Devices and methods for making uncured, near-net shape plies

Patent metadata

Field	Value
Publication number	US-2022410435-A1
Application number	US-202017779120-A
Country	US
Kind code	A1
Filing date	Nov 19, 2020
Priority date	Nov 21, 2019
Publication date	Dec 29, 2022
Grant date	—

Abstract

Disclosed herein are devices and methods for manufacturing uncured, near-net shape plies. Such devices include: a plurality of spools, each dispensing a dry tow; optionally, a plurality of spreaders to spread the dry tows; optionally, a means to combine the dry tows into a plurality of tapes or bundles; a plurality of feeders, each carrying a tow, tape or bundle, and adapted to maintain the tows, tapes or bundles in a parallel arrangement; a cutting apparatus adapted to independently cut each individual tow, tape or bundle to a pre-determined length; optionally, a conveyor adapted to transport the cut tows, tapes or bundles away from the cutting apparatus; an in-line resin infuser adapted to impregnate the dry tows, tapes or bundles with resin material; and a receiver for the cut tows, tapes or bundles, wherein the cut tows, tapes or bundles are impregnated and configured in the form of a near-net shape ply.

First claim

1 . A device for the manufacture of uncured, near-net shape plies, the device comprising:
a plurality of spools, each dispensing a dry tow; optionally, a plurality of spreaders to spread the dry tows; optionally, a means to combine the dry tows into a plurality of tapes or bundles; a plurality of feeders, each carrying a tow, tape or bundle, and adapted configured to maintain the tows, tapes or bundles in a parallel arrangement; a cutting apparatus configured to independently cut each individual tow, tape or bundle to a pre-determined length; optionally, a conveyor configured to transport the cut tows, tapes or bundles away from the cutting apparatus; an in-line resin infuser configured to impregnate the dry tows, tapes or bundles with resin material; and a receiver for the cut tows, tapes or bundles, wherein the cut tows, tapes or bundles are impregnated and configured in the form of a near-net shape ply.

2 . The device according to claim 1 wherein the cutting apparatus comprises one or more contact cutters, one or more non-contact cutters, or both.

3 . The device according to claim 1 , wherein the resin infuser is positioned to impregnate the dry tows before the feeders.

4 . The device according to claim 1 , wherein the resin infuser is positioned to impregnate the dry tows after the feeder.

5 . The device according to claim 1 , wherein the resin infuser is at least one resin bath, slot die, printing tool, resin doser, pump or a combination thereof.

6 . The device according to claim 1 , wherein the feeder is adapted to feed the near-net shape ply directly onto the receiver.

7 . The device according to claim 1 , wherein the receiver is configured to receive multiple plies at various orientations in a stacked arrangement.

8 . The device according to claim 7 , wherein the receiver is rotatable and can travel in at least one axis.

9 . The device according to claim 7 , wherein the receiver is a rotating table.

10 . The device according to claim 1 , wherein the receiver comprises a multi-axis robot equipped with an end effector configured to pick up the near-net shape ply.

11 . The device according to claim 1 , further comprising a module configured to modify the tows, tapes or bundles before cutting, or a module configured to modify or otherwise process the near-net shape ply.

12 . A method for the manufacture of an uncured, near-net shape ply, the method comprising:
providing a plurality of dry tows via a plurality of spools; optionally, spreading each of the dry tows; optionally, combining the dry tows into a plurality of tapes or bundles; feeding the plurality of dry tows, tapes or bundles via a plurality of feeders to a cutting apparatus, wherein each feeder carries a tow, tape or bundle and the plurality of feeders maintain the tows, tapes or bundles in a parallel arrangement; independently cutting each individual tow, tape or bundle to a pre-determined length in the cutting apparatus; and impregnating the dry tows, tapes or bundles with resin material in an in-line resin infuser, thereby providing an uncured, near-net shape ply.

13 . The method according to claim 12 wherein the cutting apparatus comprises one or more contact cutters, one or more non-contact cutters, or both.

14 . The method according to claim 12 , wherein the resin infuser is positioned to impregnate the dry tows before the feeders.

15 . The method according to claim 12 , wherein the resin infuser is at least one resin bath, slot die, printing tool, resin doser, pump or a combination thereof.

16 . The device according to claim 1 wherein the cutting apparatus comprises guillotine blades.

17 . The device according to claim 1 , wherein the resin infuser is positioned to impregnate the dry tows after the cutting apparatus.

18 . The device according to claim 11 , wherein the module is a module adapted to alter the tack of the tow, tape or bundle before cutting or to alter the tack of the ply.

19 . The method according to claim 12 wherein the cutting apparatus comprises guillotine blades.

Assignees

• Cytec Ind Inc

Inventors

• Poynton Gary
• Blackburn Robert

Classifications

• B29C70/06

  Fibrous reinforcements only · CPC title

• B29B11/16 Primary

  comprising fillers or reinforcement {(non-woven fabrics per se D04H1/00, D04H3/00)} · CPC title

• B29C70/386

  Automated tape laying [ATL] · CPC title

• B29B15/125 Primary

  by dipping · CPC title

• B29C70/382

  Automated fiber placement [AFP] · CPC title