SYSTEM AND HEAD FOR CONTINUOUSLY MANUFACTURING COMPOSITE STRUCTURE

• US 20190315055A1
• Filed: 02/19/2019
• Published: 10/17/2019
• Est. Priority Date: 04/12/2018
• Status: Active Grant

• Current Assignee: Continuous Composites Inc.
• Original Assignee: CC3D LLC
• Inventors: Tyler, Kenneth Lyle
• Granted Patent: US 11,130,284 B2
• Time in Patent Office: Days
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• 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 64/307 Handling of material to be used in additive manufacturing
• CPC Class Codes: B29C 64/314 Preparation
• CPC Class Codes: B29C 64/321 Feeding
• CPC Class Codes: B29C 70/16 using fibres of substantial or continuous length non-woven fabrics per se D04H3/00
• CPC Class Codes: B29C 70/384 Fiber placement heads, e.g. component parts, details or accessories
• 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 40/00 Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing

Abstract

A print head is disclosed for use in an additive manufacturing system. The print head may include a discharge outlet configured to discharge a continuous reinforcement, and an applicator disposed upstream of the discharge outlet and configured to apply a solid film to the continuous reinforcement prior to discharge. The print head may also include a cure enhancer configured to soften the solid film after discharge.

Claims

1. A system for additively manufacturing a composite structure, comprising:

a print head, including;

a discharge outlet configured to discharge a continuous reinforcement; and

an applicator disposed upstream of the discharge outlet and configured to apply a solid film to the continuous reinforcement prior to discharge;

a support configured to move the print head during discharging; and

a controller configured to selectively activate the support based on known specifications for the composite structure.

2. The system of claim 1, further including a cure enhancer configured to soften the solid film after discharge.

3. The system of claim 2, wherein the cure enhancer is mounted to the print head.

4. The system of claim 2, wherein the print head further includes a matrix chamber configured to apply a matrix coating to the continuous reinforcement prior to application of the solid film.

5. The system of claim 4, wherein the cure enhancer is further configured to initiate curing of the matrix coating.

6. The system of claim 5, wherein:

the solid film is at least one of partially transparent and porous; and

the cure enhancer is configured to direct cure energy through the solid film to the matrix coating.

7. The system of claim 4, wherein:

the solid film is a thermoplastic; and

the matrix coating is a thermoset resin.

8. The system of claim 4, wherein the applicator is further configured to at least one of remove air bubbles from the matrix coating and press the solid film onto the continuous reinforcement.

9. The system of claim 4, wherein the print head further includes rollers configured to pull the continuous reinforcement through the matrix chamber.

10. The system of claim 4, wherein:

the print head further includes a vacuum chamber located between the matrix chamber and the discharge outlet; and

the applicator applies the solid film to the continues reinforcement inside the vacuum chamber.

11. The system of claim 1, further including an edge fuser configured to fuse edges of the solid film.

12. The system of claim 11, further including a feeder located downstream of the edge fuser and configured to push the continuous reinforcement and the solid film through the discharge outlet.

13. The system of claim 1, wherein the applicator is configured to apply the solid film to opposing sides of the continuous reinforcement, such that the continuous reinforcement is sandwiched between layers of the solid film.

14. The system of claim 1, wherein:

the continuous reinforcement enters the print head already coated in a first matrix; and

the print head further includes a matrix chamber configured to apply a second matrix coating to the continuous reinforcement prior to application of the solid film.

15. A print head for an additive manufacturing system, comprising:

a discharge outlet configured to discharge a continuous reinforcement;

an applicator disposed upstream of the discharge outlet and configured to apply a solid film to the continuous reinforcement prior to discharge; and

a cure enhancer configured to soften the solid film after discharge.

16. The print head of claim 15, further including a matrix chamber configured to apply a matrix coating to the continuous reinforcement prior to application of the solid film, wherein the cure enhancer is further configured to initiate curing of the matrix coating.

17. The print head of claim 16, wherein:

the solid film is at least one of partially transparent and porous; and

the cure enhancer is configured to direct cure energy through the solid film to the matrix coating.

18. The print head of claim 16, wherein the applicator is further configured to at least one of remove air bubbles from the matrix coating and press the solid film onto the continuous reinforcement.

19. The print head of claim 16, further including a vacuum chamber located between the matrix chamber and the discharge outlet, wherein the applicator applies the solid film to the continues reinforcement inside the vacuum chamber.

20. The print head of claim 15, further including:

an edge fuser configured to fuse edges of the solid film; and

a feeder located downstream of the edge fuser and configured to push the continuous reinforcement and the solid film through the discharge outlet.