the fiber inlet at the front end of the flow channel and consists of at least two pairs of rotating shafts in the transverse and longitudinal directions to ensure that the fiber enters the impregnation flow channel at a certain angle range.
  • the impregnation angle of the curved flow channel is 120°, and the curved part is designed with rounded corners to reduce fiber wear during the impregnation process.
  • a vertical melting cavity is left at the connection between the end of the flow channel and the replaceable combined die nozzle so that the resin riser communicates with the replaceable combined die nozzle.
  • the replaceable combined die nozzle consists of a connecting section and a replacement section.
  • the connecting section is used to connect the impregnation flow channel.
  • the heating resistor coil is wrapped around the connecting section to ensure the fluidity of the resin at the die nozzle.
  • the replacement section is the wire forming outlet.
  • the diameter can be replaced with 0.6, 0.8, 1.0, 1.2mm and is not limited to the above sizes.
  • the resin riser is located directly below the combined die nozzle and is connected to the combined die nozzle. There is a rectangular gap at the bottom of the resin riser to facilitate resin flow.
  • the top of the riser is equipped with a threaded press block and a spring. The press block is controlled according to the wire forming quality. The screwing in and out adjusts the spring pressing force, discharges extra resin from the riser, and improves the wire forming quality.
  • the working principle of the present invention is:
  • control the mechanical lifting device After setting the temperature parameters according to the selected resin, control the mechanical lifting device to perform the lifting action, lift the upper part of the impregnation runner, and pass the carbon fiber dry yarn through the guide block, the impregnation runner and the replaceable die nozzle, and then control the mechanical lifting device Carry out the descending action until the upper part of the impregnation flow channel is in close contact with the lower part of the impregnation flow channel to complete the entire threading action. Start the extruder and pull the carbon fiber filament. Under the action of the internal curved structure of the impregnation runner and the melt pressure, the filament is melt-impregnated to obtain a thermoplastic resin-based composite filament with a good degree of impregnation.
  • the design of the liftable flow channel reduces the dependence on manual lifting during wire threading and wire changing, and greatly reduces safety risks in the production process.
  • die nozzles of different calibers can be easily replaced without repeated lifting and threading movements during the forming process.
  • the automatic lifting of the flow channel is realized through the mechanical lifting device, which facilitates the processing of broken wires and fiber replacement while maintaining high temperature and resin melting state, which greatly improves production continuity and production efficiency.
  • the structural design of the guide block and the flow channel reduces the occurrence of broken wires and hairiness caused by excessive friction caused by fiber deflection during the impregnation process.
  • the setting of the riser enables real-time adjustment of the amount of resin coating on the surface of the forming wire, which facilitates the control of the wire forming quality at any time.
  • the design of the replaceable combined die nozzle ensures that the wire diameter can be easily adjusted during the production process, improving the applicability and production efficiency of the impregnation device.
  • Figure 1 is an overall structural diagram of the melt impregnation device of the present invention.
  • Figure 2 is a diagram of the mechanical lifting device of the melt impregnation module of the present invention.
  • Figure 3 is a structural diagram of the impregnation flow channel of the melt impregnation device of the present invention.
  • Figure 4 is a structural diagram of a single-screw extruder of the melt impregnation device of the present invention.
  • Figure 5 is an exploded view of the riser structure of the melt impregnation device of the present invention.
  • Figure 6 is a front view of the guidewire block.
  • Figure 7 shows the assembly diagram of the melt impregnation runner.
  • the present invention provides a composite material wire melting and impregnating device with a flow channel for additive manufacturing that can automatically lift, and is used for the preparation of composite material wires.
  • the forming device includes a mechanical lifting device 1, a heating device 2, a curved resin impregnated flow channel 3, a guide wire block 4, a single-screw extruder 5, a replaceable combined die nozzle 6, and a resin riser 7 arranged in sequence.
  • the mechanical lifting device 1 includes four sets of guide screws 101 symmetrically distributed in the impregnation module, an upper cover plate connector 102, and a base connector 103.
  • the guide screw 101 is a mechanical lifting module composed of at least a pair of optical axes 104, at least one screw 105, and a stepper motor 106.
  • the curved resin impregnated flow channel 3 includes an upper part 301 of the impregnated flow channel and a lower part 302 of the impregnated flow channel.
  • the upper part 301 of the impregnation flow channel and the lower part 302 of the impregnation flow channel have a trapezoidal groove 303 as the flow channel part.
  • the groove has a plane length of 5 to 10 mm, a slope length of 5 to 10 mm, a slope angle of 15 to 25°, and a truncated cone shape.
  • the groove 304 is used to receive the molten resin delivered by the single-screw extruder 5 and distribute it into the flow channel.
  • the radius of the truncated cone-shaped groove gradually transitions from 20 mm to 10 mm.
  • a communication groove 305 is left at the end of the flow channel for connecting the replaceable combined die nozzle 6 and the resin riser 7 .
  • the screw extruder 501 is connected to a resin pellet inlet 502 for inputting the resin pellets into the S-shaped curved flow channel.
  • the replaceable combined die nozzle 6 consists of two parts: a connecting section 601 and a replacement section 602.
  • the connecting section 601 is used to connect the impregnation flow channel 3.
  • the heating resistance coil 202 is wound around the connecting section 601 to ensure the fluidity of the resin at the mold nozzle 6.
  • Replacement Section 602 is the wire forming outlet, and the diameter can be replaced by 0.6 ⁇ 1.2mm and is not limited to the above size.
  • the resin riser 7 includes a riser connection 701, a riser plug 702, a riser spring 703, a riser gasket 704, a riser sleeve 705, and a riser bolt 706.
  • the riser connection has an opening 2 mm close to the edge.
  • this embodiment provides a specific process for wire preparation using the above melt impregnation device:
  • the target is to prepare continuous carbon fiber reinforced PLA composite wire with a diameter of 1.3 mm.
  • the heating device 2 is enabled, and the screw extruder heating resistor 503 is set to 210°C. After the temperature rises to the set temperature for a certain period of time, the mechanical lifting device 1 is controlled to perform a lifting action to lift the upper part 301 of the impregnation flow channel. Pass the Toray 3K carbon fiber filament through the two pairs of rollers of the guide block 4 into the impregnation module, place the carbon fiber filament in the trapezoidal groove 303, and replace the replacement section 602 of the replaceable combined die nozzle 6 with a hole diameter of 1.3mm. Then the wire threading process is completed through the replaceable combined die mouth 6 .
  • the mechanical lifting device 1 is controlled to perform a lowering action until the upper part 301 of the immersion flow channel and the lower part 302 of the immersion flow channel are in close contact.
  • the above process can achieve safe and stable preparation of the target product.
  • the goal in this embodiment is to deal with the situation of wire breakage during the preparation of continuous carbon fiber reinforced PLA composite wire with a diameter of 1.3 mm.
  • the mechanical lifting device 1 is controlled to perform a lowering action until the upper part 301 of the immersion flow channel and the lower part 302 of the immersion flow channel are in close contact.
  • the goal is to prepare a continuous carbon fiber reinforced PLA composite wire with a diameter of 0.8 mm instead of a continuous carbon fiber reinforced PLA composite wire with a diameter of 1.3 mm.

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  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
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  • Manufacturing & Machinery (AREA)
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  • Reinforced Plastic Materials (AREA)
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Abstract

本发明公开了一种用于增材制造的流道可自动抬升复合材料丝材熔融浸渍装置包括机械抬升装置、加热装置、弯曲树脂浸渍流道、导丝块、单螺杆挤出机、可替换组合模嘴、树脂冒口。本发明可大幅度提高连续纤维丝材成形过程中更换丝材、处理断丝的效率，降低生产过程的操作难度，保障操作人员安全性；通过树脂冒口的设计可实现生产过程中小幅动态调节熔腔内压力大小，提高产品质量稳定性，最终实现高性能连续纤维复合材料丝材连续生产与快速替换。

Description

用于增材制造丝材的流道可自动抬升熔融浸渍装置 技术领域
本发明属于连续纤维增强热塑性树脂基复合材料领域，具体涉及用于增材制造的流道可自动抬升的复合材料丝材熔融浸渍装置。
背景技术
连续纤维树脂基复合材料作为一种新型、高性能材料，目前正广泛应用于航空航天、风力发电、轨道交通等领域，并在民用领域也有着广阔的应用前景。随着新型高性能热塑性树脂相关研究的进展，其性能已可与传统热固性树脂媲美，并因其环境友好、生物兼容性好成为日前研究与应用的重点。而热塑性复合材料的材料特点使其几乎完美适用于3D打印中的FDM工艺，但原位浸渍效果差，打印件孔隙含量大，纤维与树脂结合程度差极大限制了该技术的应用与发展。采用预浸渍丝材进行3D打印可实现树脂的完全包覆，极大提升了3D打印构件的成形质量与强度。传统溶液浸渍方法树脂含量降低，3D打印过程中无法实现有效粘结，目前丝材成形主要采用熔融浸渍方式。但由于热塑性树脂流动性差，粘度大，浸渍过程中易出现断丝、堵丝等问题；同时，出于纤维体积分数调整、打印丝材直径变化的考虑，需实现丝材直径的便捷调控。因此，设计出便于替丝换丝、可快速调整丝材成形尺寸的浸渍装置成为本领域的重点和难点。
已公开的一些用于制备连续纤维增强热塑性树脂复合材料浸渍装置如：公开号为CN204674042U专利申请中公开了一种熔融浸渍模头系统，包括熔体导流装置及设于其下方的玻纤浸渍装置，本身可拆卸，便于更换框架内的导向辊与张力轴，加快了拆卸和安装的速度，改善了玻纤和聚丙烯熔体的融合效果，总体提升了生产效率。但无抬升装置，处理断丝问题时需高温作业，易产生安全事故，也无法实现变直径丝材制备；公开号为CN 207859241 U专利申请中公开了一种连续纤维增强热塑性树脂复合材料熔融浸渍装置，熔融浸渍装置包括齿状结构、非接触浸渍辊、接触张力辊和非接触辊。可实现连续纤维增强热塑性树脂复合材料制备。但无抬升装置，处理断丝问题时需高温作业，易产生安全事故，也无法实现变直径丝材制备。公开号为CN 102848489 A专利申请中公开了开一种连续长纤维增强热塑性树脂成型用的熔融浸渍机头及方法，机头内设有熔体分配流道和浸渍流道，使与每束长纤维束接触的熔体压力、流量都保持一致，保证了每根连续长纤维之间浸渍效果的均衡。但无抬升装置，处理断丝问题时需高温作业，易产生安全事故，也无法实现变直径丝材制备。
发明内容
为解决上述问题，本发明公开了用于增材制造的流道可自动抬升的复合材料丝材熔融浸渍装置，实现流道的自动抬升，便于在维持高温、树脂熔融状态下处理断丝、替换纤维极大提高了生产连续性与生产效率。
用于增材制造的流道可自动抬升的复合材料丝材熔融浸渍装置，包括机械抬升装置、加热装置、弯曲树脂浸渍流道、导丝块、单螺杆挤出机、可替换组合模嘴、树脂冒口；机械抬升装置采用多组协调同步运作的丝杠导轨电机实现流道自动抬升与降落功能；加热装置包括螺杆挤出机螺筒外加热电阻、流道上下控制浸渍温度的多组加热块、可替换组合模嘴处的加热电阻；导丝块位于流道前端纤维入口处，调节纤维进入浸渍流道角度，减小磨损的产生；弯曲树脂浸渍流道由上下契合的带有梯形狭槽的压块形成S形弯曲流道；螺杆挤出机位于浸渍流道侧面，向流道内均匀输送熔融树脂；可替换组合模嘴位于浸渍流道后部；树脂冒口位于可替换模嘴下方。
进一步的，机械抬升装置至少设有四架对位分布协调同步运作的丝杠导轨电机，导轨下部与作业平台连接保证作动期间的稳定性，由滚珠丝杠及连接块将弯曲流道的上半部分与导轨连接，通过电机带动螺杆转动实现流道的自动抬升、下降与持稳。
进一步的，加热装置温度变化范围根据热塑性树脂种类设置，流道上部加热块均匀分布于上盖板，流道下部加热块均匀分布与下底板和下部W形压块内保证流道内温度稳定。
进一步的，导丝块位于流道前端纤维入口处，由横向纵向至少两对转轴组成，保证纤维以一定角度范围进入浸渍流道。
进一步的，弯曲流道浸渍角为120°，弯曲部分采用倒圆角设计减少浸渍过程中纤维磨损的产生，上下压块中间部位设有梯形凹槽作为树脂与纤维的浸渍通道，给与纤维一定的活动空间的同时防止纤维 产生过大位移。
进一步的，流道末端与可替换组合模嘴连接处留有竖向融腔，使树脂冒口与可替换组合模嘴相通。
进一步的，可替换组合模嘴由连接段和替换段两部分组成，连接段用于连接浸渍流道，加热电阻圈缠绕于连接段保证模嘴处树脂流动性，替换段为丝材成形出口，直径可替换为0.6、0.8、1.0、1.2mm且不限于上述尺寸。
进一步的，树脂冒口位于组合模嘴正下方并与组合模嘴连通，树脂冒口下部设有矩形缺口便于树脂流出，冒口顶端设有螺纹压块及弹簧，根据丝材成形质量控制压块的旋进旋出调节弹簧压紧力，将额外树脂从冒口处排出，提高丝材成形质量。
本发明的工作原理是：
将温度参数根据选定树脂设置后，控制机械抬升装置进行抬升动作，将浸渍流道上部抬升，并将碳纤维干丝穿过导丝块、浸渍流道及可替换模嘴，随后控制机械抬升装置进行下降动作至浸渍流道上部与浸渍流道下部紧密贴合，完成整个穿丝动作。启动挤出机并对碳纤维丝进行牵引动作，在浸渍流道内部弯曲结构及熔体压力作用下，对丝材进行熔融浸渍，以获得浸渍程度较好的热塑性树脂基复合材料丝材。可抬升流道的设计减小了了在穿丝、换丝等过程中抬升动作对人工的依赖性，极大降低了生产过程的安全隐患。同时通过可替换模嘴的设计实现了在成形过程中无需重复抬升、穿丝动作即可便捷替换不同口径模嘴。
与现有复合材料丝材熔融浸渍装置设备相比，本发明的优点在于：
1、通过机械抬升装置实现流道的自动抬升，便于在维持高温、树脂熔融状态下处理断丝、替换纤维极大提高了生产连续性与生产效率。
2、导向块及流道内结构设计减少了纤维在浸渍过程中由于偏移引起摩擦力过大导致的断丝及毛羽的产生。
3、冒口部位的设置实现了实时调节成形丝材表面树脂包覆量，便于丝材成形质量的随时调控。可替换组合模嘴的设计保证了生产过程中可便捷调控丝材直径，提高了浸渍装置的适用性与生产效率。
附图说明
图1为本发明熔融浸渍装置的整体结构图。
图2为本发明熔融浸渍模块的机械抬升装置图。
图3为本发明熔融浸渍装置的浸渍流道结构图。
图4为本发明熔融浸渍装置的单螺杆挤出机结构图。
图5为本发明熔融浸渍装置的冒口结构爆炸视图。
图6、为导丝块正面图。
图7、为熔融浸渍流道装配图。
具体实施方式
下面结合附图和具体实施方式，进一步阐明本发明，应理解下述具体实施方式仅用于说明本发明而不用于限制本发明的范围。需要说 明的是，下面描述中使用的词语“前”、“后”、“左”、“右”、“上”和“下”指的是附图中的方向，词语“内”和“外”分别指的是朝向或远离特定部件几何中心的方向。
如图1所示，本发明提供用于增材制造的流道可自动抬升的复合材料丝材熔融浸渍装置，用于复合材料丝材的制备。该成形装置包括依次设置的机械抬升装置1、加热装置2、弯曲树脂浸渍流道3、导丝块4、单螺杆挤出机5、可替换组合模嘴6、树脂冒口7。
请结合图1-5所示，所述机械抬升装置1包括对称分布于浸渍模块的四组导轨丝杠101，上盖板连接件102，底座连接件103。所述导轨丝杠101为至少一对光轴104、至少一根丝杠105、步进电机106构成的机械抬升模块。所述弯曲树脂浸渍流道3包括浸渍流道上部301、浸渍流道下部302。所述浸渍流道上部301、浸渍流道下部302中部开有梯形凹槽303作为流道部分，该凹槽平面长5～10mm，斜面长5～10mm，斜面角度15～25°，圆台形凹槽304用于承接单螺杆挤出机5输送的熔融树脂并分配到流道内部，该圆台形凹槽半径由20mm逐渐过渡至10mm。流道末端留有联通槽305用于使可替换组合模嘴6与树脂冒口7联通。所述螺杆挤出机501连接一个树脂粒料投放口502，用以将树脂粒料输入S形弯曲流道。所述可替换组合模嘴6包括连接段601和替换段602两部分组成，连接段601用于连接浸渍流道3，加热电阻圈202缠绕于连接段601保证模嘴6处树脂流动性，替换段602为丝材成形出口，直径可替换为0.6～1.2mm且不限于上述尺寸。所述树脂冒口7包括冒口连接701、冒口堵头702、冒口弹 簧703、冒口垫片704、冒口套筒705、冒口螺栓706，其中冒口连接靠近边缘2mm处开有矩形孔707，冒口套筒对应部位开有90°扇形孔708用于树脂顺利流出。
同时，本实施例提供了利用上述熔融浸渍装置进行丝材制备的具体过程：
本实施例中目标制备直径为1.3mm的连续碳纤维增强PLA复合丝材。
启用加热装置2，螺杆挤出机加热电阻503设置为210℃，待温度上升至设置温度一定时间后，控制机械抬升装置1进行抬升动作，将浸渍流道上部301抬升。将东丽3K碳纤维丝从导丝块4两组对辊中间穿过进入浸渍模块，并将碳纤维丝放置于梯形凹槽303中，更换可替换组合模嘴6孔径为1.3mm的替换段602，随后穿过可替换组合模嘴6完成穿丝过程。控制机械抬升装置1进行下降动作至浸渍流道上部301与浸渍流道下部302紧密贴合。将PLA粒料放置于树脂粒料投放口502，设置螺杆挤出机转速为5r/min，调节冒口螺栓706使其放松，观察冒口处情况，当有树脂流出时，牵引纤维丝开始浸渍过程，调节螺杆挤出机速度为13r/min，并根据丝材表面树脂包覆量动态调节冒口螺栓706使制丝质量稳定。如上述过程可实现目标产品的安全稳定制备。
本实施例中目标为处理制备直径为1.3mm的连续碳纤维增强PLA复合丝材制备过程中断丝情况。
停止螺杆挤出机5转动，保持加热块2、螺杆挤出机加热电阻503 温度不变，控制机械抬升装置1进行抬升动作，将浸渍流道上部301抬升。将东丽3K碳纤维丝从梯形凹槽303中挑出并夹持，牵引一段距离至表面树脂含量较少，穿过可替换组合模嘴6完成穿丝过程。控制机械抬升装置1进行下降动作至浸渍流道上部301与浸渍流道下部302紧密贴合。将PLA粒料放置于树脂粒料投放口502，设置螺杆挤出机转速为5r/min，调节冒口螺栓706使其放松，观察冒口处情况，当有树脂流出时，牵引纤维丝开始浸渍过程，调节螺杆挤出机速度为13r/min，并根据丝材表面树脂包覆量动态调节冒口螺栓706使制丝质量稳定。如上述过程可实现目标过程的安全快速实现。
本实施例中目标将制备直径为0.8mm的连续碳纤维增强PLA复合丝材改为制备制备直径为1.3mm的连续碳纤维增强PLA复合丝材。
停止螺杆挤出机5转动，保持保持加热装置2、螺杆挤出机加热电阻503温度不变，将0.8mm替换段602旋下，从丝材中穿出，随后穿过1.3mm替换段602，并将替换段602旋至连接段601上，完成模嘴替换过程。设置螺杆挤出机转速为5r/min，调节冒口螺栓706使其放松，观察冒口处情况，当有树脂流出时，牵引纤维丝开始浸渍过程，调节螺杆挤出机速度为13r/min，并根据丝材表面树脂包覆量动态调节冒口螺栓706使制丝质量稳定。如上述过程可实现目标过程的快速实现。
本发明方案所公开的技术手段不仅限于上述实施方式所公开的技术手段，还包括由以上技术特征任意组合所组成的技术方案。

Claims (10)

  1. 用于增材制造的流道可自动抬升的复合材料丝材熔融浸渍装置，其特征在于：包括机械抬升装置(1)、加热装置(2)、弯曲树脂浸渍流道(3)、导丝块(4)、单螺杆挤出机(5)、可替换组合模嘴(6)和树脂冒口(7)；弯曲树脂浸渍流道(3)通过机械抬升装置(1)实现上、下运动；加热装置(2)包括流道上下控制浸渍温度的多组加热块；导丝块(4)位于弯曲树脂浸渍流道(3)前端的纤维入口处，螺杆挤出机(5)位于弯曲树脂浸渍流道(3)的侧面；向弯曲树脂浸渍流道(3)内均匀输送熔融树脂；可替换组合模嘴(6)位于弯曲树脂浸渍流道(3)的后部；树脂冒口(7)位于可替换组合模嘴(6)的下方；其中弯曲树脂浸渍流道(3)由上、下两部分契合而成的带有梯形狭槽的压块形成S形弯曲流道。
  2. 根据权利要求1所述的用于增材制造的流道可自动抬升的复合材料丝材熔融浸渍装置，其特征在于：机械抬升装置(1)包括至少设四架对称分布的导轨丝杠机构(101)，每个导轨丝杠机构(101)的底部均与作业平台连接；其中导轨丝杠机构(101)包括光轴(104)、丝杠(105)、步进电机(106)、上盖板连接件(102)和底座连接件(103)；其中丝杠(105)的两端旁分别对称设有光轴(104)；步进电机(106)的且输出轴与丝杠杆(105)连接；上盖板连接件(102)分别与丝杠(105)和光轴(104)滑动连接且与弯曲树脂浸渍流道(3)的上半部分连接；其中弯曲树脂浸渍流道(3)的下半部分固定在底座连接件(103)上。
  3. 根据权利要求1所述的用于增材制造的流道可自动抬升的复合材料丝材熔融浸渍装置，其特征在于：所述弯曲树脂浸渍流道(3)包括浸渍流道上部(301)、浸渍流道下部(302)；所述浸渍流道上部(301)、浸渍流道下部(302)的中部均开有梯形凹槽(303)作为流道部分，所述梯形凹槽(303)的凹槽平面长5～10mm，斜面长5～10mm，斜面角度15～25°，圆台形凹槽(304)用于承接单螺杆挤出机(5)输送的熔融树脂并分配到流道内部，该圆台形凹槽(304)的半径由挤出机处20mm逐渐过渡至流道处10mm；流道末端留有联通槽(305)用于使可替换组合模嘴6与树脂冒口7联通。
  4. 根据权利要求1所述的用于增材制造的流道可自动抬升的复合材料丝材熔融浸渍装置，其特征在于：所述螺杆挤出机(501)连接一个树脂粒料投放口(502)，用以将树脂粒料输入弯曲树脂浸渍流道(3)内；其中所述螺杆挤出机(501)的表面缠绕螺杆挤出机加热电阻(503)。
  5. 根据权利要求1所述的用于增材制造的流道可自动抬升的复合材料丝材熔融浸渍装置，其特征在于：所述可替换组合模嘴(6)包括连接段(601)和替换段(602)两部分组成，连接段(601)用于连接弯曲树脂浸渍流道(3)，加热电阻圈(603)缠绕于连接段(601)保证模嘴(6)处树脂流动性，替换段(602)直径可替换为0.6～1.2mm且不限于上述尺寸。
  6. 根据权利要求1所述的用于增材制造的流道可自动抬升的复合材料丝材熔融浸渍装置，其特征在于：所述树脂冒口(7)可替换组合 模嘴(6)的正下方；包括依次设置的冒口连接(701)、冒口堵头(702)、冒口弹簧(703)、冒口垫片(704)、冒口套筒(705)和冒口螺栓(706)，其中冒口连接(701)靠近边缘2mm处开有矩形孔(707)用于树脂流出，冒口套筒(705)对应部位开有90°扇形孔(708)用于树脂顺利流出。
  7. 根据权利要求5所述的用于增材制造的流道可自动抬升的复合材料丝材熔融浸渍装置，其特征在于：替换段(602)为丝材成形出口，直径可替换为0.6、0.8、1.0、1.2mm且不限于上述尺寸。
  8. 根据权利要求1所述的用于增材制造的流道可自动抬升的复合材料丝材熔融浸渍装置，其特征在于，浸渍流道上部(301)的加热块均匀分布于上盖板，浸渍流道下部(302)的下部加热块均匀分布于下底板内保证流道内温度稳定。
  9. 根据权利要求1所述的用于增材制造的流道可自动抬升的复合材料丝材熔融浸渍装置，其特征在于，导丝块(4)位于流道前端纤维入口处，由横向纵向至少两对转轴组成，保证纤维以一定角度范围进入浸渍流道。
  10. 根据权利要求1所述的用于增材制造的流道可自动抬升的复合材料丝材熔融浸渍装置，其特征在于，弯曲树脂浸渍流道(3)的浸渍角为120°，弯曲部分采用倒圆角设计减少浸渍过程中纤维磨损的产生，上、下压块中间部位设有梯形凹槽作为树脂与纤维的浸渍通道，给与纤维一定的活动空间的同时防止纤维产生过大位移。
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