Continuous fiber-reinforced component fabrication

Patent metadata

Field	Value
Publication number	US-2016114532-A1
Application number	US-201414890294-A
Country	US
Kind code	A1
Filing date	Feb 27, 2014
Priority date	May 31, 2013
Publication date	Apr 28, 2016
Grant date	—

Abstract

A machine for fabricating a fiber-reinforced component by additive manufacturing is disclosed. The machine may have a surface, a matrix feed configured to deposit a plurality of matrix layers on the surface, and a fiber feed configured to deposit a fiber layer on at least one of the plurality of matrix layers. The deposition of the plurality of matrix layers and the fiber layer may be controlled by a computer.

First claim

What is claimed is:

1 . A machine for fabricating a fiber-reinforced component by additive manufacturing comprising:
a surface; a matrix feed configured to deposit a plurality of matrix layers on the surface; and a fiber feed configured to deposit a fiber layer at least one of the plurality of matrix layers, the deposition of the plurality of matrix layers and the fiber layer being controlled by a computer.

2 . The machine, according to claim 1 , wherein the fiber layer comprises a continuous fiber.

3 . The machine, according to claim 1 , further comprising a first energy-source configured to soften any of the plurality of matrix layers.

4 . The machine, according to claim 3 , further comprising a pressure source configured to press the fiber layer into a previously deposited matrix layer.

5 . The machine, according to claim 4 , wherein the pressure source emits heated air under a pressure.

6 . The machine, according to claim 4 , further comprising a second energy source configured to melt any of the plurality of the matrix layers.

7 . The machine, according to claim 6 , wherein a truck supports the matrix feed and the fiber feed.

8 . The machine, according to claim 7 , wherein the truck further supports the first energy source, the pressure source, and the second energy source.

9 . The machine, according to claim 7 , wherein the computer is operatively associated with the truck to control movement of the truck with respect to the surface.

10 . The machine, according to claim 7 , wherein the matrix layer comprises one or more polymers.

11 . A method for fabricating a fiber-reinforced component by additive manufacturing comprising:
depositing a matrix layer on a surface; and depositing a fiber layer on a previously deposited matrix layer, the fiber layer comprising a continuous fiber.

12 . The method, according to claim 11 , further comprising depositing a subsequent matrix layer on the fiber layer.

13 . The method, according to claim 12 , further comprising embedding the fiber layer into the previously deposited matrix layer.

14 . The method, according to claim 13 , further comprising fusing the previously deposited matrix layer and the subsequent matrix layer.

15 . The method, according to claim 14 , wherein the method is automated and controlled by a computer.

16 . A fiber-reinforced component fabricated by an additive manufacturing process comprising:
depositing a matrix layer on a surface; and depositing a fiber layer on a previously deposited matrix layer, the fiber layer comprising a continuous fiber.

17 . The component, according to claim 16 , further comprising depositing a subsequent matrix layer on the fiber layer.

18 . The component, according to claim 17 , further comprising embedding the fiber layer into the previously deposited matrix layer.

19 . The component, according to claim 18 , further comprising fusing the previously deposited matrix layer and the subsequent matrix layer.

20 . The component, according to claim 19 , wherein the additive manufacturing process is automated and controlled by a computer.

Assignees

• United Technologies Corp

Inventors

• Schirtzinger Gary A
• Twelves Wendell V
• Butcher Evan
• Dautova Lyutsia
• Ott Joe

Classifications

• B29C64/112

  using individual droplets, e.g. from jetting heads · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B29C64/118

  using filamentary material being melted, e.g. fused deposition modelling [FDM] · CPC title

• B29C70/682

  Preformed parts characterised by their structure, e.g. form · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title