Head and system for continuously manufacturing composite hollow structure

Patent metadata

Field	Value
Publication number	US-10882249-B2
Application number	US-201816136613-A
Country	US
Kind code	B2
Filing date	Sep 20, 2018
Priority date	Apr 15, 2016
Publication date	Jan 5, 2021
Grant date	Jan 5, 2021

Abstract

A head is disclosed for use with a continuous manufacturing system. The head may have a housing configured to receive a matrix and a continuous fiber, and a diverter located at an end of the housing. The diverter may be configured to divert radially outward a matrix-coated fiber. The head may also include a cutoff having an edge configured to press the matrix-coated fiber against the diverter.

First claim

What is claimed is:

1. A method of additively manufacturing tubular structures, comprising:
passing matrix-wetted continuous reinforcements over a diverter, wherein the diverter is within a head of an additively manufacturing system; moving the head during the passing of the matrix-wetted continuous reinforcements over the diverter;
exposing the matrix-wetted continuous reinforcements to a cure energy; and
selectively moving a cutoff toward the diverter at a location upstream of cure energy exposure to sever the matrix-wetted continuous reinforcements.

2. The method of claim 1 , further including forming the matrix-wetted continuous reinforcements into a tube before passing the matrix-wetted continuous reinforcements over the diverter.

3. The method of claim 2 , wherein exposing the matrix-wetted continuous reinforcements to the cure energy includes exposing internal and external surfaces of the tube to cure energy.

4. The method of claim 2 , further including weaving the matrix-wetted continuous reinforcements.

5. The method of claim 1 , wherein passing the matrix-wetted continuous reinforcements over the diverter includes diverting the matrix-wetted continuous reinforcements radially outward.

6. The method of claim 1 , wherein passing the matrix-wetted continuous reinforcements over the diverter includes passing the matrix-wetted continuous reinforcements through an annular gap between the diverter and a housing of the head.

7. The method of claim 1 , wherein exposing the matrix-wetted continuous reinforcements to a cure energy includes exposing the matrix-wetted continuous reinforcements to UV light.

8. The method of claim 1 , selectively moving the cutoff toward the diverter includes moving the cutoff in an axial direction of the diverter.

9. The method of claim 1 , wherein:
the diverter is bell-shaped; and
selectively moving the cutoff toward the diverter includes pressing the matrix-wetted continuous reinforcements against a downstream mouth of the diverter.

10. The method of claim 1 , further including selectively moving the diverter to adjust a wall thickness of a structure formed by the matrix-wetted continuous reinforcements.

11. The method of claim 10 , wherein selectively moving the diverter to adjust the wall thickness includes reducing the wall thickness of the structure at a time of severing.

12. The method of claim 1 , further including selectively moving the diverter to clamp the matrix-wetted continuous reinforcements at a time of severing.

13. A method of additively manufacturing tubular structures, comprising:
passing matrix-wetted continuous reinforcements over a diverter to form a tube;
exposing the matrix-wetted continuous reinforcements to a cure energy, wherein the diverter is within a head of an additively manufacturing system; moving the head during the passing of the matrix-wetted continuous reinforcements over the diverter;
selectively moving the diverter to reduce a wall thickness of the tube; and
selectively moving a cutoff toward the diverter at a time of reduced wall thickness to sever the matrix-wetted continuous reinforcements.

14. The method of claim 13 , further including selectively moving the diverter to clamp the matrix-wetted continuous reinforcements at a time of severing.

15. The method of claim 13 , wherein selectively moving the cutoff toward the diverter includes moving the cutoff toward the diverter before the matrix-wetted continuous reinforcements are cured.

16. The method of claim 13 , wherein exposing the matrix-wetted continuous reinforcements to the cure energy includes exposing internal and external surfaces of the tube to cure energy.

17. The method of claim 13 , further including weaving the matrix-wetted continuous reinforcements.

18. The method of claim 13 , wherein exposing the matrix-wetted continuous reinforcements to a cure energy includes exposing the matrix-wetted continuous reinforcements to UV light.

19. The method of claim 13 , selectively moving the cutoff toward the diverter includes moving the cutoff in an axial direction of the diverter.

20. The method of claim 13 , wherein:
the diverter is bell-shaped; and
selectively moving the cutoff toward the diverter includes pressing the matrix-wetted continuous reinforcements against a downstream mouth of the diverter.

Assignees

• Cc3D Llc
• Continuous Composites Inc

Inventors

• Tyler Kenneth Lyle

Classifications

• B29C48/2886

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

• B29D23/00

  Producing tubular articles (B29D24/00 takes precedence) · CPC title

• B29C70/52

  Pultrusion, i.e. forming and compressing by continuously pulling through a die · CPC title

• B29C48/09

  Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels · CPC title

• B29L2023/00

  Tubular articles (B29L2024/00 takes precedence {; catheters B29L2031/7542}) · CPC title