Method for continuously manufacturing composite hollow structure

Patent metadata

Field	Value
Publication number	US-10105910-B2
Application number	US-201615130412-A
Country	US
Kind code	B2
Filing date	Apr 15, 2016
Priority date	Apr 15, 2016
Publication date	Oct 23, 2018
Grant date	Oct 23, 2018

Abstract

A method is disclosed for continuously manufacturing a composite hollow structure. The method may include continuously coating fibers with a matrix, and revolving matrix-coated fibers about a non-fiber axis. The method may also include diverting the matrix-coated fibers radially outward away from the non-fiber axis, and curing the matrix-coated fibers.

First claim

What is claimed is:

1. A method of continuously manufacturing a composite hollow structure, comprising:
continuously coating fibers with a matrix to form matrix-coated fibers;
revolving the matrix-coated fibers about a non-fiber axis;
diverting the matrix-coated fibers radially outward away from the non-fiber axis;
dynamically adjusting a trajectory of the non-fiber axis of the composite hollow structure; and
curing the matrix-coated fibers to maintain the adjusted trajectory of the composite hollow structure.

2. The method of claim 1 , wherein revolving matrix-coated fibers includes:
revolving a first subset of the matrix-coated fibers in a first direction; and
revolving a second subset of the matrix-coated fibers in a second direction opposite the first direction.

3. The method of claim 2 , wherein revolving the first and second subsets of matrix-coated fibers includes synchronously oscillating between the first and second directions.

4. The method of claim 2 , wherein revolving the first and second subsets of matrix-coated fibers includes revolving the first and second subsets of matrix-coated fibers through a range of up to 180°.

5. The method of claim 4 , wherein revolving the first and second subsets of matrix-coated fibers includes revolving the first and second subsets of matrix-coated fibers through a range of about 15° to about 30°.

6. The method of claim 2 , wherein revolving the first and second subsets of the matrix-coated fibers includes revolving the first subset of the matrix-coated fibers through a range different than a revolving range of the second subset of the matrix-coated fibers.

7. The method of claim 2 , wherein revolving the first and second subsets of the matrix-coated fibers includes continuously revolving the first subset of the matrix-coated fibers in the first direction and selectively revolving the second subset of the matrix coated fibers in the first direction.

8. The method of claim 2 , wherein revolving the first and second subsets of the matrix-coated fibers includes revolving the first subset of the matrix-coated fibers at a first rate and revolving the second subset of the matrix-coated fibers at a second rate.

9. The method of claim 8 , further including dynamically adjusting the first and second rates during manufacturing of the composite hollow structure.

10. The method of claim 2 , further including dynamically adjusting a pattern of weave created by revolving the first and second subsets of matrix-coated fibers during manufacturing of the composite hollow structure.

11. The method of claim 2 , further including pressing the first subset of the matrix-coated fibers against the second subset of the matrix-coated fibers.

12. The method of claim 11 , further including varying the pressing to thereby adjust a wall thickness of the composite hollow structure.

13. The method of claim 2 , wherein the first subset of the matrix-coated fibers has at least one of a different diameter and a different material type than the second subset of the matrix-coated fibers.

14. The method of claim 2 , wherein the first subset of the matrix-coated fibers has a different type of matrix than the second subset of the matrix-coated fibers.

15. The method of claim 1 , wherein curing the matrix-coated fibers includes curing the matrix-coated fibers from inside the composite hollow structure.

16. The method of claim 1 , wherein curing the matrix-coated fibers includes directing at least one of UV light and ultrasonic vibrations toward the matrix-coated fibers.

17. The method of claim 16 , further including controlling an environment of the matrix-coated fibers for a period of time during and after the at least one of the UV light and the ultrasonic vibrations are directed toward the matrix-coated fibers.

18. The method of claim 1 , further including mechanically pinching the matrix-coated fibers prior to curing the matrix-coated fibers in order to fix a length of the composite hollow structure.

19. The method of claim 1 , further including filling an interior of the composite hollow structure as the hollow structure is curing.

20. A method of continuously manufacturing a composite hollow structure, comprising:
continuously coating fibers with a matrix to form matrix-coated fibers;
revolving a first subset of the matrix-coated fibers in a first direction; and
revolving a second subset of the matrix-coated fibers in a second direction opposite the first;
diverting the first and second subsets of the matrix-coated fibers radially outward away from a non-fiber axis;
pressing the first subset of the matrix-coated fibers against the second subset of the matrix-coated fibers;
dynamically adjusting revolving of the first and second subsets of the matrix-coated fibers during manufacturing of the composite hollow structure;
curing the first and second subsets of the matrix-coated fibers to retain the adjusted first and second subsets of the matrix coated fibers; and
mechanically pinching the first and second subsets of the matrix-coated fibers prior to curing the first and second subsets of the matrix-coated fibers in order to fix a length of the composite hollow structure.

Assignees

• Cc3D Llc

Inventors

• Tyler Kenneth Lyle

Classifications

• B29C2035/0827

  using UV radiation · CPC title

• B29C48/338

  using a die with concentric parts, e.g. rings, cylinders · CPC title

• B29C48/301

  having reciprocating, oscillating or rotating parts · CPC title

• B29C35/0261

  using ultrasonic or sonic vibrations · CPC title

• B29C48/2886

  of fillers or of fibrous materials, e.g. short-fibre reinforcements · CPC title