Systems and methods for additively manufacturing composite parts

Patent metadata

Field	Value
Publication number	US-11072158-B2
Application number	US-201916578895-A
Country	US
Kind code	B2
Filing date	Sep 23, 2019
Priority date	Nov 7, 2016
Publication date	Jul 27, 2021
Grant date	Jul 27, 2021

Abstract

Systems and methods for additively manufacturing composite parts are disclosed. Methods comprise combining a plurality of pre-consolidated tows to define a macro tow and dispensing the macro tow in three dimensions to define the composite part. Each pre-consolidated tow comprises a fiber tow within a non-liquid binding matrix. The combining comprises actively altering a shape and/or size of a cross-sectional profile of the macro tow along a length of the macro tow as it is being defined.

First claim

The invention claimed is:

1. A method of additively manufacturing a composite part, the method comprising:
combining a plurality of pre-consolidated tows to define a macro tow, wherein each pre-consolidated tow comprises a fiber tow within a non-liquid binding matrix, wherein the combining comprises actively altering a shape or a size of a cross-sectional profile of the macro tow along a length of the macro tow as it is being defined;
selectively stopping and starting a feed of a selection of the plurality of pre-consolidated tows to alter the shape or the size of the cross-sectional profile of the macro tow as the macro tow is being defined; and
dispensing the macro tow in three dimensions to define the composite part.

2. The method of claim 1 , wherein the non-liquid binding matrix is self-adherent, such that the combining comprises adhering together the plurality of pre-consolidated tows.

3. The method of claim 1 , wherein the combining comprises combining the plurality of pre-consolidated tows with one or more elongate structures, wherein each elongate structure comprises one or more of an optical fiber, a wire, a metal wire, a conductive wire, a wire bundle, a sensor, circuitry, a hollow tube, a foam, and a magnetic material.

4. The method of claim 3 , wherein the elongate structures are free of a binding matrix.

5. The method of claim 3 , wherein the combining comprises feeding the plurality of pre-consolidated tows and the one or more elongate structures into a corresponding plurality of inlets.

6. The method of claim 5 , wherein the inlets converge to a single outlet, wherein the dispensing comprises dispensing the macro tow from the single outlet.

7. The method of claim 1 , wherein the combining comprises feeding the plurality of pre-consolidated tows into a corresponding plurality of inlets.

8. The method of claim 7 , wherein the inlets converge to a single outlet, wherein the dispensing comprises dispensing the macro tow from the single outlet.

9. The method of claim 7 , wherein the inlets are arranged in an array configured to selectively define a plurality of shapes corresponding to cross-sectional profiles of the macro tow based on into which subsets of the inlets the plurality of pre-consolidated tows are fed.

10. The method of claim 7 , wherein the actively altering comprises actively feeding the plurality of pre-consolidated tows into a predetermined subset of the inlets.

11. The method of claim 1 , wherein the combining comprises defining the cross-sectional profile of the macro tow as circular.

12. The method of claim 1 , wherein the combining comprises defining the cross-sectional profile of the macro tow as polygonal.

13. The method of claim 12 , wherein the dispensing comprises nesting the macro tow against itself when the cross-sectional profile is polygonal.

14. The method of claim 1 , wherein the combining comprises defining the cross-sectional profile of the macro tow as asymmetrical.

15. The method of claim 1 , further comprising:
feeding pre-consolidated tows of the plurality of pre-consolidated tows at different rates to impart a curvature in the macro tow as the macro tow is being defined.

16. The method of claim 1 , further comprising:
applying an adhesive to the plurality of pre-consolidated tows to one or both of adhere the plurality of pre-consolidated tows together to further define the macro tow and to adhere together spaced-apart portions of the macro tow as the composite part is being manufactured.

17. The method of claim 16 , wherein the applying comprises one or more of dripping the adhesive, spraying the adhesive, and drawing the plurality of pre-consolidated tows through a volume of the adhesive.

18. The method of claim 16 , wherein the adhesive is a different material from the non-liquid binding matrix.

19. The method of claim 16 , wherein the adhesive is a liquid state of the non-liquid binding matrix.

20. The method of claim 1 , wherein the non-liquid binding matrix comprises one or more of a polymer, a resin, a thermoplastic, a thermoset, a photopolymer, an ultra-violet photopolymer, a visible-light photopolymer, an infrared-light photopolymer, an x-ray photopolymer, a partially cured binding matrix, a fully cured binding matrix, and an epoxy.

Assignees

• Boeing Co

Inventors

• Wilenski Mark Stewart
• Kozar Michael Patrick
• Evans Nick Shadbeh

Classifications

• B33Y70/10

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title

• B29C31/04 Primary

  Feeding {of the material to be moulded}, e.g. into a mould cavity {(B29C39/08 takes precedence; using a material distribution system to two or more fixed injection moulds B29C45/125)} · CPC title

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title

• B32B39/00

  Layout of apparatus or plants, e.g. modular laminating systems · CPC title

• B32B37/14

  characterised by the properties of the layers · CPC title