Methods for additively manufacturing composite parts

Patent metadata

Field	Value
Publication number	US-10189242-B2
Application number	US-201614995620-A
Country	US
Kind code	B2
Filing date	Jan 14, 2016
Priority date	Jul 31, 2015
Publication date	Jan 29, 2019
Grant date	Jan 29, 2019

Abstract

A method of additively manufacturing a composite part is disclosed. The method comprises depositing a segment of a continuous flexible line along a print path. The continuous flexible line comprises a non-resin component and a thermosetting resin component that is not fully cured. The method further comprises, while advancing the continuous flexible line toward the print path, delivering a predetermined or actively determined amount of curing energy at least to a portion of the segment of the continuous flexible line at a controlled rate after the segment of the continuous flexible line is deposited along the print path to at least partially cure at least the portion of the segment of the continuous flexible line.

First claim

What is claimed is:

1. A method of additively manufacturing a composite part, the method comprising:
depositing a segment of a continuous flexible line along a print path, wherein the continuous flexible line comprises a non-resin component and a thermosetting resin component that is not fully cured; and
while advancing the continuous flexible line toward the print path, delivering a ring of a predetermined or actively determined amount of curing energy that intersects at least a portion of the segment of the continuous flexible line at a controlled rate after the segment of the continuous flexible line is deposited along the print path to at least partially cure at least the portion of the segment of the continuous flexible line to a desired level of cure; and
wherein the ring of the curing energy is delivered by at least one galvanometer mirror-positioning system.

2. The method according to claim 1 , further comprising applying a thermosetting resin to the non-resin component while pushing the continuous flexible line out of a delivery guide, wherein the thermosetting resin component comprises at least some of the thermosetting resin applied to the non-resin component.

3. The method according to claim 2 , wherein applying the thermosetting resin to the non-resin component while pushing the continuous flexible line out of the delivery guide comprises injecting the thermosetting resin into the delivery guide.

4. The method according to claim 3 , wherein injecting the thermosetting resin into the delivery guide comprises separately injecting a first part of the thermosetting resin and a second part of the thermosetting resin into the delivery guide.

5. The method according to claim 4 , further comprising mixing the first part of the thermosetting resin and the second part of the thermosetting resin within the delivery guide.

6. The method according to claim 3 , further comprising mixing a first part of the thermosetting resin and a second part of the thermosetting resin externally to the delivery guide.

7. The method according to claim 2 , wherein:
applying the thermosetting resin to the non-resin component while pushing the continuous flexible line out of the delivery guide comprises metering a flow of the thermosetting resin; and
metering the flow of the thermosetting resin comprises detecting a level of the thermosetting resin within the delivery guide.

8. The method according to claim 7 , wherein metering the flow of the thermosetting resin comprises selectively reducing or selectively increasing the flow of the thermosetting resin to the delivery guide responsive to the level of the thermosetting resin within the delivery guide.

9. The method according to claim 2 , wherein:
applying the thermosetting resin to the non-resin component while pushing the continuous flexible line out of the delivery guide comprises metering a flow of the thermosetting resin;
metering the flow of the thermosetting resin comprises detecting a saturation level of the non-resin component with the thermosetting resin; and
metering the flow of the thermosetting resin comprises selectively reducing or selectively increasing the flow of the thermosetting resin to the delivery guide responsive to the saturation level of the non-resin component with the thermosetting resin.

10. The method according to claim 2 , further comprising:
maintaining the thermosetting resin below a threshold temperature at least prior to applying the thermosetting resin to the non-resin component.

11. The method according to 10 , wherein the threshold temperature is no greater than 20° C.

12. The method according to claim 2 , wherein:
applying the thermosetting resin to the non-resin component while pushing the continuous flexible line out of the delivery guide comprises metering a flow of the thermosetting resin; and
metering the flow of the thermosetting resin comprises metering a flow of a first part of the thermosetting resin and metering a flow of a second part of the thermosetting resin.

13. The method according to claim 2 , further comprising:
maintaining the thermosetting resin component below a threshold temperature prior to depositing the segment of the continuous flexible line along the print path.

14. The method according to 13 , wherein the threshold temperature is no greater than 20° C.

15. The method according to claim 1 , wherein delivering the ring of the predetermined or actively determined amount of the curing energy that intersects at least the portion of the segment of the continuous flexible line at the controlled rate comprises partially curing a first layer of the segment of the continuous flexible line as the first layer is being deposited and further curing the first layer as a second layer is being deposited against the first layer.

16. The method according to claim 1 , further comprising, simultaneously with depositing the segment of the continuous flexible line along the print path, compacting at least a section of the segment of the continuous flexible line after the segment of the continuous flexible line is deposited along the print path.

17. The method according to claim 16 , wherein compacting at least the section of the segment of the continuous flexible line after the segment of the continuous flexible line is deposited along the print path comprises heating the section of the segment of the continuous flexible line to at least partially cure at least the section of the segment of the continuous flexible line.

18. The method according to claim 16 , wherein compacting at least the section of the segment of the continuous flexible line after the segment of the continuous flexible line is deposited along the print path comprises imparting a desired cross-sectional shape to the segment of the continuous flexible line.

19. The method according to claim 1 , further comprising, simultaneously with depositing the segment of the continuous flexible line along the print path, roughening at least a section of the segment of the continuous flexible line after the segment of the continuous flexible line is deposited along the print path.

20. The method according to claim 19 , wherein roughening at least the section of the segment of the continuous flexible line after the segment of the continuous flexible line is deposited along the print path comprises heating the section of the segment of the continuous flexible line to at least partially cure at least the section of the segment of the continuous flexible line.

21. The method according to claim 19 , further comprising, simultaneously with roughening at least the section of the segment of the continuous flexible line, collecting debris resulting from roughening at least the section of the segment of the continuous flexible line.

22. The method according to claim 19 , further comprising, simultaneously with roughening at least the section of the segment of the continuous flexible line, dispersing debris resulting from roughening at least the section of the segment of the continuous flexible line.

23. The method according to claim 1 , further comprising selectively cutting the continuous flexible line, wherein the continuous flexible line is selectively cut simultaneously with depositing the segment of the continuous flexible line along the print path.

24. The method according to claim 1 , wherein depositing the segment of the continuous flexible line along the print path comprises pushing the continuous flexibl

Assignees

• Boeing Co

Inventors

• Evans Nick S
• Torres Faraón
• Ziegler Ryan G
• Harrison Samuel F
• Grijalva Iii Ciro J
• Osborn Hayden S

Classifications

• B29C64/321

  Feeding · CPC title

• B29C2035/0827

  using UV radiation · CPC title

• B29K2995/005

  Oriented · CPC title

• B29C70/38

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

• B29K2105/12

  of short lengths, e.g. chopped filaments, staple fibres or bristles · CPC title