SYSTEM FOR CONTINUOUSLY MANUFACTURING COMPOSITE STRUCTURE

• US 20190315056A1
• 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: STUART, NATHANIEL ISAAK, Alvarado, Tyler B., Stockett, Ryan C.
• Granted Patent: US 11,110,656 B2
• Time in Patent Office: Days
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/218 Rollers
• CPC Class Codes: B29C 64/241 for rotary motion
• CPC Class Codes: B29C 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/307 Handling of material to be used in additive manufacturing
• CPC Class Codes: B29C 64/379 Handling of additively manufactured objects, e.g. using robots
• 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

Abstract

A system is disclosed for use in additively manufacturing a composite structure. The system may include at least one support, and a print head operatively connected to the at least one support and configured to discharge composite material. The system may further include an auxiliary tool operatively connected to the at least one support and configured to receive the composite material discharged by the print head.

Claims

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

at least one support;

a print head operatively connected to the at least one support and configured to discharge composite material;

an auxiliary tool operatively connected to the at least one support and configured to receive the composite material discharged by the print head.

2. The system of claim 1, wherein:

the at least one support includes a first support and a second support;

the print head is operatively connected to the first support; and

the auxiliary tool is operatively connected to the second support.

3. The system of claim 1, wherein the auxiliary tool includes at least one of a conveyor belt and a roller onto which the composite material is discharged.

4. The system of claim 3, wherein the auxiliary tool is a conveyor belt that is configured to curl and thereby adjust a shape of the composite material discharged thereon.

5. The system of claim 3, wherein the auxiliary tool further includes a motor configured to drive rotation of the at least one of the conveyor belt and roller.

6. The system of claim 1, wherein the auxiliary tool is configured to provide resistance to compaction of the composite material during discharge of the composite material into free space.

7. The system of claim 6, further including a compactor attached to the print head and configured to compact the composite material on the auxiliary tool.

8. The system of claim 6, further including a compactor attached to the auxiliary tool and configured to compact the composite material on the auxiliary tool.

9. The system of claim 1, wherein:

the at least one support includes a single support; and

the auxiliary tool is configured to selectively move from a stowed position to an engaged position at a discharge location of the print head.

10. The system of claim 1, further including a gimbal-like connector operatively connecting the auxiliary tool to the at least one support.

11. The system of claim 1, further including a controller configured to coordinate motion of the auxiliary tool with motion of the print head, such that the auxiliary tool is maintained at a discharge location of the print head.

12. The system of claim 1, further including a controller configured to coordinate motion of the auxiliary tool with motion of the print head, such that the auxiliary tool always trails behind a discharge location of the print head.

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

cause the at least one support to move the print head relative to an anchor point to discharge material at a first rate; and

cause the at least one support to move the auxiliary tool relative to the print head to increase the first rate.

14. The system of claim 1, wherein the print head includes a cure enhancer to at least partially cure the composite material at discharge.

15. The system of claim 14, wherein the auxiliary tool includes a cure enhancer to further cure the composite material.

16. The system of claim 1, wherein the at least one support includes at least one a robotic arm.

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

a support;

a print head operatively connected to the support and configured to discharge composite material;

at least one of a conveyor belt and a roller operatively connected to the support and configured to receive the composite material discharged by the print head,

wherein the at least one of the conveyor belt and roller is configured to selectively move from a stowed position to an engaged position at a discharge location of the print head.

18. The system of claim 17, further including motor configured to drive rotation of the at least one of the conveyor belt and roller.

19. The system of claim 17, further including a compactor configured to compact the composite material onto the at least one of the conveyor belt and roller.

20. The system of claim 17, wherein:

the print head includes a first cure enhancer to at least partially cure the composite material at discharge; and

the system further includes a second cure enhancer associated with the at least one of the conveyor belt and the roller and configured to further cure the composite material.