Additive manufacturing system having shutter mechanism

• US 10,632,673 B2
• Filed: 06/01/2017
• Issued: 04/28/2020
• Est. Priority Date: 09/06/2016
• Status: Active Grant

• Current Assignee: Continuous Composites Inc.
• Original Assignee: Continuous Composites Inc.
• Inventors: Tyler, Kenneth Lyle
• Primary Examiner(s): Malekzadeh, Seyed Masoud
• Assistant Examiner(s): Cummins, IV, Manley L
• Application Number:
  US15/611,430
• Publication Number:
  US 20180065320A1
• Time in Patent Office: 1,062 Days
• Field of Search: None
• CPC Class Codes: B05D 1/26 performed by applying the liquid or other fluent material from an outlet device in contact with, or almost in contact with, the surface
• CPC Class Codes: B25J 9/026 Gantry-type
• CPC Class Codes: B25J 9/046 Revolute coordinate type
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 35/0805 using electromagnetic radiation
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• CPC Class Codes: B29C 48/08 flexible, e.g. films
• CPC Class Codes: B29C 48/12 Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
• CPC Class Codes: B29C 48/154 Coating solid articles, i.e. non-hollow articles
• CPC Class Codes: B29C 48/2556 provided in or in the proximity of dies B29C48/302, B29C48/31, B29C48/325 take precedence
• CPC Class Codes: B29C 48/266 Means for allowing relative movements between the apparatus parts, e.g. for twisting the extruded article or for moving the die along a surface to be coated
• CPC Class Codes: B29C 48/30 Extrusion nozzles or dies extrusion characterised by the shape or cross-section of the extruded article B29C48/03
• CPC Class Codes: B29C 48/301 having reciprocating, oscillating or rotating parts
• CPC Class Codes: B29C 48/304 specially adapted for bringing together components, e.g. melts within the die
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/188 involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/264 Arrangements for irradiation
• CPC Class Codes: B29C 70/384 Fiber placement heads, e.g. component parts, details or accessories
• CPC Class Codes: B29K 2105/0058 Liquid or visquous
• CPC Class Codes: B29K 2105/08 : of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
• CPC Class Codes: B33Y 10/00 : Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 : Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 70/10 : Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials

Abstract

A system is disclosed for use in additively manufacturing a composite structure. The system may include a head configured to discharge a composite material including a matrix and continuous reinforcement. The system may also include a shutter mechanism mounted to the head and configured to grasp the continuous reinforcement after discharge from the head.

Claims

1. An additive manufacturing system, comprising:

a head configured to discharge a composite material including a matrix and a continuous reinforcement;

a first shutter mechanism mounted to the head, configured to receive the composite material, and moveable only from an open position at which the composite material is free to pass through the first shutter mechanism to a completely closed position at which the composite material is severed from the head; and

a second shutter mechanism at least partially enclosed inside of the first shutter mechanism, and configured to move only between a fully open position at which the composite material is free to pass through the second shutter mechanism and a partially open position at which the second shutter mechanism grasps the continuous reinforcement after discharge from the head at a location upstream of where severing occurs.

2. The additive manufacturing system of claim 1, further including a controller having a memory with operational instructions stored therein for causing the second shutter mechanism to grasp and hold the continuous reinforcement during coordinated movement of the head against an anchor point as the matrix cures at a start of a manufacturing process.

3. The additive manufacturing system of claim 1, further including at least one cure enhancer, wherein the second shutter mechanism is configured to selectively block energy generated by the at least one cure enhancer from reaching the matrix.

4. The additive manufacturing system of claim 3, wherein the first shutter mechanism includes:

an annular frame connected to the head at a nozzle tip; and

a plurality of leaves configured to pivot open and closed during rotation of the annular frame.

5. The additive manufacturing system of claim 4, wherein the at least one cure enhancer is located inside of the annular frame.

6. The additive manufacturing system of claim 4, further including:

an actuator configured to rotate the annular frame; and

a controller configured to selectively energize the actuator.

7. The additive manufacturing system of claim 6, wherein the controller is configured to:

receive information regarding a structure to be manufactured with the composite material; and

coordinate operation of the first and second shutter mechanisms with movement of the head based on the information.

8. The additive manufacturing system of claim 1, wherein:

the print head is configured to gravity feed matrix through the nozzle with the continuous reinforcement; and

the second shutter mechanism is further configured to close around the continuous reinforcement without severing and inhibit matrix leakage from the head when the second shutter mechanism is in the closed position.

9. An additive manufacturing system, comprising:

a head having a nozzle configured to discharge a composite material including a matrix and a continuous reinforcement;

at least one light source located adjacent the nozzle and configured to enhance curing of the matrix; and

a shutter mechanism mounted to the head and configured to completely enclose the nozzle and the at least one light source and selectively block energy generated by the at least one light source from reaching the matrix.

10. The additive manufacturing system of claim 9, wherein the shutter mechanism includes:

an annular frame connected to the head at a nozzle; and

a plurality of leaves configured to pivot open and closed during rotation of the annular frame.

11. The additive manufacturing system of claim 10, wherein the at least one light source is located inside of the annular frame.

12. The additive manufacturing system of claim 11, further including:

an actuator configured to rotate the annular frame; and

a controller configured to selectively energize the actuator.

13. The additive manufacturing system of claim 12, wherein the controller is configured to:

receive information regarding a structure to be manufactured with the composite material; and

coordinate operation of the shutter mechanism with movement of the head based on the information.

14. The additive manufacturing system of claim 9, wherein the shutter mechanism is configured to move from an open position at which energy from the at least one light source is unrestricted by the shutter mechanism, to a partially open position at which energy from the at least one light source is at least partially restricted.

15. The additive manufacturing system of claim 14, wherein the shutter mechanism is further configured to move to a closed position at which energy from the at least one light source is completely restricted by the shutter mechanism.

16. An additive manufacturing system, comprising:

a head configured to discharge a composite material including a matrix and a continuous reinforcement;

a support connected to the head and configured to move the head in multiple dimensions during discharging;

a cure enhancer mounted on the head and configured to expose the matrix to cure energy at discharge;

a shutter mechanism mounted to the head and configured to;

selectively grasp and sever the continuous reinforcement; and

selectively block energy generated by the at least one cure enhancer from reaching the matrix; and

a controller having a memory with operational instructions stored therein for;

receiving information regarding a structure to be manufactured with the composite material; and

selectively coordinating operation of the shutter mechanism, the cure enhancer, and the support to grasp the composite material with the shutter mechanism during anchoring, to move the head away from an anchor with the support to initiate discharging, to cure the composite material with the cure enhancer during discharging, and to sever the composite material with the shutter mechanism after discharging, based on the information.