Interlaced three-dimensional printed composites and machines for fabricating same

Patent metadata

Field	Value
Publication number	US-11111626-B2
Application number	US-201715788061-A
Country	US
Kind code	B2
Filing date	Oct 19, 2017
Priority date	Aug 8, 2014
Publication date	Sep 7, 2021
Grant date	Sep 7, 2021

Abstract

A machine for fabricating three-dimensional interlaced composite components including a frame, a deposition surface, a first set of two or more warp heads, a second set of two or more of warp heads, and a weft inserter. An interlaced composite component including a first set of two or more warp filaments parallel to each other and a first set of two or more weft filaments parallel to each other. Warp filaments are interlaced with, and bonded to, weft filaments. Warp filaments and weft filaments are interlaced in at least two different weave patterns. Warp filaments and weft filaments are continuous, and the weave patterns transition from one pattern to another.

First claim

What is claimed is:

1. A three-dimensional interlaced composite fabricated by a machine comprising a frame, a deposition surface, a first set of two or more warp heads adapted to deposit a first set of warp filaments on the deposition surface in a first warp direction, and move parallel to one another within a first plane, a second set of two or more of warp heads adapted to deposit a second set of warp filaments on the deposition surface in a second warp direction, and move parallel to one another within the first plane, wherein the second set of warp heads do not move collinearly with the first set of warp heads, and a weft inserter adapted to deposit a first and second set of weft filaments on the deposition surface in a weft direction, and traverse a length of the deposition surface in the warp direction, wherein the weft direction is different than at least one of the first and second warp directions;
wherein the three-dimensional interlaced composite is fabricated by the machine by:
depositing onto the deposition surface the first set warp filaments;
inserting, on top of the first set of warp filaments, the first set of weft filaments being parallel to one another and substantially coplanar;
depositing, on top of the first set of weft filaments, the second set of warp filaments; and
inserting, on top of the second set of warp filaments, the second set of weft filaments being parallel to one another and substantially coplanar;

wherein the three-dimensional interlaced composite is formed when at least one of the warp filaments passes over at least one of the weft filaments and passes under at least another of the weft filaments; and
wherein the three-dimensional interlaced composite comprises:
the first and second set of warp filaments; and
the first and second set of weft filaments;
wherein one or more of the warp filaments of the first and second set of warp filaments comprise reinforcing fibers that are pre-impregnated and therefore saturated with resin.

2. The three-dimensional interlaced composite of claim 1 , wherein the three-dimensional interlaced composite is formed when at least one warp filament of the first set of warp filaments passes over at least one weft filament of the first set of weft filaments and passes under at least another of the weft filaments of the first set of weft filaments.

3. The three-dimensional interlaced composite of claim 1 , wherein the three-dimensional interlaced composite is formed when at least one warp filament of the first set of warp filaments passes over at least one weft filament of the second set of weft filaments and passes under at least another of the weft filaments of the second set of weft filaments.

4. An interlaced composite component comprising:
two or more warp filaments parallel to each other; and
two or more weft filaments parallel to each other;
wherein one or more of the warp filaments comprise reinforcing fibers that are pre-impregnated and therefore saturated with resin;
wherein at least a portion of the warp filaments are interlaced with at least a portion of the weft filaments at locations of interlacing;
wherein at least a portion of the locations of interlacing, the interlaced warp filament and the interlaced weft filament are bonded to one another only at such portions of locations of interlacing;
wherein at least a portion of the warp filaments and at least a portion of the weft filaments are interlaced in at least two different weave patterns selected from the group consisting of plain weave, twill weave, and satin weave;
wherein at least a portion of the warp filaments and at least a portion of the weft filaments are continuous and the weave patterns transition from one pattern to another; and
wherein each location of bonding of the interlaced composite component is a location of interlacing.

5. The interlaced composite component of claim 4 , wherein at least a portion of the warp filaments comprise reinforcing fibers bonded to a polymer matrix.

6. The interlaced composite component of claim 4 , wherein the resin is a thermoplastic resin.

7. The interlaced composite component of claim 4 , wherein at least a portion of the warp filaments and at least a portion of the weft filaments comprise comingled reinforcing fibers and thermoplastic fibers.

8. The interlaced composite component of claim 4 , wherein at each location of interlacing, the interlaced warp filament and the interlaced weft filament are bonded to one another.

9. An interlaced composite component comprising:
a first set of warp filaments at least a portion of which are parallel to each other;
a first set of weft filaments at least a portion of which are parallel to each other;
a second set of warp filaments at least a portion of which are parallel to each other; and
a second set of weft filaments at least a portion of which are parallel to each other;
wherein at least a portion of the weft filaments of the first set of weft filaments are substantially coplanar;
wherein at least a portion of the weft filaments of the second set weft filaments are substantially coplanar, and positioned either directly above or directly below at least a portion of the first set of weft filaments;
wherein at least a portion of the warp filaments of the first set of warp filaments alternate between being interlaced with, and bonded to, at least a portion of the weft filaments of the first set of weft filaments and at least a portion of the weft filaments of the second set of weft filaments;
wherein at least a portion of the warp filaments of the second set of warp filaments alternate between being interlaced with, and bonded to, at least a portion of the weft filaments of the first set of weft filaments and at least a portion of the weft filaments of the second set of weft filaments; and
wherein either or both:
in at least a portion of the composite, weft filaments of both the first set of weft filaments and the second set of weft filaments remain unbonded from one another; and
at least a portion of the warp filaments of the second set warp filaments are positioned either directly above or directly below at least a portion of the first set of warp filaments.

10. The interlaced composite component of claim 9 , wherein either or both:
at least a portion of the warp filaments of the second set of warp filaments and at least a portion of the weft filaments of the second set of weft filaments are interlaced in at least two different weave patterns selected from the group consisting of plain weave, twill weave, and satin weave; and
at least a portion of the warp filaments of the second set of warp filaments and at least a portion of the weft filaments of the second set of weft filaments are continuous and the weave patterns transition from one pattern to another.

11. An interlaced composite component comprising:
a first set of two or more warp filaments parallel to each other and separated from one another by a warp gap; and
a first set of two or more weft filaments parallel to each other and separated from one another by a weft gap;
wherein at least a portion of the warp filaments of the first set of warp filaments are interlaced with at least a portion of the weft filaments of the first set of weft filaments at locations of interlacing;
wherein at at least a portion of the locations of interlacing, the interlaced warp filament of the first set of warp filaments and the interlaced weft filament of the first set of weft filaments are bonded to one another only at such portions of locations of interlacing;
wherein the warp and weft gaps define one or more openings in the composite component configured to one or both limit crack propagation and buckli

Assignees

• Georgia Tech Res Inst

Inventors

• Oberste Christopher Marc
• Wang Ben
• Wang Kan

Classifications

• B29C70/24 Primary

  oriented in at least three directions forming a three-dimensional [3D] structure · CPC title

• D03D47/273

  Rapier rods · CPC title

• D10B2101/12

  Carbon; Pitch · CPC title

• D03D41/004

  Looms for three-dimensional fabrics · CPC title

• D10B2505/02

  Reinforcing materials; Prepregs · CPC title