U.S. patent application number 17/660101 was filed with the patent office on 2022-08-04 for system and head for continuously manufacturing composite structure.
This patent application is currently assigned to Continuous Composites Inc.. The applicant listed for this patent is Continuous Composites Inc.. Invention is credited to Marcus Raye Vincent Brodie, Kyle Frank Cummings, Ryan C. Stockett, Samuel VanDenBerg.
Application Number | 20220242040 17/660101 |
Document ID | / |
Family ID | 1000006276864 |
Filed Date | 2022-08-04 |
United States Patent
Application |
20220242040 |
Kind Code |
A1 |
Cummings; Kyle Frank ; et
al. |
August 4, 2022 |
SYSTEM AND HEAD FOR CONTINUOUSLY MANUFACTURING COMPOSITE
STRUCTURE
Abstract
A system is disclosed for additively manufacturing a composite
structure. The system may include a print head configured to
discharge a continuous reinforcement that is at least partially
coated in a matrix, and a compactor configured to compact the
continuous reinforcement and the matrix. The system may also
include a cure enhancer configured to direct a path of cure energy
toward the matrix after discharge, wherein the path of cure energy
passes through at least a portion of the compactor.
Inventors: |
Cummings; Kyle Frank;
(Everett, WA) ; Brodie; Marcus Raye Vincent;
(Erie, PA) ; VanDenBerg; Samuel; (Hayden, ID)
; Stockett; Ryan C.; (Spokane, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Continuous Composites Inc. |
Coeur d'Alene |
ID |
US |
|
|
Assignee: |
Continuous Composites Inc.
Coeur d'Alene
ID
|
Family ID: |
1000006276864 |
Appl. No.: |
17/660101 |
Filed: |
April 21, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
16516113 |
Jul 18, 2019 |
11358331 |
|
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17660101 |
|
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62853610 |
May 28, 2019 |
|
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62769498 |
Nov 19, 2018 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C 64/165 20170801;
B33Y 10/00 20141201; B29C 64/264 20170801; B33Y 30/00 20141201;
B29C 64/209 20170801 |
International
Class: |
B29C 64/209 20060101
B29C064/209; B33Y 30/00 20060101 B33Y030/00; B33Y 10/00 20060101
B33Y010/00; B29C 64/264 20060101 B29C064/264; B29C 64/165 20060101
B29C064/165 |
Claims
1. An additive manufacturing system, comprising: a support; and a
print head operatively connected to and moveable in a travel
direction by the support, the print head including: an outlet
configured to discharge a material during motion in the travel
direction, the material trailing from the outlet in a direction
opposite the travel direction; a compactor configured to compact
the material during discharge; and a cure enhancer leading the
outlet relative to the travel direction and configured to direct
cure energy toward the material being discharged.
2. The additive manufacturing system of claim 1, wherein the cure
enhancer is configured to expose the material to cure energy prior
to the material being compacted by the compactor.
3. The additive manufacturing system of claim 2, wherein: the cure
enhancer is a first cure enhancer; and the additive manufacturing
system further includes a second cure enhancer configured to direct
cure energy toward the material in at least one of a different
direction or at a different location.
4. The additive manufacturing system of claim 3, wherein the second
cure enhancer trails the outlet relative to the travel
direction.
5. The additive manufacturing system of claim 4, wherein the second
cure enhancer also trails the compactor.
6. The additive manufacturing system of claim 3, wherein the second
cure enhancer leads the outlet.
7. The additive manufacturing system of claim 3, wherein the second
cure enhancer is configured to expose the material to cure energy
after the material has been compacted by the compactor.
8. The additive manufacturing system of claim 3, wherein the second
cure enhancer is configured to expose the material to cure energy
at a same location where the material is being compacted by the
compactor.
9. The additive manufacturing system of claim 3, wherein: the first
cure enhancer is configured to expose the material to cure energy
from a direction that is orthogonal to an axis of the compactor;
and the second cure enhancer is configured to expose the material
to cure energy from an angle that is one of parallel or oblique to
the axis of the compactor.
10. The additive manufacturing system of claim 1, wherein a portion
of the compactor is configured to block cure energy from the cure
enhancer.
11. The additive manufacturing system of claim 10, wherein the
portion of the compactor is located at a side oriented toward the
cure enhancer.
12. The additive manufacturing system of claim 1, wherein the cure
energy passes from a leading outside of the compactor, through the
compactor, to the material being compacted.
13. The additive manufacturing system of claim 1, wherein the
compactor includes a wheel, and an annular groove in the wheel that
is configured to guide the material.
14. The additive manufacturing system of claim 1, wherein the
compactor is configured to redirect a path of cure energy.
15. An additive manufacturing system, comprising: a support; and a
print head operatively connected to and moveable in a travel
direction by the support, the print head including: an outlet
configured to discharge a material during motion in the travel
direction, the material trailing from the outlet in a direction
opposite the travel direction; a compactor having a wheel
configured to compact the material during discharge; a first cure
enhancer configured to direct cure energy toward the material being
discharged from a direction that is orthogonal to an axis of the
wheel; and a second cure enhancer configured to direct cure energy
toward the material being discharged from a direction that is one
of parallel or oblique to the axis of the wheel.
16. The additive manufacturing system of claim 15, wherein at least
one of the first or second cure enhancers is configured to expose
the material to cure energy prior to the material being compacted
by the compactor.
17. The additive manufacturing system of claim 15, wherein at least
one of first or second cure enhancers trails the outlet relative to
the travel direction.
18. The additive manufacturing system of claim 17, wherein at least
one of first or second cure enhancers also trails the
compactor.
19. The additive manufacturing system of claim 15, wherein both of
the first and second cure enhancers leads the outlet.
20. The additive manufacturing system of claim 15, wherein at least
one of the first or second cure enhancers is configured to expose
the material to cure energy at a same location where the material
is being compacted by the compactor.
Description
RELATED APPLICATIONS
[0001] This application is a continuation application of U.S.
Non-Provisional application Ser. No. 16/516,113 filed on Jul. 18,
2019, which is based on and claims the benefit of priority from
United States Provisional Application Nos. 62/769,498 that was
filed on Nov. 19, 2018 and 62/853,610 that was filed on May 28,
2019, the contents of all of which are expressly incorporated
herein by reference.
TECHNICAL FIELD
[0002] The present disclosure relates generally to a manufacturing
system and, more particularly, to a system and head for
continuously manufacturing composite structures.
BACKGROUND
[0003] Continuous fiber 3D printing (a.k.a., CF3D.RTM.) involves
the use of continuous fibers embedded within a matrix discharging
from a moveable print head. The matrix can be a traditional
thermoplastic, a powdered metal, a liquid resin (e.g., a UV curable
and/or two-part resin), or a combination of any of these and other
known matrixes. Upon exiting the print head, a head-mounted cure
enhancer (e.g., a UV light, an ultrasonic emitter, a heat source, a
catalyst supply, etc.) is activated to initiate and/or complete
curing of the matrix. This curing occurs almost immediately,
allowing for unsupported structures to be fabricated in free space.
When fibers, particularly continuous fibers, are embedded within
the structure, a strength of the structure may be multiplied beyond
the matrix-dependent strength. An example of this technology is
disclosed in U.S. Pat. No. 9,511,543 that issued to Tyler on Dec.
6, 2016 ("the '543 patent").
[0004] Although CF3D.RTM. provides for increased strength, compared
to manufacturing processes that do not utilize continuous fiber
reinforcement, improvements can be made to the structure and/or
operation of existing systems. The disclosed additive manufacturing
system is uniquely configured to provide these improvements and/or
to address other issues of the prior art.
SUMMARY
[0005] In one aspect, the present disclosure is directed to an
additive manufacturing system. The additive manufacturing system
may include a print head configured to discharge a continuous
reinforcement that is at least partially coated in a matrix, and a
compactor configured to compact the continuous reinforcement and
the matrix. The additive manufacturing system may also include a
cure enhancer configured to direct a path of cure energy toward the
matrix after discharge, wherein the path of cure energy passes
through at least a portion of the compactor.
[0006] In another aspect, the present disclosure is directed to a
method for additively manufacturing a composite structure. The
method may include discharging a continuous reinforcement that is
at least partially coated in a matrix, and compacting the
continuous reinforcement and the matrix with a compactor. The
method may also include directing cure energy through the compactor
toward the matrix.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a diagrammatic illustration of an exemplary
disclosed additive manufacturing system;
[0008] FIGS. 2 and 3 are end-view and cross-sectional
illustrations, respectively, of an exemplary disclosed compactor
that may be utilized with the system of FIG. 1;
[0009] FIG. 4 is an isometric illustration of another exemplary
disclosed compactor that may be utilized with the system of FIG.
1;
[0010] FIG. 5 is an end-view illustration of another exemplary
disclosed compactor that may be utilized with the system of FIG. 1;
and
[0011] FIGS. 6-14 are schematic illustrations of various
arrangements of compactors that may be utilized with the system of
FIG. 1.
DETAILED DESCRIPTION
[0012] FIG. 1 illustrates an exemplary system 10, which may be used
to manufacture a composite structure 12 having any desired
cross-sectional shape (e.g., ellipsoidal, polygonal, etc.). System
10 may include at least a moveable support 14 and a print head
("head") 16. Head 16 may be coupled to and moved by support 14. In
the disclosed embodiment of FIG. 1, support 14 is a robotic arm
capable of moving head 16 in multiple directions during fabrication
of structure 12, such that a resulting longitudinal axis of
structure 12 is three-dimensional. It is contemplated, however,
that support 14 could alternatively be an overhead gantry, a hybrid
gantry/arm, or another type of movement system that is capable of
moving head 16 in multiple directions during fabrication of
structure 12. Although support 14 is shown as being capable of
multi-axis (e.g., six or more axes) movement, it is contemplated
that any other type of support 14 capable of moving head 16 in the
same or in a different manner could also be utilized, if desired.
In some embodiments, a drive may mechanically couple head 16 to
support 14 and may include components that cooperate to move and/or
supply power or materials to head 16.
[0013] Head 16 may be configured to receive or otherwise contain a
matrix. The matrix may include any type of material (e.g., a liquid
resin, such as a zero-volatile organic compound resin; a powdered
metal; a solid filament, etc.) that is curable. Exemplary matrixes
include thermosets, single- or multi-part epoxy resins, polyester
resins, cationic epoxies, acrylated epoxies, urethanes, esters,
thermoplastics, photopolymers, polyepoxides, thiols, alkenes,
thiolenes, reversible resins (e.g., Triazolinedione, a
covalent-adaptable network, a spatioselective reversible resin,
etc.) and more. In one embodiment, the matrix inside head 16 may be
pressurized, for example by an external device (e.g., an extruder
or another type of pump--not shown) that is connected to head 16
via a corresponding conduit (not shown). In another embodiment,
however, the matrix pressure may be generated completely inside of
head 16 by a similar type of device. In yet other embodiments, the
matrix may be gravity-fed through and/or mixed within head 16. In
some instances, the matrix inside head 16 may need to be kept cool
and/or dark to inhibit premature curing; while in other instances,
the matrix may need to be kept warm for similar reasons. In either
situation, head 16 may be specially configured (e.g., insulated,
temperature-controlled, shielded, etc.) to provide for these
needs.
[0014] The matrix may be used to coat, encase, or otherwise at
least partially surround (e.g., wet) any number of continuous
reinforcements (e.g., separate fibers, tows, rovings, ribbons,
and/or sheets of material) and, together with the reinforcements,
make up at least a portion (e.g., a wall) of composite structure
12. The reinforcements may be stored within (e.g., on separate
internal spools--not shown) or otherwise passed through head 16
(e.g., fed from one or more external spools--not shown). When
multiple reinforcements are simultaneously used, the reinforcements
may be of the same type and have the same diameter and
cross-sectional shape (e.g., circular, square, flat, hollow, solid,
etc.), or of a different type with different diameters and/or
cross-sectional shapes. The reinforcements may include, for
example, carbon fibers, vegetable fibers, wood fibers, mineral
fibers, glass fibers, metallic wires, optical tubes, etc. It should
be noted that the term "reinforcement" is meant to encompass both
structural and nonstructural types of continuous materials that can
be at least partially encased in the matrix discharging from head
16.
[0015] The reinforcements may be exposed to (e.g., coated with) the
matrix while the reinforcements are inside head 16, while the
reinforcements are being passed to head 16 (e.g., as a prepreg
material), and/or while the reinforcements are discharging from
head 16, as desired. The matrix, dry reinforcements, and/or
reinforcements that are already exposed to the matrix (e.g., wetted
reinforcements) may be transported into head 16 in any manner
apparent to one skilled in the art.
[0016] The matrix and reinforcement may be discharged from head 16
via at least two different modes of operation. In a first mode of
operation, the matrix and reinforcement are extruded (e.g., pushed
under pressure and/or mechanical force) from head 16, as head 16 is
moved by support 14 to create the 3-dimensional shape of structure
12. In a second mode of operation, at least the reinforcement is
pulled from head 16, such that a tensile stress is created in the
reinforcement during discharge. In this mode of operation, the
matrix may cling to the reinforcement and thereby also be pulled
from head 16 along with the reinforcement, and/or the matrix may be
discharged from head 16 under pressure along with the pulled
reinforcement. In the second mode of operation, where the matrix
material is being pulled from head 16 with the reinforcement, the
resulting tension in the reinforcement may increase a strength of
structure 12 (e.g., by aligning the reinforcements, inhibiting
buckling, equally distributing loads, etc.), while also allowing
for a greater length of unsupported structure 12 to have a
straighter trajectory (e.g., by creating moments that oppose
gravity).
[0017] The reinforcement may be pulled from head 16 as a result of
head 16 moving away from an anchor point 18. In particular, at the
start of structure-formation, a length of matrix-impregnated
reinforcement may be pulled and/or pushed from head 16, deposited
onto a stationary or moveable anchor point 18, and cured, such that
the discharged material adheres to anchor point 18. Thereafter,
head 16 may be moved away from anchor point 18, and the relative
movement may cause additional reinforcement to be pulled from head
16. It should be noted that the movement of the reinforcement
through head 16 could be assisted (e.g., via internal feed
mechanisms), if desired. However, the discharge rate of the
reinforcement from head 16 may primarily be the result of relative
movement between head 16 and anchor point 18, such that tension is
created within the reinforcement.
[0018] Any number of reinforcements (represented as "R") may be
passed axially through head 16 and be discharged together with at
least a partial coating of matrix (matrix represented as "M" in
FIG. 2). At discharge (or shortly thereafter), one or more cure
enhancers (e.g., one or more light sources, ultrasonic emitters,
lasers, heaters, catalyst dispensers, microwave generators, etc.)
20 may expose the matrix coating to a cure energy (e.g., light
energy, electromagnetic radiation, vibrations, heat, a chemical
catalyst or hardener, etc.). The cure energy may trigger a chemical
reaction, increase a rate of chemical reaction already occurring
within the matrix, sinter the material, harden the material, or
otherwise cause the material to cure as it discharges from head
16.
[0019] A controller 22 may be provided and communicatively coupled
with support 14, head 16, and any number and type of cure enhancers
20. Controller 22 may embody a single processor or multiple
processors that include a means for controlling an operation of
system 10. Controller 22 may include one or more general- or
special-purpose processors or microprocessors. Controller 22 may
further include or be associated with a memory for storing data
such as, for example, design limits, performance characteristics,
operational instructions, matrix characteristics, reinforcement
characteristics, characteristics of structure 12, and corresponding
parameters of each component of system 10. Various other known
circuits may be associated with controller 22, including power
supply circuitry, signal-conditioning circuitry, solenoid/motor
driver circuitry, communication circuitry, and other appropriate
circuitry. Moreover, controller 22 may be capable of communicating
with other components of system 10 via wired and/or wireless
transmission.
[0020] One or more maps may be stored in the memory of controller
22 and used during fabrication of structure 12. Each of these maps
may include a collection of data in the form of models, lookup
tables, graphs, and/or equations. In the disclosed embodiment, the
maps are used by controller 22 to determine desired characteristics
of cure enhancers 20, the associated matrix, and/or the associated
reinforcements at different locations within structure 12. The
characteristics may include, among others, a type, quantity, and/or
configuration of reinforcement and/or matrix to be discharged at a
particular location within structure 12, and/or an amount,
intensity, shape, and/or location of desired curing. Controller 22
may then correlate operation of support 14 (e.g., the location
and/or orientation of head 16) and/or the discharge of material
from head 16 (a type of material, desired performance of the
material, cross-linking requirements of the material, a discharge
rate, etc.) with the operation of cure enhancers 20, such that
structure 12 is produced in a desired manner.
[0021] In some applications, higher levels of interlaminar
strength, increased fiber volume, and/or decreased void content may
be realized by pressing newly discharging material against
underlying layers of material that were discharged during previous
fabrication passes of head 16, before and/or while the newly
discharged material is exposed to the energy from cure enhancers
20. Historically, this pressing action was facilitated by a rolling
or sliding compactor located at the discharge end of head 16. An
exemplary compactor 24 is illustrated in FIGS. 2 and 3.
[0022] As shown in the embodiments of FIGS. 2 and 3, compactor 24
may include a wheel 26 that functions as a nip point of head 16
(e.g., a final point of deposition and/or curing, where wheel 26
engages previously discharged layers of structure 12 and/or a build
platform). One or more internal conduits 28 may extend from cure
enhancer(s) 20 (e.g., from a laser or UV light) to a curing
location 30 at a periphery of compactor 24. For example, conduit(s)
28 may extend axially through a general center of wheel 26, and
then radially to the outer periphery. Alternatively, conduit(s) 28
may extend radially and then axially or diagonally, as desired. It
is contemplated that curing location 30 could be positioned closer
to an end of wheel 26, if desired. One or more optical components
(e.g., mirrors, filters, prisms, lenses, etc.) 32 may be used to
direct, filter, focus, or otherwise condition energy from cure
enhancer(s) 20 prior to the energy reaching the outer periphery of
wheel 26. An outer surface 34 of wheel 26 may be at least partially
transparent, such that the energy may pass therethrough. In one
embodiment, curing location 30 is at the nip point of wheel 26. In
another embodiment, curing location 30 may trail behind the nip
point.
[0023] In order to inhibit energy dissipation and/or loss of the
cure energy within compactor 24, outer surface 34 may be segmented
via one or more dividers 36. Dividers 36 may lie in a plane
generally aligned with and passing through an axis of wheel 26, and
extend radially outward at least partially through outer surface
34. Dividers 36 may be fabricated from or otherwise coated with a
material configured to reflect the energy from cure enhancer(s) 20.
Any number of dividers 36 may be utilized to create as many
separated energy-transmitting channels and/or energy-blocking areas
as desired. In addition to dividers 36, it is contemplated that one
or more dividers 38 lying in a plane generally orthogonal to (or
oriented at an oblique angle relative to) the axis of wheel 26 may
be used to further focus the energy from cure enhancer(s) 20. In
some applications, a spacing between dividers 36 and/or 38 may be
adjustable during material discharge to selectively vary and/or
focus cure path parameters.
[0024] During discharge, the reinforcement may at least partially
wrap around wheel 26 to the nip point at or near curing location
30. Cure energy may pass through wheel 26 and at least partially
cure the coating of matrix on the reinforcement.
[0025] In another example of compactor 24 shown in FIG. 4, wheel 26
may be replaced with an inner roller 40 and an outer roller 42.
Inner roller 40 may be generally stationary (e.g., with respect to
head 16) during fabrication, while outer roller 42 may be
configured to rotate and/or slide around the outside of inner
roller 40. Inner roller 40 may be generally opaque and
discontinuous (e.g., include an axially oriented slit 44) at the
nip point, while outer roller 42 may be generally transparent and
continuous. The energy from cure enhancer(s) 20 may be directed to
slit 44, such that the matrix at the nip point is at least
partially cured. In one embodiment, cure enhancer(s) 20 are located
inside of inner roller 40. In another embodiment, energy conduits
(e.g., one or more light pipes) extend from external cure
enhancer(s) 20 to slit 44. The energy passing through slit 44 may
generally form a line that extends orthogonally across the
reinforcement wrapped around outer roller 42.
[0026] It is contemplated that the amount and/or intensity of
energy within the line formed by slit 44 may be generally
consistent along a length of the line. However, in some
applications, it may be beneficial for portions of the line to have
a greater amount and/or intensity of cure energy. This may be
helpful, for example, when cornering, such that material at an
outer radius of a corner (e.g., where a velocity of compactor 24
over the material may be greater) may be exposed to about the same
amount and/or intensity of energy as material passing under
compactor 24 at an inner radius of the corner. This gradient may be
achieved via additional cure enhancer(s) 20 that are selectively
activated, additional conduits that are selectively exposed to the
cure energy, and/or conduits having greater energy passing
capabilities.
[0027] During discharge of the composite material, the matrix may
snap-cure as slit 44 moves over the material, thereby limiting
wandering of the associated reinforcement in the axial direction of
compactor 24. Both inner and outer rollers 40, 42 may be biased
toward the discharging material (e.g., via a spring, a pneumatic
piston, a mechanical bracket, etc.--not shown), such that the
material is compacted by a desired amount at the time of
curing.
[0028] In some applications, it may be possible for excess matrix
material to cure onto the transparent outer surface of roller 42.
In these applications, a scraper 46 may be provided to scrape away
or otherwise remove the excess matrix.
[0029] FIG. 5 illustrates another example of compactor 24, wherein
cure energy passes around at least a portion of compactor 24 near
the nip point. As seen in this embodiment, compactor 24 may have a
belt 48 in place of wheel 26. Like wheel 26, belt 48 may be at
least partially transparent. Belt 48 may be wrapped around one or
more rollers 50, which may or may not be driven, and a guide 52.
Energy may be directed from cure enhancer(s) 20 through a conduit
54, guide 52, and belt 48 to expose and cure the matrix coating the
reinforcement. Guide 52 may be a cylindrical, spherical, or other
shaped roller, partial roller, or fixed low-friction surface that
is located at the outlet of conduit 54 to help guide belt 48 past
the outlet. It is contemplated that any number of guides 52 may be
arranged adjacent each other across a width of belt 48, if desired,
for use in curing the matrix coating any number of adjacent
reinforcements. In some embodiments, guides 52 may be individually
position-adjustable (e.g., via one or more linear actuators 56),
such that a transverse shape of the belt may be manipulated.
Compactor 24 may be adjustable in a Z-direction (e.g., via a linear
and/or rotary actuator 58), if desired. In some embodiment, a
tensioner 60 may be utilized to maintain a desired tension within
belt 48.
[0030] Although compactor 24 in the embodiments of FIGS. 2-5 have
been described as capable of passing energy from cure enhancer(s)
20 radially outward in a directly generally aligned with an axis of
head 16, other arrangements may be possible. FIGS. 6-14 illustrate
some of these possible arrangements.
[0031] In the example of FIG. 6, cure energy may be directed from
one or more cure enhancers 20 located at a leading side of
compactor 24 (see left-most cure enhancer 20) toward the nip point
at cure location 30, located at a trailing side of compactor 24
(see right-most cure enhancer 20) toward the nip point, or
simultaneously from both the leading and trailing sides. As shown
in FIGS. 7 and 8, the path(s) of energy from cure enhancer(s) 20 to
the nip point at cure location 30 may be oriented generally
orthogonal to the axis of compactor 24 (see upper-most paths of
FIGS. 7 and 8), co-axial (see right-most path), parallel to the
axis of compactor 24 (lower-most path), and/or at an oblique angle
relative to the axis (see left-most path of FIG. 7 and right-most
path of FIG. 8). The paths may pass through transparent portions
(e.g., wheel 26) of compactor 24 or remain entirely outside of
compactor 24.
[0032] As shown in the examples of FIGS. 9 and 11, the path(s) of
cure energy may be aimed at the nip point (i.e., at an intersection
of a current material discharge and an underlying layer, such that
both simultaneously receive energy). Alternatively, one or more
paths of energy could be aimed separately at the discharging
material and the underlying layer, for example at a location
upstream of the nip point, as shown in FIG. 10. This may function
to preheat and/or more deeply cure the underlying layer while
initiating curing of the newly discharging layer. It is
contemplated that a portion of compactor 24 (e.g., a portion of
wheel 26) may be opaque (as shown in FIG. 9), to inhibit cure
energy from passing therethrough to undesired locations.
[0033] In some embodiments, instead of the energy path(s) passing
straight through compactor 24, one or more of the path(s) may be
redirected (e.g., bent--shown in FIG. 12 or reflected--shown in
FIG. 13). This redirection of the energy path(s) may be
accomplished via a change a density selection for a portion (e.g.,
for wheel 26) of compactor 24 and/or via optical component 32).
Redirecting of the energy path may allow for more precise alignment
of curing location 30 with the nip point of compactor 24, while
avoiding interferences with other components, structures, and/or
materials.
[0034] In a final example illustrated in FIG. 14, the path of cure
energy may initiate inside of compactor 24 and extend radially
outward. In one embodiment, the energy may be transmitted via any
number of light pipes (like what is shown in FIG. 4) or similar
conduits that are arranged axially around a perimeter of compactor
24. In another embodiment, the energy may be transmitted via any
number of light pipes or similar conduits that are arranged
annularly around the perimeter of compactor 24. For example, one or
more light pipes could be arranged within an annular groove or
channel 62 that passes through the nip point of compactor 24.
Channel 62 may function to retain the discharging material at a
desired axial location on compactor 24 and inhibit undesired
wandering, especially during cornering of head 16.
INDUSTRIAL APPLICABILITY
[0035] The disclosed systems may be used to continuously
manufacture composite structures having any desired cross-sectional
shape and length. The composite structures may include any number
of different fibers of the same or different types and of the same
or different diameters, and any number of different matrixes of the
same or different makeup. Operation of system 10 will now be
described in detail.
[0036] At a start of a manufacturing event, information regarding a
desired structure 12 may be loaded into system 10 (e.g., into
controller 22 that is responsible for regulating operations of
support 14 and/or head 16). This information may include, among
other things, a size (e.g., diameter, wall thickness, length,
etc.), a contour (e.g., a trajectory), surface features (e.g.,
ridge size, location, thickness, length; flange size, location,
thickness, length; etc.), connection geometry (e.g., locations and
sizes of couplings, tees, splices, etc.), desired weave patterns,
weave transition locations, etc. It should be noted that this
information may alternatively or additionally be loaded into system
10 at different times and/or continuously during the manufacturing
event, if desired. Based on the component information, one or more
different reinforcements and/or matrix materials may be selectively
installed and/or continuously supplied into system 10.
[0037] To install the reinforcements, individual fibers, tows,
and/or ribbons may be passed through head 16. In some embodiments,
the reinforcements may be passed under compactor 24 (e.g., under
wheel 26) and/or attached to anchor point 18. Installation of the
matrix material may include filling head 16 and/or coupling of an
extruder (not shown) to head 16.
[0038] The component information may then be used to control
operation of system 10. For example, the reinforcements may be
pulled and/or pushed along with the matrix material from head 16.
Support 14 may also selectively move head 16 and/or the anchor
point in a desired manner, such that an axis of the resulting
structure 12 follows a desired three-dimensional trajectory. Once
structure 12 has grown to a desired length, structure 12 may be
severed from system 10.
[0039] The disclosed head 16 may have improved curing and
discharge-location control. Curing may be improved via precise
control over the location at which a desired amount and intensity
of cure energy impinges discharging material. Discharge-location
control may improve curing at the nip location, such that the
discharging material does not move significantly after compactor 24
has moved over the material.
[0040] It will be apparent to those skilled in the art that various
modifications and variations can be made to the disclosed system
and head. Other embodiments will be apparent to those skilled in
the art from consideration of the specification and practice of the
disclosed system and head. For example, it is contemplated that the
disclosed cure enhancer/compactor relationships may be applied to
heads 16 which include a nozzle that feeds material to compactor 24
or that are nozzle-less, as desired. It is intended that the
specification and examples be considered as exemplary only, with a
true scope being indicated by the following claims and their
equivalents.
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