3D thermoplastic composite pultrusion system and method
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B29C-070/52
B29C-051/20
B29C-051/26
B29C-051/46
G05B-019/4099
B29C-051/14
B29C-051/42
E04B-001/32
B29C-043/48
B29C-047/88
B29C-043/22
B29C-033/02
B29C-059/04
B29C-053/04
B29K-101/12
B29L-031/08
출원번호
US-0864544
(2015-09-24)
등록번호
US-9616623
(2017-04-11)
발명자
/ 주소
Johnson, David W.
Garrett, Scott A.
Moyers, Stephen G.
출원인 / 주소
Ebert Composites Corporation
대리인 / 주소
Procopio Cory Hargreaves and Savitch LLP
인용정보
피인용 횟수 :
3인용 특허 :
19
초록▼
A 3D thermoplastic pultrusion system and method based upon a 3D variable die system and including one or more sets of 3D thermoplastic forming machines to continuously produce thermoplastic composite pultrusions with at least one of varying cross-section geometry and constant surface contours, varyi
A 3D thermoplastic pultrusion system and method based upon a 3D variable die system and including one or more sets of 3D thermoplastic forming machines to continuously produce thermoplastic composite pultrusions with at least one of varying cross-section geometry and constant surface contours, varying cross-section geometry and varying surface contours, and constant cross-section geometry and varying surface contours.
대표청구항▼
1. A method of creating a 3D thermoplastic composite pultrusion with a 3D thermoplastic pultrusion system including a pultrusion die, a pultrusion gripper mechanism, and one or more sets of 3D thermoplastic forming machines including one or more pairs of shapeable and flexible actively chilled bands
1. A method of creating a 3D thermoplastic composite pultrusion with a 3D thermoplastic pultrusion system including a pultrusion die, a pultrusion gripper mechanism, and one or more sets of 3D thermoplastic forming machines including one or more pairs of shapeable and flexible actively chilled bands, each pair of flexible chilled bands being capable of applying pressure at a specific thickness to a fiber thermoplastic composite material pultrusion from opposite sides, comprising the following for a given cross-section of the fiber thermoplastic composite material: incrementally advancing a fiber thermoplastic composite material into the pultrusion die in a no compression condition using the pultrusion gripper mechanism, followed by incrementally consolidating and heating the fiber thermoplastic composite material by compressing and heating the fiber thermoplastic composite material with the thermoplastic pultrusion die in a compression condition and at a zero line speed,followed by first releasing the thermoplastic pultrusion die and incrementally advancing the heated and consolidated fiber thermoplastic composite material an incremental distance, with the thermoplastic pultrusion die system in a no compression condition using the pultrusion gripper mechanism,followed by simultaneous forming and chilling the pultruded heated fiber thermoplastic composite material into a 3D thermoplastic composite pultrusion having varying surface contours in both a pultrusion direction and 90 degrees to the pultrusion direction by simultaneously chilling the pultruded heated fiber thermoplastic composite material and applying pressure with the one or more pairs of flexible actively chilled bands, programmed to be displaced in a manner such that the composite is chilled at a specific thickness assuring chilling at sufficient pressure with the one or more sets of 3D thermoplastic forming machines at a zero line speed,followed by opening the one or more sets of 3D thermoplastic forming machines and advancing the 3D thermoplastic composite pultrusion an incremental distance using the pultrusion gripper mechanism. 2. The method of creating a 3D thermoplastic composite pultrusion of claim 1, wherein the 3D thermoplastic forming machines do not include molds. 3. The method of creating a 3D thermoplastic composite pultrusion of claim 1, wherein the one or more sets of 3D thermoplastic forming machines include a plurality of CNC actuators connected to the one or more pairs of flexible actively chilled bands, and the method further including shaping the one or more pairs of flexible actively chilled bands by the CNC actuators to form the fiber thermoplastic composite material into the 3D thermoplastic composite pultrusion. 4. The method of creating a 3D thermoplastic composite pultrusion of claim 3, wherein the CNC actuators include at least two degrees of motion, an axial degree of motion and a non-axial degree of motion, and shaping the one or more pairs of flexible actively chilled bands by the CNC actuators includes moving the CNC actuators in at least two degrees of motion, an axial degree of motion and a non-axial degree of motion, to shape the one or more pairs of flexible actively chilled bands. 5. The method of creating a 3D thermoplastic composite pultrusion of claim 3, wherein the CNC actuators include three degrees of motion, an axial degree of motion and two non-axial degrees of motion, and shaping the one or more pairs of flexible actively chilled bands by the CNC actuators includes moving the CNC actuators in three degrees of motion, an axial degree of motion and two non-axial degrees of motion, to shape the one or more pairs of flexible actively chilled bands. 6. The method of creating a 3D thermoplastic composite pultrusion of claim 3, further including swivel joints connecting the plurality of CNC actuators to the one or more pairs of flexible actively chilled bands, the swivels joints enabling pivoting movement of the one or more flexible actively chilled bands relative to the CNC actuators and enabling the CNC actuators to push, pull, rotate, and move the one or more pairs of flexible actively chilled bands, and shaping the one or more pairs of flexible actively chilled bands by the CNC actuators includes pivoting the one or more pairs of flexible actively chilled bands relative to the CNC actuators and enabling the CNC actuators to push, pull, rotate, and move the one or more pairs of flexible actively chilled bands using the swivel joints to shape the one or more pairs of flexible actively chilled bands. 7. The method of creating a 3D thermoplastic composite pultrusion of claim 3, further including actuator bearings, and the CNC actuators rotatable about the actuator bearings, and shaping the one or more pairs of flexible actively chilled bands by the CNC actuators includes rotating the CNC actuators about the actuator bearings to shape the one or more pairs of flexible actively chilled bands. 8. The method of creating a 3D thermoplastic composite pultrusion of claim 1, wherein the pultrusion gripper mechanism is capable of CNC movement and gripping the chilled thermoplastic composite having various changing shapes in the pultrusion direction, and the method further comprising gripping the chilled thermoplastic composite having various changing shapes in the pultrusion direction with the pultrusion gripper mechanism. 9. The method of creating a 3D thermoplastic composite pultrusion of claim 1, wherein the pultruded heated fiber thermoplastic composite material includes a fiber composite material including a first sandwich skin, a second sandwich skin, an interior core, and distinct groups of 3D Z-axis fibers that extend from the first sandwich skin to the second sandwich skin, linking the sandwich skins together. 10. The method of creating a 3D thermoplastic composite pultrusion of claim 3, wherein the 3D thermoplastic forming machines include thrusting and retracting plates attached to the actuators. 11. The method of creating a 3D thermoplastic composite pultrusion of claim 1, wherein the 3D thermoplastic composite pultrusion is a member from the group consisting of aerospace composites, automotive composites, doors, hoods, aircraft body panels, luggage compartments, airplane interior sections, aerodynamic surfaces, piping, and duct-work. 12. The method of creating a 3D thermoplastic composite pultrusion of claim 1, wherein the one or more pairs of flexible actively chilled bands are actively chilled by one of fluid cooling and air flow cooling. 13. The method of creating a 3D thermoplastic composite pultrusion of claim 1, further comprising performing the recited steps on different sections of a continuous pultrusion of the fiber thermoplastic composite material such that continuous operation is coordinated. 14. A method of creating a 3D thermoplastic composite pultrusion with a 3D thermoplastic pultrusion system including a pultrusion die, a material advancement mechanism, and one or more sets of 3D thermoplastic forming machines including one or more pairs of shapeable and flexible actively chilled bands and a plurality of CNC actuators connected to the one or more pairs of more flexible actively chilled bands shapeable by the CNC actuators to form a fiber thermoplastic composite material into the 3D thermoplastic composite pultrusion, each pair of flexible actively chilled bands being capable of applying pressure at a specific thickness to the fiber thermoplastic composite material pultrusion from opposite sides, the CNC actuators including at least two degrees of motion, an axial degree of motion and a non-axial degree of motion, comprising the following for a given cross-section of the fiber thermoplastic composite material: incrementally advancing the fiber thermoplastic composite material into a heated pultrusion die in a no compression condition using the material advancement mechanism;followed by incrementally consolidating and heating the fiber thermoplastic composite material by compressing and heating the fiber thermoplastic composite material with the thermoplastic pultrusion die in a compression condition and at a zero line speed;followed by first releasing the thermoplastic pultrusion die and incrementally advancing the heated and consolidated fiber thermoplastic composite material an incremental distance, with the thermoplastic pultrusion die in a no compression condition using the material advancement mechanism;followed by simultaneous forming and chilling the pultruded heated fiber thermoplastic composite material into a 3D thermoplastic composite pultrusion having varying surface contours in both a pultrusion direction and 90 degrees to the pultrusion direction with the plurality of CNC actuators moving in at least two degrees of motion, an axial degree of motion and a non-axial degree of motion, to control the one or more pairs of flexible actively chilled bands of the one or more sets of 3D thermoplastic forming machines at a zero line speed,followed by opening the one or more sets of 3D thermoplastic forming machines and advancing the 3D thermoplastic composite pultrusion an incremental distance using the material advancement mechanism. 15. The method of creating a 3D thermoplastic composite pultrusion of claim 14, wherein the CNC actuators include three degrees of motion, an axial degree of motion and two non-axial degrees of motion, and shaping the one or more pairs of flexible actively chilled bands by the CNC actuators includes moving the CNC actuators in three degrees of motion, an axial degree of motion and two non-axial degrees of motion, to shape the one or more pairs of flexible actively chilled bands. 16. The method of creating a 3D thermoplastic composite pultrusion of claim 14, further including swivel joints connecting the plurality of CNC actuators to the one or more pairs of flexible actively chilled bands, the swivels joints enabling pivoting movement of the one or more pairs of flexible actively chilled bands relative to the CNC actuators and enabling the CNC actuators to push, pull, rotate, and move the one or more pairs of flexible actively chilled bands, and shaping the one or more pairs of flexible actively chilled bands by the CNC actuators includes pivoting the one or more pairs of flexible actively chilled bands relative to the CNC actuators and enabling the CNC actuators to push, pull, rotate, and move the one or more pairs of flexible actively chilled bands using the swivel joints to shape the one or more pairs of flexible actively chilled bands. 17. The method of creating a 3D thermoplastic composite pultrusion of claim 14, further including actuator bearings, and the CNC actuators rotatable about the actuator bearings, and shaping the one or more pairs of flexible actively chilled bands by the CNC actuators includes rotating the CNC actuators about the actuator bearings to shape the one or more pairs of flexible actively chilled bands. 18. The method of creating a 3D thermoplastic composite pultrusion of claim 14, further comprising performing the recited steps on different sections of a continuous pultrusion of the fiber thermoplastic composite material such that continuous operation is coordinated.
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이 특허에 인용된 특허 (19)
Jacobson Theodore L. (605 Forest Lake Pacifica CA 94044), Apparatus for continuous forming of complex molded shapes.
Benoit Jol M. D. (Cesson La Foret FRX) Dambrine Bruno J. G. (Chartrettes FRX) David Laurent J. P. (Limours FRX) Fouche Patrick (Viry-Chatillon FRX) Girault Daniel G. (Melun FRX) Grosbois Christophe G, Gas turbine blade comprising layers of composite material.
Lambing Cynthia L. T. (Apollo PA) Barbus John J. (Monroeville PA) Miller Donald C. (Ford City PA), Method for pultruding fiber-reinforced thermoplastic stock.
Johnson, David W.; Hook, James M.; Garrett, Scott A.; Moyers, Steven G., Method of clinching the top and bottom ends of Z-axis fibers into the respective top and bottom surfaces of a composite laminate.
Wang Weiping ; Evans Charles Richard ; Bachrach William Elliot ; Muldoon John Michael ; Crogan Albert Benjamen ; Tyler Robert Paul, Selectively flexible caul and method of use.
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