Methods for additively manufacturing composite parts
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IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B29C-067/00
B33Y-070/00
B29C-069/00
B29C-070/28
B05D-001/26
B05D-001/34
B05D-003/06
B05D-003/12
B29C-035/16
B29C-070/16
B29C-070/38
B29C-070/54
C09D-005/00
B29B-011/00
B29B-011/16
C09D-201/00
B29C-047/00
B29C-064/106
B29K-105/00
B33Y-010/00
B29L-031/30
B29L-031/00
B33Y-030/00
B33Y-040/00
B29K-063/00
B29K-105/08
B29K-105/10
B33Y-050/02
B29K-101/10
B29K-105/12
B29C-035/08
B29K-105/06
B29C-064/135
B29C-064/129
B29C-064/25
출원번호
US-0063443
(2016-03-07)
등록번호
US-10183479
(2019-01-22)
발명자
/ 주소
Evans, Nick S.
Torres, Faraón
Ziegler, Ryan G.
Harrison, Samuel F.
Grijalva, III, Ciro J.
Osborn, Hayden S.
출원인 / 주소
The Boeing Company
대리인 / 주소
Dascenzo Intellectual Property Law, P.C.
인용정보
피인용 횟수 :
0인용 특허 :
20
초록▼
A method of additively manufacturing a composite part comprises applying a first quantity of a first part of a thermosetting resin to a first element of a non-resin component by pulling the first element through a first resin-part applicator and applying a second quantity of a second part of the the
A method of additively manufacturing a composite part comprises applying a first quantity of a first part of a thermosetting resin to a first element of a non-resin component by pulling the first element through a first resin-part applicator and applying a second quantity of a second part of the thermosetting resin to a second element of the non-resin component by pulling the second element through a second resin-part applicator. The method also comprises combining the first element with the first quantity of first part and the second element with the second quantity of second part, to create a continuous flexible line. The method additionally comprises routing the continuous flexible line into a delivery guide and depositing, via the delivery guide, a segment of the continuous flexible line along a print path.
대표청구항▼
1. A method of additively manufacturing a composite part, the method comprising: applying a first quantity of a first part of a thermosetting resin to a first element of a non-resin component by pulling the first element of the non-resin component through a first resin-part applicator;applying a sec
1. A method of additively manufacturing a composite part, the method comprising: applying a first quantity of a first part of a thermosetting resin to a first element of a non-resin component by pulling the first element of the non-resin component through a first resin-part applicator;applying a second quantity of a second part of the thermosetting resin to a second element of the non-resin component by pulling the second element of the non-resin component through a second resin-part applicator;combining: the first element of the non-resin component with the first quantity of the first part of the thermosetting resin, applied to the first element of the non-resin component; andthe second element of the non-resin component with the second quantity of the second part of the thermosetting resin, applied to the second element of the non-resin component, to create a continuous flexible line comprising the non-resin component and a thermosetting-resin component that comprises at least some of the first quantity of the first part of the thermosetting resin and at least some of the second quantity of the second part of the thermosetting resin;routing the continuous flexible line into a delivery guide using a feed mechanism, wherein the feed mechanism comprises opposing rollers and a scraper in contact with at least one of the opposing rollers; anddepositing, via the delivery guide, a segment of the continuous flexible line along a print path;removing, using the scraper, residue of the thermosetting-resin component, produced by the engagement between the opposing rollers and the continuous flexible line as the opposing rollers rotate to translate the continuous flexible line to push the continuous flexible line through the delivery guide; andcollecting, into a collection reservoir, the residue of the thermosetting-resin component, removed by the scraper. 2. The method according to claim 1, wherein: the delivery guide comprises a guide line passage through which the continuous flexible line is delivered to the print path;the guide line passage of the delivery guide has an inlet;the feed mechanism is configured to push the continuous flexible line through the guide line passage;the opposing rollers have respective rotational axes;the delivery guide further comprises a first end portion, a second end portion, and a junction between the first end portion and the second end portion;the first end portion is shaped to be complementary to one of the opposing rollers and the second end portion is shaped to be complementary to another of the opposing rollers; anda shortest distance (D) between the junction and a plane, containing the respective rotational axes of the opposing rollers, is less than a radius of a smallest one of the opposing rollers. 3. The method according to claim 2, wherein the junction comprises an edge. 4. The method according to claim 1, wherein pulling the first element of the non-resin component through the first resin-part applicator comprises pulling the first element of the non-resin component through a first volume of the first part of the thermosetting resin to apply the first quantity of the first part of the thermosetting resin to the first element of the non-resin component. 5. The method according to claim 4, wherein pulling the second element of the non-resin component through the second resin-part applicator comprises pulling the second element of the non-resin component through a second volume of the second part of the thermosetting resin to apply the second quantity of the second part of the thermosetting resin to the second element of the non-resin component. 6. The method according to claim 1, wherein applying the first quantity of the first part of the thermosetting resin to the first element of the non-resin component comprises dripping or spraying, by the first resin-part applicator, the first quantity of the first part of the thermosetting resin onto the first element of the non-resin component. 7. The method according to claim 6, wherein applying the second quantity of the second part of the thermosetting resin to the second element of the non-resin component comprises dripping or spraying, by the second resin-part applicator, the second quantity of the second part of the thermosetting resin onto the second element of the non-resin component. 8. The method according to claim 1, further comprising separating a tow into the first element of the non-resin component and the second element of the non-resin component upstream of the first resin-part applicator and the second resin-part applicator. 9. The method according to claim 1, further comprising while advancing the continuous flexible line toward the print path, delivering a predetermined or actively determined amount of curing energy at least to a portion of the segment of the continuous flexible line at a controlled rate after the segment of the continuous flexible line is deposited along the print path to at least partially cure at least the portion of the segment of the continuous flexible line; wherein delivering the predetermined or actively determined amount of the curing energy at least to the portion of the segment of the continuous flexible line at the controlled rate comprises partially curing a first layer of the segment of the continuous flexible line as the first layer is being deposited and further curing the first layer as a second layer is being deposited against the first layer. 10. The method according to claim 1, further comprising while advancing the continuous flexible line toward the print path, delivering a predetermined or actively determined amount of curing energy at least to a portion of the segment of the continuous flexible line at a controlled rate after the segment of the continuous flexible line is deposited along the print path to at least partially cure at least the portion of the segment of the continuous flexible line; wherein delivering the predetermined or actively determined amount of the curing energy at least to the portion of the segment of the continuous flexible line at the controlled rate comprises curing less than an entirety of the composite part. 11. The method according to claim 1, further comprising while advancing the continuous flexible line toward the print path, delivering a predetermined or actively determined amount of curing energy at least to a portion of the segment of the continuous flexible line at a controlled rate after the segment of the continuous flexible line is deposited along the print path to at least partially cure at least the portion of the segment of the continuous flexible line; wherein delivering the predetermined or actively determined amount of the curing energy at least to the portion of the segment of the continuous flexible line at the controlled rate comprises selectively varying at least one of a delivery rate or a delivery duration of the curing energy to impart varying physical characteristics to the composite part. 12. The method according to claim 1, further comprising maintaining the thermosetting resin below a threshold temperature at least prior to applying the thermosetting resin to the non-resin component. 13. The method according to claim 12, wherein the threshold temperature is no greater than 20° C. 14. The method according to claim 1, further comprising maintaining the thermosetting-resin component below a threshold temperature prior to depositing the segment of the continuous flexible line along the print path. 15. The method according to claim 1, wherein depositing the segment of the continuous flexible line along the print path comprises layering the continuous flexible line against itself to additively manufacture the composite part. 16. The method according to claim 1, wherein depositing the segment of the continuous flexible line along the print path comprises depositing the continuous flexible line in a predetermined pattern to selectively control one or more physical characteristics of the composite part. 17. The method according to claim 16, wherein the physical characteristics comprise at least one of strength, stiffness, flexibility, ductility, or hardness. 18. The method according to claim 1, further comprising, simultaneously with depositing the segment of the continuous flexible line along the print path, compacting at least a section of the segment of the continuous flexible line after the segment of the continuous flexible line is deposited along the print path. 19. The method according to claim 18, wherein compacting at least the section of the segment of the continuous flexible line after the segment of the continuous flexible line is deposited along the print path comprises heating the section of the segment of the continuous flexible line to at least partially cure at least the section of the segment of the continuous flexible line. 20. The method according to claim 18, wherein compacting at least the section of the segment of the continuous flexible line after the segment of the continuous flexible line is deposited along the print path comprises imparting a desired cross-sectional shape to the segment of the continuous flexible line. 21. The method according to claim 1, further comprising, simultaneously with depositing the segment of the continuous flexible line along the print path, roughening at least a section of the segment of the continuous flexible line after the segment of the continuous flexible line is deposited along the print path. 22. The method according to claim 21, further comprising, simultaneously with roughening at least the section of the segment of the continuous flexible line, collecting debris resulting from roughening at least the section of the segment of the continuous flexible line. 23. The method according to claim 21, further comprising, simultaneously with roughening at least the section of the segment of the continuous flexible line, dispersing debris resulting from roughening at least the section of the segment of the continuous flexible line. 24. The method according to claim 21, wherein roughening at least the section of the segment of the continuous flexible line after the segment of the continuous flexible line is deposited along the print path comprises heating the section of the segment of the continuous flexible line to at least partially cure at least the section of the segment of the continuous flexible line. 25. The method according to claim 1, further comprising selectively cutting the continuous flexible line, wherein the continuous flexible line is selectively cut simultaneously with depositing the segment of the continuous flexible line along the print path. 26. The method according to claim 1, wherein: the continuous flexible line is a first continuous flexible line;the segment of the continuous flexible line is a first segment of the first continuous flexible line;the method further comprises depositing a second segment of a second continuous flexible line along the print path; andthe second continuous flexible line comprises at least one component that differs from at least one component of the first continuous flexible line. 27. The method according to claim 1, wherein depositing the segment of the continuous flexible line along the print path comprises pushing the continuous flexible line through a delivery guide. 28. The method according to claim 1, further comprising texturing the continuous flexible line as the continuous flexible line is being deposited. 29. The method according to claim 1, wherein: at least one of the opposing rollers comprises a circumferential channel that contacts the continuous flexible line, andthe scraper comprises a projection that removes from the circumferential channel the residue of the thermosetting-epoxy-resin component, produced by the engagement between the circumferential channel and the continuous flexible line as the opposing rollers rotate to translate the continuous flexible line to push the continuous flexible line through the delivery guide. 30. The method according to claim 1, further comprising, simultaneously with depositing the segment of the continuous flexible line along the print path, detecting defects in the composite part. 31. The method according to claim 1, wherein: depositing the segment of the continuous flexible line along the print path comprises depositing at least a portion of the segment of the continuous flexible line over one or more sacrificial layers; andthe method further comprises removing the one or more sacrificial layers to form the composite part. 32. The method according to claim 1, further comprising curing the composite part in an autoclave or in an oven. 33. The method according to claim 1, wherein depositing the segment of the continuous flexible line along the print path is performed within a chamber that is one of positively pressurized or negatively pressurized relative to atmospheric pressure. 34. The method according to claim 1, wherein: depositing the segment of the continuous flexible line along the print path comprises initially depositing the segment of the continuous flexible line against a surface; andthe method further comprises heating the surface. 35. The method according to 1, wherein depositing the segment of the continuous flexible line along the print path comprises initially depositing the segment of the continuous flexible line against a surface; andthe method further comprises applying a vacuum to the surface. 36. A method of additively manufacturing a composite part, the method comprising: applying a first quantity of a first part of a thermosetting resin to a first element of a non-resin component by pulling the first element of the non-resin component through a first resin-part applicator;applying a second quantity of a second part of the thermosetting resin to a second element of the non-resin component by pulling the second element of the non-resin component through a second resin-part applicator;combining: the first element of the non-resin component with the first quantity of the first part of the thermosetting resin, applied to the first element of the non-resin component; andthe second element of the non-resin component with the second quantity of the second part of the thermosetting resin, applied to the second element of the non-resin component, to create a continuous flexible line, comprising the non-resin component and a thermosetting-resin component that comprises at least some of the first quantity of the first part of the thermosetting resin and at least some of the second quantity of the second part of the thermosetting resin;routing the continuous flexible line into a delivery guide;depositing, via the delivery guide, a segment of the continuous flexible line along a print path; andwhile advancing the continuous flexible line toward the print path, delivering a ring of curing energy that intersects at least a portion of the segment of the continuous flexible line to at least partially cure at least the portion of the segment of the continuous flexible line, wherein the ring of the curing energy is delivered by at least one galvanometer mirror-positioning system. 37. The method according to claim 36, wherein delivering the ring of curing energy comprises partially curing a first layer of the segment of the continuous flexible line as the first layer is being deposited and further curing the first layer as a second layer is being deposited against the first layer. 38. The method according to claim 36, wherein delivering the ring of curing energy comprises curing less than an entirety of the composite part. 39. The method according to claim 36, further comprising restrictively curing at least a portion of the composite part. 40. The method according to claim 39, wherein the portion of the composite part is restrictively cured to facilitate subsequent processing of the portion. 41. The method according to claim 36, wherein delivering the ring of the curing energy comprises selectively varying at least one of a delivery rate or a delivery duration of the curing energy to impart varying physical characteristics to the composite part, wherein the varying physical characteristics comprise at least one of strength, stiffness, flexibility, ductility, or hardness. 42. The method according to claim 36, further comprising, simultaneously with delivering the ring of the curing energy, at least partially protecting at least the portion of the segment of the continuous flexible line from environmental exposure after the segment exits the delivery guide. 43. The method according to claim 42, wherein at least the portion of the segment of the continuous flexible line is at least partially protected from the environmental exposure with a shielding gas. 44. The method according to claim 36, wherein: at least one of depositing the segment of the continuous flexible line along the print path or delivering the ring of the curing energy provides different physical characteristics at different locations of the composite part; andthe physical characteristics comprise at least one of strength, stiffness, flexibility, ductility, or hardness.
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