IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0530859
(2006-09-11)
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등록번호 |
US-7387147
(2008-06-17)
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발명자
/ 주소 |
- Johnson,David W.
- Garrett,Scott A.
- Hooks,James M.
- Moyers,Stephen G.
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출원인 / 주소 |
- Ebert Composites Corporation
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대리인 / 주소 |
|
인용정보 |
피인용 횟수 :
13 인용 특허 :
99 |
초록
▼
A method of inserting z-axis reinforcing fibers into a multi-layer composite laminate. Layers of material made up of z-axis fiber and y-axis fibers are automatically transported into a z-fiber deposition machine having a housing with upper and lower surfaces. Z-axis apertures are formed in the respe
A method of inserting z-axis reinforcing fibers into a multi-layer composite laminate. Layers of material made up of z-axis fiber and y-axis fibers are automatically transported into a z-fiber deposition machine having a housing with upper and lower surfaces. Z-axis apertures are formed in the respective upper and lower surfaces. An elongated solid rod having a tapered front tip is aligned in close proximity to the aperture in the bottom surface. The rod is first rotated by a motor and then actuated upwardly completely through the thickness of the layer of x-y material by an actuator. A first hollow tube having a z-axis is axially aligned with the aperture in the top surface and a fiber bundle is threaded downwardly through a first hollow tube to a position adjacent its bottom end. The z-fiber deposition machine has structure to feed a predetermined length of the fiber bundle downwardly through the first hollow tube so that it follows the pathway in the x-y material formed by the rod which is now withdrawn downwardly through the aperture in the bottom wall. The z-axis fiber is thus deposited into the x-y material. The top end of the z-axis fiber is then severed and the x-y material is then advanced a predetermined distance to complete the cycle and is, thus, set to be repeated.
대표청구항
▼
What is claimed is: 1. An apparatus for inserting a reinforcing fiber into a composite laminate material for reinforcement of the composite laminate material, comprising: a housing having spaced guide members defining a feed path for a composite laminate material through the apparatus, the laminate
What is claimed is: 1. An apparatus for inserting a reinforcing fiber into a composite laminate material for reinforcement of the composite laminate material, comprising: a housing having spaced guide members defining a feed path for a composite laminate material through the apparatus, the laminate material having opposite first and second surfaces, the guide members configured to contain the laminate material as it is conveyed along the feed path; an elongated pathway deposition device configured to form a pathway through the laminate material in the feed path, the pathway deposition device being oriented in a first direction along a fiber insertion axis extending at an angle to the feed path towards the first surface of a laminate material in the feed path, the deposition device having a front tip, a body portion, and a rear end and being moveable relative to the guide members between a first position in which the front tip is spaced from the first surface of the laminate material and a second position in which the pathway deposition device extends across the feed path and through the composite laminate material in the feed path to form a pathway; an elongated fiber insertion element oriented in a second direction opposite to the first direction along the fiber insertion axis towards the second surface of the laminate material, the fiber insertion element having a front end facing the second surface of the laminate material contained in the feed path and a rear end; the fiber insertion element being moveable relative to the guide members between a first fiber insertion position spaced from the second surface of the laminate material in the feed path and a second fiber insertion position extending across the feed path and through a pathway formed by the pathway deposition device in the laminate material contained in the feed path; a fiber bundle feed mechanism configured to supply a length of fiber bundle to the fiber insertion element in one of the fiber insertion positions; a first drive mechanism configured to drive one of the pathway deposition device and the guide members whereby the pathway deposition device is moved between the first and second positions; a second drive mechanism configured to drive one of the fiber insertion element and the guide members, whereby the fiber insertion element is moved between the first fiber insertion position and the second fiber insertion position; and a release mechanism configured to release the fiber bundle from the fiber insertion element in the second fiber insertion position, whereby the fiber insertion element can be withdrawn from the laminate material while the length of reinforcing bundle remains in the laminate material. 2. The apparatus of claim 1, further comprising a cutting device for severing the length of the fiber bundle fed to the fiber insertion element from a supply of fiber bundle. 3. The apparatus of claim 2, wherein the cutting device is configured to sever the length of fiber bundle from the supply after insertion of the length of fiber bundle into the laminate material. 4. The apparatus of claim 3, wherein the cutting device is mounted on one of the guide members on one side of the guide path for location adjacent the second surface of a laminate material in the guide path, and is configured to move in a direction parallel to the guide path and across the fiber insertion axis to cut the fiber bundle. 5. The apparatus of claim 1, wherein the guide members comprise spaced, parallel first and second plates, the first plate having a first aperture aligned with the fiber insertion axis and the second plate having a second aperture aligned with the first aperture along the fiber insertion axis. 6. The apparatus of claim 5, wherein the first and second plates are at a predetermined spacing configured to guide and constrain a composite laminate material of predetermined thickness along the guide path. 7. The apparatus of claim 1, further comprising a third drive mechanism configured to rotate the pathway deposition device as it moves from the first position to the second position through the composite laminate material in the guide path. 8. The apparatus of claim 1, further comprising a step drive mechanism configured to drive the laminate material along the guide path in steps equal to a predetermined inserted fiber spacing, and to pause between successive steps, whereby a length of reinforcing fiber bundle is deposited through the laminate material in the pause between each step of the step drive mechanism. 9. The apparatus of claim 8, further comprising a synchronizing mechanism for synchronizing stepping of the step drive mechanism with operation of the first and second drive mechanisms, whereby lengths of reinforcing fiber bundle are successively deposited at spaced positions through the laminate material during successive pauses in operation of the step drive mechanism. 10. The apparatus of claim 1, further comprising a step drive mechanism configured to drive the pathway deposition device and the fiber insertion element relative to the guide path between spaced positions on the laminate material in the guide path, the step drive mechanism further configured to pause between successive spaced positions, the first and second drive mechanisms being configured to place a length of reinforcing fiber bundle through the laminate material at each spaced position during each pause in operation of the step drive mechanism. 11. The apparatus of claim 1, further comprising a pultrusion die configured to cure the composite material after placement of reinforcing fiber bundles through the material. 12. The apparatus of claim 1, wherein the composite material has x-axis and y-axis fibers and the fiber insertion axis is a z-axis perpendicular to the x and y fiber axes. 13. The apparatus of claim 1, further comprising a dampening spring acting on the rear end of the pathway deposition device. 14. The apparatus of claim 1, wherein the guide path has a predetermined thickness configured to guide and constrain a composite laminate material having at least a single layer of x-axis fibers and y-axis fibers. 15. The apparatus of claim 14, wherein the guide path has a predetermined thickness configured to guide and constrain a composite laminate material having multiple layers of x-axis fibers and y-axis fibers in each layer. 16. The apparatus of claim 15, wherein the guide path has a predetermined thickness configured to guide and constrain a composite laminate material having multiple layers made up of x-axis fibers and y-axis fibers in each layer with core layers between at least some of the x-y fiber layers. 17. The apparatus of claim 1, further comprising a supply of z-axis fiber bundle, the fiber bundle feed mechanism being configured to feed the z-axis fiber bundle from the supply to the fiber insertion element, and a cutting device for cutting the z-axis fiber bundle at a predetermined position spaced from the forward end corresponding to a desired length of z-axis fiber bundle to be inserted through the composite laminate material in the guide path. 18. The apparatus of claim 1, wherein the fiber bundle feed mechanism is configured to supply fiber bundle to the fiber insertion element in the first fiber insertion position, and the release mechanism comprises a first fiber clamp configured to releasably clamp a forward end of the fiber bundle to the fiber insertion element as the fiber insertion element is moved from the first fiber insertion position to the second fiber insertion position, the fiber clamp being configured to release the forward end of the fiber bundle when the fiber insertion element is moved back from the second fiber insertion position to the first fiber insertion position. 19. The apparatus of claim 18, further comprising a second fiber clamp configured to clamp the fiber bundle in a stationary position as the fiber insertion element moves back from the second fiber insertion position to the first fiber insertion position, whereby the length of fiber bundle deposited in the composite laminate material remains in position as the fiber insertion element is withdrawn. 20. The apparatus of claim 19, further comprising a cutting device configured for cutting the fiber bundle adjacent the second surface of the composite material, and a cutting device actuator configured to actuate the cutting device when the fiber insertion element has been moved from the second fiber insertion position to the first fiber insertion position. 21. The apparatus of claim 1, wherein the fiber bundle feed mechanism is configured to supply fiber bundle to the fiber insertion element in the second fiber insertion position prior to withdrawal of the fiber insertion element from the composite laminate material. 22. The apparatus of claim 1, wherein at least one of the drive mechanisms is configured to move at least one of the pathway deposition device and the fiber insertion element after the pathway deposition device has been inserted through the laminate material such that the front end of the fiber insertion element meets the tip of the pathway deposition device, and the first and second drive mechanisms are configured to operate in synchronism after the front end of the fiber insertion element meets the tip of the pathway deposition device such that the pathway deposition device and fiber insertion device are moved together through the thickness of the composite laminate material prior to separation of the front end of the fiber bundle from the fiber insertion element.
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