Method of forming a carbon fiber layup

Patent metadata

Field	Value
Publication number	US-10093067-B2
Application number	US-201414533951-A
Country	US
Kind code	B2
Filing date	Nov 5, 2014
Priority date	Nov 5, 2014
Publication date	Oct 9, 2018
Grant date	Oct 9, 2018

Abstract

A manufactured component, method and apparatus for advanced manufacturing that includes a polymeric working material formed into a mandrel with a carbon fiber overlay formed in a continuation of the process. The mandrel build and the carbon fiber overlay of the component preferably take place at atmospheric temperatures.

First claim

What is claimed is:

1. A method of forming a carbon fiber layup in a fused deposition modeling build comprising:
providing a supply of thermoplastic working material to a nozzle;
depositing the thermoplastic working material through the nozzle to form a mandrel within a work area, wherein the build occurs within an unheated work area;
maintaining a position of the mandrel within the work area;
applying carbon fiber over the mandrel to form a carbon fiber layup; and
removing the mandrel from the carbon fiber layup.

2. The method of claim 1 wherein the build occurs entirely within a gantry.

3. The method of claim 1 further comprising heating the thermoplastic working material with a heating element positioned with respect to the nozzle.

4. The method of claim 3 wherein the heating element comprises a coil positioned around the nozzle.

5. The method of claim 1 wherein the thermoplastic working material is provided in pelletized form.

6. The method of claim 1 wherein the thermoplastic working material is provided in a filament.

7. The method of claim 1 wherein the nozzle moves through three axes of travel within the gantry.

8. A process for manufacturing a component using fused deposition modeling comprising the steps of:
directing a desired flow of a thermoplastic working material onto a work surface within a gantry;
forming a mandrel with the thermoplastic working material;
directing a carbon fiber layup over the mandrel within the gantry;
building up the mandrel and the carbon fiber layup at atmospheric temperature; and
removing the mandrel to form the component.

9. A process for manufacturing a component using fused deposition modeling comprising the steps of:
directing a desired flow of a working material onto a work surface within a gantry, wherein the working material comprises at least one of ABS, polycarbonate, PLA, Ultem, Nylon, and PPSF/PPSU;
forming a mandrel with the working material;
directing a carbon fiber layup over the mandrel within the gantry;
building up the mandrel and the carbon fiber layup at an atmospheric temperature between 10 and 30° C.; and
removing the mandrel to form the component.

10. The process of claim 8 wherein the working material is provided in pelletized form to a nozzle, the nozzle having three axes of movement within the gantry.

11. The process of claim 8 wherein the working material is provided in a filament.

12. The process of claim 8 , wherein the working material and the carbon fiber layup are provided through a common print head.

13. The process of claim 8 wherein atmospheric temperature is between 10 and 30° C.

14. The process of claim 9 wherein the working material is provided in pelletized form to a nozzle, the nozzle having three axes of movement within the gantry.

15. The process of claim 9 wherein the working material and the carbon fiber layup are provided through a common print head.

Assignees

• Ut Battelle Llc

Inventors

• Kunc Vlastimil
• Lind Randall F
• Love Lonnie J

Classifications

• B29C64/118

  using filamentary material being melted, e.g. fused deposition modelling [FDM] · CPC title

• B29C70/38 Primary

  Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns {(application heads for tyres B29D30/28)} · CPC title

• B29K2101/12

  Thermoplastic materials · CPC title

• B29C33/52

  soluble or fusible {(in particular used in injection moulding B29C45/4457)} · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title