Apparatus and process for producing fiber reinforced composite objects
First Claim
1. Apparatus for making three-dimensional, composite material-based objects of a predetermined shape by sequentially depositing multiple layers of continuous reinforcement fibers and solidifying matrix material on a base member in a desired pattern, comprising:
- (a) a movable head having flow-passage means therein connected to a dispensing outlet at one end thereof, said outlet comprising a tip with a discharge orifice of predetermined size therein;
(b) a supply of reinforcement fibers and a matrix material, means for mixing said reinforcement fibers and matrix material to form a continuous preimpregnated tow, and means for introducing said reinforcement fibers and matrix material into said flow-passage means so that said matrix material is in a fluid state;
(c) a base member located in the close, working vicinity of said dispensing outlet of said movable head;
(d) mechanical means for moving said base member relative to said movable head in three dimensions along "X," "Y," and "Z" axes in a rectangular coordinate system in a predetermined sequence and pattern, and for displacing said movable head a predetermined incremental distance relative to said base member and thence relative to each successive layer deposited prior to the start of the formation of each successive layer to form multiple layers of said reinforcement fibers and matrix material of predetermined thickness which build up on each other sequentially as said matrix material solidifies after discharge from said orifice; and
(e) means for metering the discharge of said reinforcement fibers and matrix material from said discharge orifice at a predetermined rate onto said base member to form a three-dimensional object as said base member and said movable head are moved relative to each other.
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Accused Products
Abstract
A process and apparatus for making three-dimensional, composite material objects of a predetermined shape by sequentially depositing multiple layers of continuous reinforcement fibers and solidifying matrix material on a base member in a desired pattern. The apparatus comprises (a) a movable nozzle having a flow passage and a dispensing outlet, (b) a supply of reinforcement fibers and a matrix material, a mixing device for impregnating the fibers with a matrix material to form a preimpregnated tow, and a heating device for introducing the matrix material in a fluid state, (c) a base member to support the object being made, (d) mechanical movement devices for moving the base member relative to the movable nozzle in a predetermined sequence and pattern, and for displacing the movable nozzle a predetermined incremental distance relative to the base member and relative to each successive layer deposited prior to the start of the formation of each successive layer to form multiple layers of composite material of a predetermined thickness, and (e) a metering device for discharging the preimpregnated tow at a predetermined rate onto the base member. The apparatus preferably further comprises (f) a computer-aided design computer and supporting software programs that are capable of creating a three-dimensional drawing of a desired object and converting the drawing into multiple elevation layer data, and (g) a three-dimensional motion controller electronically linked to the mechanical movement devices and operative to actuate these movement devices in response to the drive signals received from the computer.
387 Citations
24 Claims
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1. Apparatus for making three-dimensional, composite material-based objects of a predetermined shape by sequentially depositing multiple layers of continuous reinforcement fibers and solidifying matrix material on a base member in a desired pattern, comprising:
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(a) a movable head having flow-passage means therein connected to a dispensing outlet at one end thereof, said outlet comprising a tip with a discharge orifice of predetermined size therein; (b) a supply of reinforcement fibers and a matrix material, means for mixing said reinforcement fibers and matrix material to form a continuous preimpregnated tow, and means for introducing said reinforcement fibers and matrix material into said flow-passage means so that said matrix material is in a fluid state; (c) a base member located in the close, working vicinity of said dispensing outlet of said movable head; (d) mechanical means for moving said base member relative to said movable head in three dimensions along "X," "Y," and "Z" axes in a rectangular coordinate system in a predetermined sequence and pattern, and for displacing said movable head a predetermined incremental distance relative to said base member and thence relative to each successive layer deposited prior to the start of the formation of each successive layer to form multiple layers of said reinforcement fibers and matrix material of predetermined thickness which build up on each other sequentially as said matrix material solidifies after discharge from said orifice; and (e) means for metering the discharge of said reinforcement fibers and matrix material from said discharge orifice at a predetermined rate onto said base member to form a three-dimensional object as said base member and said movable head are moved relative to each other. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
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19. A process for making a composite material-based three-dimensional object comprising:
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(a) introducing a supply of reinforcement fibers and a matrix material into a flow passage of a discharge nozzle on a moveable dispensing head, said nozzle having a dispensing outlet at one end thereof in fluid-flow communication with said flow passage; (b) mixing said reinforcement fibers and matrix material to form a continuous preimpregnated tow and dispensing said preimpregnated tow from said dispensing outlet onto a base member positioned in the vicinity of said nozzle, said matrix material being in a predetermined physical state that permits said matrix material to readily solidify after discharge; (c) concurrently with the dispensing of said preimpregnated tow onto said base member, mechanically effecting relative movement of said base member and said dispensing head with respect to each other in a predetermined pattern to form a first layer of said preimpregnated tow on said base member; and (d) displacing said dispensing head a predetermined layer thickness distance from said first layer, and after the portion of said first layer adjacent said nozzle has substantially solidified, dispensing a second layer of said preimpregnated tow onto said first layer from said dispensing outlet while concurrently moving said base member and said dispensing head relative to each other, whereby said second layer solidifies and adheres to said first layer; and (e) depositing multiple layers of said preimpregnated tow built up on top of each other in multiple passes by repeated dispensing of said preimpregnated tow from said dispensing outlet as said base member and said dispensing head are moved relative to each other, with said dispensing head and said base member being displaced a predetermined distance after each preceding layer is formed, and with the dispensing of each successive layer being controlled to occur after the matrix material in the preceding layer immediately adjacent to said nozzle has substantially solidified. - View Dependent Claims (20, 21, 22, 23)
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24. A process for making a composite material-based three-dimensional object comprising:
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(a) creating a drawing of a three-dimensional object on a computer in a computer-aided design process wherein the drawing comprises a plurality of thin segments which, in combination, define said object; (b) generating programmed signals corresponding to each of said segments in a predetermined sequence; (c) introducing a supply of reinforcement fibers and a matrix material into a flow passage of a discharge nozzle on a moveable dispensing head, said nozzle having a dispensing outlet at one end thereof in fluid-flow communication with said flow passage; (d) mixing said reinforcement fibers and matrix material to form a continuous preimpregnated tow and dispensing said preimpregnated tow from said dispensing outlet onto a base member positioned in the vicinity of said nozzle, said matrix material being in a predetermined physical state such that said material readily solidifies after discharge; (e) concurrently with the dispensing of said preimpregnated tow onto said base member, and in response to said programmed signals, mechanically effecting relative movement of said base member and said dispensing head with respect to each other in a predetermined pattern to form a first layer of said preimpregnated tow on said base member; and
,(f) in response to said programmed signals, displacing said dispensing head a predetermined layer thickness distance from said first layer, and after the portion of said first layer adjacent said nozzle has substantially solidified, dispensing a second layer of said preimpregnated tow onto said first layer from said dispensing outlet while concurrently moving said base member and said dispensing head relative to each other, whereby said second layer solidifies and adheres to said first layer; and (g) again in response to said programmed signals, depositing multiple layers of said preimpregnated tow built up on top of each other in multiple passes by repeated dispensing of said preimpregnated tow from said dispensing outlet as said base member and said dispensing head are moved relative to each other, with said dispensing head and said base member being displaced a predetermined distance after each preceding layer is formed, and with the dispensing of each successive layer being controlled to occur after the matrix material in the preceding layer immediately adjacent to said nozzle has substantially solidified, whereby a three-dimensional object of predetermined design is fabricated substantially layer by layer on said base member.
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Specification