阅读说明：本技术 一种连续干纤维增材制造方法 (Continuous dry fiber additive manufacturing method ) 是由 吕明迪 关昊辰 杨朝坤 于 2021-08-06 设计创作，主要内容包括：本发明公开了一种连续干纤维增材制造方法,包括对连续干纤维进行膨化处理,将膨体纱干纤维与干纤维形成併合纤维分别输入至输出端头,经过叠层铺设和刺辊针刺,使干纤维相互纠结而成三维干纤维胚体,再经过沉积或浸渍、热压工艺处理,得到三维纤维预制体,再对其进行机加工和涂装处理,最终得到孔隙率≤1.5％的连续纤维增强树脂基复合材料成品。本发明为快速成型连续干纤维预制体提供了可靠的方法,为三维纤维预制体成型提供了快速、低成本的制造手段,为复合材料增材制造开辟了新的纤维预制体加工方法,为高性能复合材料发展奠定新的技术支撑。(The invention discloses a continuous dry fiber additive manufacturing method, which comprises the steps of carrying out puffing treatment on continuous dry fibers, respectively inputting combined fibers formed by bulked yarn dry fibers and the dry fibers into an output end, carrying out lamination laying and licker-in needling to enable the dry fibers to be mutually entangled to form a three-dimensional dry fiber blank, carrying out deposition or impregnation and hot-pressing treatment to obtain a three-dimensional fiber preform, and carrying out machining and coating treatment on the three-dimensional fiber preform to finally obtain a continuous fiber reinforced resin matrix composite finished product with the porosity of less than or equal to 1.5%. The invention provides a reliable method for quickly forming the continuous dry fiber preform, provides a quick and low-cost manufacturing means for forming the three-dimensional fiber preform, opens up a new fiber preform processing method for the additive manufacturing of composite materials, and lays a new technical support for the development of high-performance composite materials.)

1. A continuous dry fiber additive manufacturing method is characterized in that: comprises the following steps of (a) carrying out,

step one, carrying out bulking treatment on continuous dry fibers to obtain continuous dry fiber bulked yarns and forming bulked yarn rolls;

step two, inputting the dry fiber bulked yarns and the dry fibers into an output end head in a one-to-one correspondence manner in a dust-free space, continuously outputting the combined fibers formed by the dry fiber bulked yarns and the dry fibers by the output end head according to a set track, and laminating and spreading the combined fibers to form a fiber forming blank;

thirdly, after the merged fibers laid in a laminated manner reach a set thickness, performing a licker-in needling operation on the side surface and the top surface of the fiber forming blank body once, thereby forming a three-dimensional dry fiber blank body;

and fourthly, depositing or dipping the three-dimensional dry fiber blank to obtain a high-temperature composite material product, treating the high-temperature composite material product by a hot pressing process to obtain a three-dimensional fiber preform, and machining and coating the three-dimensional fiber preform to finally obtain a finished product of the continuous fiber reinforced resin matrix composite material with the porosity of less than or equal to 1.5%.

2. The continuous dry fiber additive manufacturing method of claim 1, wherein: in the first step, the single filaments in the dry fiber bulked yarn are in a separated state, the filament bundle of the dry fiber bulked yarn is in a wavy pattern shape andor a spiral shape, and the dry fiber is a thermosetting resin composite material.

3. The continuous dry fiber additive manufacturing method of claim 1, wherein: and after the combined fibers laid flat each time in the third step reach a set length, the combined fibers need to be cut once through a shearing device, and the shearing device is arranged at the lower end of the output end.

4. The continuous dry fiber additive manufacturing method of claim 1, wherein: and in the third step, the set thickness is 8-24 layers of the combined fibers.

5. The continuous dry fiber additive manufacturing method of claim 1, wherein: and the needling operation of the licker-in the third step is completed through three forming licker-in, and the needling reciprocating frequency of the forming licker-in is 1-5 times of the reciprocating frequency of the output end.

6. The continuous dry fiber additive manufacturing method of claim 5, wherein: the output head end and the forming licker-in are arranged on the same bracket, and the three forming licker-in are respectively positioned on the two side surfaces and the top surface of the fiber forming blank body.

7. The continuous dry fiber additive manufacturing method of claim 5, wherein: the cylindrical surface of the forming licker-in is evenly distributed with a plurality of pricking pins, and the tip ends of the pricking pins are provided with barbs.

8. The continuous dry fiber additive manufacturing method of claim 1, wherein: and a conveying device, a tension control clamping roller and a guide roller are arranged on a channel for forming combined fibers by the dry fiber bulked yarns and the dry fibers, and the tension control clamping roller can respectively regulate and control the prestress of the dry fiber bulked yarns and the prestress of the dry fibers.

9. The continuous dry fiber additive manufacturing method of claim 1, wherein: the dry fiber is glass fiber, carbon fiber, ultra-high molecular weight polyethylene fiber or aramid fiber.

10. The continuous dry fiber additive manufacturing method of claim 1, wherein: the hot-pressing process treatment of the high-temperature composite material product in the fourth step is the process treatment of autoclave and/or bag pressing and vacuumizing.

Technical Field

The invention relates to the technical field of additive manufacturing, in particular to a continuous dry fiber additive manufacturing method.

Background

With the wide application of fiber composite materials becoming more and more extensive and the rapid development of 3D output technology, the 3D output of continuous fibers of composite materials is in a new stage of thick, thin and thin development, and has a explosive growth situation in the fields of new product development, mold manufacturing and machining.

The method of in-situ impregnation, tow coextrusion, tow extrusion, in-situ combination, prepreg and the like is adopted, so that some problems of continuous fiber additive manufacturing are solved, but new problems are brought, such as reduction of comprehensive performance of fibers, requirement of high-quality resin or prepreg, cleaning of an output end and the like, the advantages of existing fiber resources are not brought into play, fiber properties are changed for adapting to additive manufacturing, and the manufacturing of a high-performance composite material is not facilitated.

However, in the existing additive manufacturing process of continuous dry fibers, a male mold and a female mold are needed for manufacturing the thermosetting resin composite material, the resin glue solution is singly impregnated and compounded, and the processes of heating, curing and compounding are separated and cannot be continuously carried out, so that the processing cost is high and the processing efficiency is low.

Disclosure of Invention

The invention aims to provide a continuous dry fiber additive manufacturing method, which solves the problems in the prior art, enables dry fiber additive manufacturing to be rapid and low in cost, and can prepare a composite material with excellent performance and a product thereof.

In order to achieve the purpose, the invention provides the following scheme:

the invention provides a continuous dry fiber additive manufacturing method, which comprises the following steps,

step one, carrying out bulking treatment on continuous dry fibers to obtain continuous dry fiber bulked yarns and forming bulked yarn rolls;

step two, inputting the dry fiber bulked yarns and the dry fibers into an output end head in a one-to-one correspondence manner in a dust-free space, continuously outputting the combined fibers formed by the dry fiber bulked yarns and the dry fibers by the output end head according to a set track, and laminating and spreading the combined fibers to form a fiber forming blank;

thirdly, after the merged fibers laid in a laminated manner reach a set thickness, performing a licker-in needling operation on the side surface and the top surface of the fiber forming blank body once, thereby forming a three-dimensional dry fiber blank body;

and fourthly, depositing or dipping the three-dimensional dry fiber blank to obtain a high-temperature composite material product, treating the high-temperature composite material product by a hot pressing process to obtain a three-dimensional fiber preform, and machining and coating the three-dimensional fiber preform to finally obtain a finished product of the continuous fiber reinforced thermosetting resin-based composite material with the porosity of less than or equal to 1.5%.

Preferably, the monofilaments in the dry fiber bulked yarn in the step one are in a separated state, the tows of the dry fiber bulked yarn are in a wavy pattern shape andor a spiral shape, and the dry fiber is a thermosetting resin composite material.

Preferably, after the combined fibers laid each time in the third step reach a set length, the combined fibers need to be cut once through a cutting device, and the cutting device is arranged at the lower end of the output end.

Preferably, the set thickness in the third step is 8-24 layers of the combined fibers.

Preferably, the needling operation of the licker-in the third step is completed by three forming licker-in, and the needling reciprocating frequency of the forming licker-in is 1-5 times of the reciprocating frequency of the output end head.

Preferably, the output head end and the forming licker-in are arranged on the same bracket, and the three forming licker-in are respectively positioned on the two side surfaces and the top surface of the fiber forming blank body.

Preferably, a plurality of pricking pins are uniformly distributed on the cylindrical surface of the forming pricking roller, and barbs are arranged at the tip ends of the pricking pins.

Preferably, a conveying device, a tension control clamping roller and a guide roller are arranged on a channel for forming the combined fiber by the dry fiber bulked yarn and the dry fiber, and the tension control clamping roller can respectively regulate and control the prestress of the dry fiber bulked yarn and the dry fiber.

Preferably, the dry fiber is glass fiber, carbon fiber, ultra-high molecular weight polyethylene fiber or aramid fiber.

Preferably, the hot-pressing process treatment of the high-temperature composite material product in the fourth step is a process treatment of autoclave and/or bag-pressing vacuum pumping.

Compared with the prior art, the invention has the following technical effects:

the invention provides a reliable method for quickly forming the continuous dry fiber composite material, provides a quick and low-cost manufacturing means for forming the three-dimensional fiber preform, opens up a new fiber preform processing method for the additive manufacturing of the composite material, and lays a new technical support for the development of the high-performance composite material.

Drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.

FIG. 1 is a schematic diagram I of the manufacturing structure of a three-dimensional fiber preform according to the present invention;

FIG. 2 is a schematic diagram of a second manufacturing structure of the three-dimensional fiber preform according to the present invention;

FIG. 3 is a schematic diagram of a third manufacturing structure of a three-dimensional fiber preform according to the present invention;

FIG. 4 is a schematic representation of the construction of the dry fiber bulked yarns of the present invention;

FIG. 5 is a schematic view of the lancet of the present invention;

wherein: 50-barbs, 100-felting needles, 200-flat-pressing licker-in, 300-left licker-in, 310-right licker-in, 400-fiber forming blank, 500-dry fiber bulked yarn, 600-bulked yarn package, 700-dry fiber package, 800-output end, 900-guide roller and 910-shearing device.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without inventive effort based on the embodiments of the present invention, are within the scope of the present invention.

The invention aims to provide a continuous dry fiber additive manufacturing method, which aims to solve the problems in the prior art, so that the dry fiber additive manufacturing is rapid and low in cost, and composite materials with excellent performance and products thereof can be prepared.

In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.

As shown in fig. 1 to 5: this example provides a continuous dry fiber additive manufacturing method, comprising the steps of,

step one, continuous dry fibers (monofilament entangled bundles) can be subjected to bulking treatment by utilizing a licker-in needling operation, so that an adhesive film between the fibers can be damaged, continuous dry fiber bulked yarns 500 are obtained, and bulked yarn rolls are formed; the single filaments of the dry fiber bulked yarn 500 are in a separated state, the tows of the dry fiber bulked yarn 500 are in a wave pattern shape or a spiral shape, the dry fibers are thermosetting resin composite materials and are tows consisting of single fibers with the diameter of 4-9 mu m, and the dry fibers and the dry fiber bulked yarn 500 which are not subjected to bulking treatment are respectively manufactured into packages. The bulked yarn package 600 and the dry fiber package 700 are symmetrically and rotatably arranged on shaft brackets at two sides outside the dust-free box body. A conveying device, a tension control clamping roller and a guide roller 900 are arranged on a channel of the dry fiber bulked yarn 500 and the dry fiber to form the combined fiber, and the tension control clamping roller can respectively regulate and control the prestress of the dry fiber bulked yarn 500 and the dry fiber.

And secondly, inputting the dry fiber bulked yarns 500 and the dry fibers into an output end 800 in a dust-free space in a one-to-one correspondence (equal width) manner, continuously outputting the combined fibers formed by the dry fiber bulked yarns 500 and the dry fibers by the output end 800 according to a set track, and laminating and spreading the combined fibers to form the fiber forming blank 400.

Thirdly, after the combined fibers laid in a laminated manner reach a set thickness, performing a licker-in needling operation on the side surface and the top surface of the fiber forming blank 400 once, thereby forming a three-dimensional dry fiber blank; after the laid combined fibers reach a set length, the combined fibers need to be cut once by the cutting device 910, and the cutting device 910 is arranged at the lower end of the output end 800. Setting the thickness to be 8-24 layers and combining the fibers. The needling operation of the licker-in is completed by three forming licker-in, and the needling reciprocating frequency of the forming licker-in is 1-5 times of the reciprocating frequency of the output end 800. The output head end and the forming licker-in are arranged on the same bracket, and the three forming licker-in are respectively positioned on the two side surfaces and the top surface of the fiber forming blank body 400, namely a left licker-in 300, a right licker-in 310 and a flat pressing licker-in 200. The forming licker-in rollers on two sides can roll simultaneously or independently, and the forming licker-in roller on the other side can be lifted. The cylindrical surface of the forming licker-in is evenly provided with a plurality of felting needles 100, the sharp ends of the felting needles 100 are provided with barbs 50, and partial dry fiber monofilaments are entangled with each other along the depth direction of the felting needles 100 under the effect of the needling, so that a three-dimensional dry fiber blank with a certain thickness is formed.

And step four, depositing or dipping the three-dimensional dry fiber blank to obtain a high-temperature composite material product, carrying out hot-pressing treatment on the high-temperature composite material product to obtain a three-dimensional fiber preform, and then carrying out machining and coating treatment on the three-dimensional fiber preform to finally obtain a finished product of the continuous fiber reinforced resin matrix composite material with the porosity of less than or equal to 1.5%.

The hot pressing process treatment of the high-temperature composite material product in the fourth step is the process treatment of autoclave and/or bag pressing and vacuumizing.

Wherein the dry fiber is glass fiber, carbon fiber, ultra-high molecular weight polyethylene fiber or aramid fiber. When the raw material is 12K continuous dry carbon fiber, when the operation of combining fiber layers reaches the designed thickness of laminated laying, the operation of roller needling is carried out once, and the reciprocating frequency of needling is equal to the reciprocating frequency of the output end 800. When the raw material is 6K continuous dry carbon fiber, when the operation of combining fiber layers reaches the designed thickness of laminated laying, namely 30mm, the operation of roller needling is carried out once, and the reciprocating frequency of needling is 2 times that of the output end 800. When the raw material is 12K continuous dry carbon fiber, when the operation of combining fiber layers reaches the design thickness of 40mm of laminated and tiled, the operation of roller needling is carried out once, and the reciprocating frequency of needling is 2 times that of the output end 800. When the raw material is 2400tex continuous dry glass fiber, when the operation of combining fiber laying reaches the designed thickness of laminated laying, 20mm, a licker-in needling operation is carried out once, and the reciprocating frequency of needling is 2 times that of the output end 800. When the raw material is 24K continuous dry carbon fiber, when the operation of combining fiber layers reaches the designed thickness of laminated laying, 60mm, a licker-in needling operation is carried out once, and the reciprocating frequency of the needling is 2 times that of the output end 800. When the raw material is mixed fiber (two fiber layers are mixed) of 12K dry carbon fiber and 2400tex glass fiber dry fiber, when the combined fiber laying operation reaches the design thickness of laminated laying, namely 100mm, a licker-in needling operation is performed once, and the reciprocating frequency of needling is 2 times that of the output end head 800.

The principle and the implementation mode of the present invention are explained by applying specific examples in the present specification, and the above descriptions of the examples are only used to help understanding the method and the core idea of the present invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the above, the present disclosure should not be construed as limiting the invention.