Systems for additively manufacturing composite parts
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B29C-064/20
B29C-064/165
B29C-070/38
B29C-070/52
B29B-015/12
B29C-064/106
B29C-064/386
B33Y-030/00
출원번호
US-0841470
(2015-08-31)
등록번호
US-10232550
(2019-03-19)
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 system for additively manufacturing a composite part comprises a delivery assembly, a feed mechanism, and a source of curing energy. The delivery assembly comprises a delivery guide movable relative to a surface and is configured to deposit a continuous flexible line along a print path. The delive
A system for additively manufacturing a composite part comprises a delivery assembly, a feed mechanism, and a source of curing energy. The delivery assembly comprises a delivery guide movable relative to a surface and is configured to deposit a continuous flexible line along a print path. The delivery assembly further comprises a first inlet, configured to receive a non-resin component, and a second inlet, configured to receive a photopolymer resin. The delivery assembly applies the photopolymer resin to the non-resin component. The feed mechanism pushes the continuous flexible line out of the delivery guide. The source of the curing energy delivers the curing energy to a portion of the continuous flexible line after it exits the delivery guide.
대표청구항▼
1. A system for additively manufacturing a composite part, the system comprising: a delivery assembly, wherein: the delivery assembly comprises a delivery guide, movable relative to a surface and configured to deposit at least a segment of a continuous flexible line along a print path,the print path
1. A system for additively manufacturing a composite part, the system comprising: a delivery assembly, wherein: the delivery assembly comprises a delivery guide, movable relative to a surface and configured to deposit at least a segment of a continuous flexible line along a print path,the print path is stationary relative to the surface,the delivery assembly further comprises a first inlet, configured to receive a non-resin component, and a second inlet, configured to receive a photopolymer resin, andthe delivery assembly is configured to apply the photopolymer resin to the non-resin component;a feed mechanism, configured to push the continuous flexible line, comprising the non-resin component and further comprising a photopolymer-resin component that comprises at least some of the photopolymer resin applied to the non-resin component by the delivery assembly, out of the delivery guide, and wherein the feed mechanism comprises: opposing rollers, configured to engage opposite sides of the continuous flexible line and configured to selectively rotate to push the continuous flexible line through the delivery guide;a scraper in contact with at least one of the opposing rollers to remove residue of the photopolymer-resin component, produced when the opposing rollers engage the continuous flexible line as the opposing rollers rotate to selectively translate the continuous flexible line to push the continuous flexible line through the delivery guide; anda collection reservoir, configured to collect the residue of the photopolymer-resin component, removed by the scraper; anda source of a curing energy, wherein the source is configured to deliver the curing energy at least to a portion of the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide. 2. The system according to claim 1, wherein: the delivery assembly further comprises an upstream portion;the delivery guide and the upstream portion are located on opposite sides of the feed mechanism;the feed mechanism is configured to push the continuous flexible line through the delivery guide and to pull the continuous flexible line through the upstream portion of the delivery assembly;the upstream portion of the delivery assembly comprises the second inlet, an upstream outlet, through which the continuous flexible line exits the upstream portion, and an upstream line passage, extending from the first inlet to the upstream outlet; andthe second inlet of the upstream portion of the delivery assembly is in fluid communication with the upstream line passage. 3. The system according to claim 2, further comprising a resin-metering system, configured to actively control a flow of the photopolymer resin to the second inlet of the upstream portion, wherein the resin-metering system comprises at least one sensor configured to detect a level of the photopolymer resin in the upstream line passage. 4. The system according to claim 3, wherein: the at least one sensor comprises a high-level sensor positioned upstream from the second inlet of the upstream portion and configured to detect when the level of the photopolymer resin is at or above an upper threshold level in the upstream line passage; andthe resin-metering system is configured to reduce the flow of the photopolymer resin responsive to the photopolymer resin being at or above the upper threshold level in the upstream line passage. 5. The system according to claim 3, wherein: the at least one sensor comprises a low-level sensor, configured to detect when the level of the photopolymer resin is at or below a lower threshold level in the upstream line passage; andthe resin-metering system is configured to increase the flow of the photopolymer resin responsive to the photopolymer resin being at or below the lower threshold level in the upstream line passage. 6. The system according to claim 3, wherein the at least one sensor comprises a saturation sensor, positioned to detect a level of saturation of the non-resin component with the photopolymer resin prior to exiting the delivery guide. 7. The system according to claim 3, wherein the resin-metering system further comprises a pump, configured to selectively increase and decrease the flow of the photopolymer resin responsive to input from the at least one sensor. 8. The system according to claim 1, wherein the source of the curing energy is operatively coupled to the delivery assembly and is configured to move with the delivery guide. 9. The system according to claim 1, wherein the source of the curing energy is configured to partially cure a first layer of the segment of the continuous flexible line as at least a portion of the first layer is being deposited by the delivery guide against the surface and to further cure the first layer and to partially cure a second layer as the second layer is being deposited by the delivery guide against the first layer. 10. The system according to claim 1, wherein: the delivery guide comprises a guide inlet, a guide outlet, through which the continuous flexible line exits the delivery guide, and a guide line passage, extending from the guide inlet to the guide outlet,the feed mechanism is configured to push the continuous flexible line through the guide line passage;the feed mechanism comprises a support frame;the opposing rollers have respective rotational axes; andthe opposing rollers are rotatably coupled to the support frame. 11. The system according to claim 1, further comprising a compactor, operatively coupled to the delivery assembly and configured to impart a compaction force at least to a section of the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide. 12. The system according to claim 1, further comprising a surface roughener, operatively coupled to the delivery assembly and configured to abrade at least a section of the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide. 13. The system 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 and the guide line passage comprises a guide outlet, the system further comprising a cutter, configured to selectively cut the continuous flexible line adjacent to the guide outlet. 14. The system according to claim 1, further comprising a defect detector, configured to detect defects in the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide. 15. The system according to claim 4, further comprising an overflow reservoir, positioned to collect the photopolymer resin that flows from the second inlet of the upstream portion through the upstream line passage and exits the first inlet, wherein the high-level sensor is positioned to detect the level of the photopolymer resin within the overflow reservoir. 16. The system according to claim 10, wherein the opposing rollers are configured to facilitate impregnation of the non-resin component with the photopolymer resin. 17. The system according to claim 10, wherein: 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. 18. The system according to claim 17, wherein the junction comprises an edge. 19. The system according to claim 1, wherein: at least one of the opposing rollers comprises a circumferential channel, configured to contact the continuous flexible line; andthe scraper comprises a projection, configured to remove, from the circumferential channel, the residue of the photopolymer-resin component, produced when the circumferential channel engages the continuous flexible line as the opposing rollers rotate to selectively translate the continuous flexible line to push the continuous flexible line through the guide line passage. 20. The system according to claim 10, wherein: the delivery guide further comprises a curing-energy passage,the source of the curing energy is configured to deliver the curing energy through the curing-energy passage at least to the portion of the segment of the continuous flexible line, andthe curing-energy passage is optically isolated from the guide line passage. 21. The system according to claim 20, wherein the curing-energy passage encircles the guide line passage, such that the curing energy exiting from the curing-energy passage results in a ring of the curing energy, intersecting the segment of the continuous flexible line. 22. The system according to claim 11, wherein: the compactor comprises a compaction roller, having a compaction-roller surface that is configured to roll over at least the section of the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide; andthe compaction-roller surface is textured. 23. The system according to claim 11, wherein: the compactor comprises a compaction roller, having a compaction-roller surface that is configured to roll over at least the section of the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide; andthe compaction-roller surface is shaped to impart a predetermined cross-sectional shape at least to the section of the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide. 24. The system according to claim 11, wherein: the compactor comprises a compaction wiper, having a wiper drag surface that is configured to drag against at least the section of the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide; andthe wiper drag surface is textured. 25. The system according to claim 11, wherein: the compactor comprises a compaction wiper, having a wiper drag surface that is configured to drag against at least the section of the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide; andthe wiper drag surface is shaped to impart a predetermined cross-sectional shape to the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide. 26. The system according to claim 11, wherein the compactor is spring-biased toward the section of the segment of the continuous flexible line. 27. The system according to claim 11, wherein the compactor is rotatable relative to the delivery guide. 28. The system according to claim 11, wherein the compactor is configured to trail the delivery guide when the delivery guide moves relative to the surface. 29. The system according to claim 11, wherein: the compactor comprises a skirt, coupled to the delivery guide, andthe skirt comprises a skirt drag surface that is positioned to drag against at least the section of the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide. 30. The system according to claim 11, further comprising a pivoting arm, coupled relative to the delivery assembly such that the pivoting arm trails the delivery guide as the delivery guide moves relative to the surface, and wherein the compactor is coupled to the pivoting arm. 31. The system according to claim 30, further comprising: a pivoting-arm actuator, operatively coupled to the pivoting arm and configured to actively control a rotational position of the pivoting arm relative to the delivery guide as the delivery guide moves relative to the surface; andwherein the pivoting-arm actuator is configured to actively coordinate the rotational position of the pivoting arm with movement of the delivery guide relative to the surface. 32. The system according to claim 12, further comprising: a pivoting arm, configured such that the pivoting arm trails the delivery guide as the delivery guide moves relative to the surface; anda pivoting-arm actuator, operatively coupled to the pivoting arm and configured to actively control a rotational position of the pivoting arm relative to the delivery guide as the delivery guide moves relative to the surface; andwherein: the pivoting-arm actuator is configured to actively coordinate the rotational position of the pivoting arm with movement of the delivery guide relative to the surface; andthe surface roughener is coupled to the pivoting arm. 33. The system according to claim 32, wherein the surface roughener comprises a roughening roller that is configured to rotationally abrade at least the section of the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide. 34. The system according to claim 32, wherein the surface roughener comprises a roughening drag surface that is configured to translationally abrade at least the section of the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide. 35. The system according to claim 32, wherein the surface roughener is spring-biased toward the section of the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide. 36. The system according to claim 32, further comprising a compactor, and wherein the surface roughener is positioned to abrade at least the section of the segment of the continuous flexible line following compaction of at least the section by the compactor. 37. The system according to claim 32, further comprising: a debris inlet, operatively coupled to the pivoting arm and configured to collect debris, resulting from abrading at least the section of the segment of the continuous flexible line with the surface roughener; anda vacuum source, selectively communicatively coupled with the debris inlet. 38. The system according to claim 32, further comprising: a pressurized-gas outlet, operatively coupled to the pivoting arm and configured to disperse debris, resulting from roughening of the segment of the continuous flexible line by the surface roughener, with a pressurized gas; anda pressurized-gas source, selectively communicatively coupled with the pressurized-gas outlet. 39. The system according to claim 32, wherein the source of the curing energy is configured to deliver the curing energy at least to the portion of the segment of the continuous flexible line prior to the surface roughener abrading the portion. 40. The system according to claim 32, wherein the source of the curing energy is configured to deliver the curing energy at least to the portion of the segment of the continuous flexible line after the surface roughener abrades the portion. 41. The system according to claim 2, further comprising an overflow reservoir, positioned to collect the photopolymer resin that flows from the second inlet of the upstream portion through the upstream line passage and exits the first inlet. 42. The system according to claim 1, wherein: the delivery guide comprises a guide inlet, the second inlet, a guide outlet, through which the continuous flexible line exits the delivery guide, and a guide line passage extending from the guide inlet to the guide outlet, andthe second inlet of the delivery guide is in fluid communication with the guide line passage. 43. The system according to claim 42, further comprising a resin-metering system, configured to actively control a flow of the photopolymer resin to the second inlet of the delivery guide, and wherein the resin-metering system comprises at least one sensor, configured to detect a level of the photopolymer resin in the guide line passage. 44. The system according to claim 43, wherein: the at least one sensor comprises a low-level sensor, configured to detect when the level of the photopolymer resin is at or below a lower threshold level in the guide line passage; andthe resin-metering system is configured to increase the flow of the photopolymer resin responsive to the photopolymer resin being at or below the lower threshold level in the guide line passage. 45. The system according to claim 43, wherein the at least one sensor comprises a saturation sensor, positioned to detect a level of saturation of the non-resin component with the photopolymer resin prior to exiting the delivery guide. 46. The system according to claim 43, wherein the resin-metering system further comprises a pump, configured to selectively increase and decrease the flow of the photopolymer resin responsive to input from the at least one sensor. 47. The system according to claim 1, wherein the source of the curing energy comprises at least one galvanometer mirror-positioning system, configured to deliver a ring of the curing energy at least to the portion of the segment of the continuous flexible line responsive to movement of the delivery guide relative to the surface. 48. A system for additively manufacturing a composite part, the system comprising: a delivery assembly, wherein: the delivery assembly comprises a delivery guide movable relative to a surface and configured to deposit at least a segment of a continuous flexible line along a print path,the print path is stationary relative to the surface,the delivery assembly further comprises a first inlet, configured to receive a non-resin component, and a second inlet, configured to receive a photopolymer resin, andthe delivery assembly is configured to apply the photopolymer resin to the non-resin component;a feed mechanism, configured to push the continuous flexible line, comprising the non-resin component and further comprising a photopolymer-resin component that comprises at least some of the photopolymer resin applied to the non-resin component by the delivery assembly, out of the delivery guide; anda source of a curing energy, wherein the source comprises at least one galvanometer mirror-positioning system, configured to deliver a ring of the curing energy at least to a portion of the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide and responsive to movement of the delivery guide relative to the surface. 49. A system for additively manufacturing a composite part, the system comprising: a delivery assembly, wherein: the delivery assembly comprises a delivery guide movable relative to a surface and configured to deposit at least a segment of a continuous flexible line along a print path,the print path is stationary relative to the surface,the delivery assembly further comprises a first inlet, configured to receive a non-resin component, and a second inlet, configured to receive a photopolymer resin, andthe delivery assembly is configured to apply the photopolymer resin to the non-resin component;a feed mechanism, configured to push the continuous flexible line, comprising the non-resin component and further comprising a photopolymer-resin component that comprises at least some of the photopolymer resin, applied to the non-resin component by the delivery assembly, out of the delivery guide;a source of a curing energy, wherein the source is configured to deliver the curing energy at least to a portion of the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide; anda resin-metering system; andwherein: the delivery assembly further comprises an upstream portion opposite the delivery guide relative to the feed mechanism;the feed mechanism is configured to push the continuous flexible line through the delivery guide and pull the continuous flexible line through the upstream portion;the upstream portion comprises the second inlet, an upstream outlet, through which the continuous flexible line exits the upstream portion, and an upstream line passage, extending from the first inlet to the upstream outlet;the second inlet of the upstream portion is in fluid communication with the upstream line passage;the resin-metering system is configured to actively control a flow of the photopolymer resin to the second inlet of the upstream portion;the resin-metering system comprises at least one sensor, configured to detect a level of the photopolymer resin in the upstream line passage;the at least one sensor comprises a high-level sensor positioned upstream from the second inlet of the upstream portion and configured to detect when the level of the photopolymer resin is at or above an upper threshold level in the upstream line passage; andthe resin-metering system is configured to reduce the flow of the photopolymer resin responsive to the photopolymer resin being at or above the upper threshold level in the upstream line passage.
연구과제 타임라인
LOADING...
LOADING...
LOADING...
LOADING...
LOADING...
이 특허에 인용된 특허 (20)
Spence Stuart T. (South Pasadena CA) Almquist Thomas A. (San Gabriel CA) Tarnoff Harry L. (Van Nuys CA) Juran Warren (Sylmar CA), Apparatus and method for calibrating and normalizing a stereolithographic apparatus.
Secretan Stanley (9211 Elizabeth Lake Rd. Leona Valley CA 93551) Bayless Earl T. (28051 Wildwind Rd. Canyon Country CA 91351), Continuous extruded bead object fabrication apparatus.
Swanson, William J.; Turley, Patrick W.; Leavitt, Paul J.; Karwoski, Peter J.; LaBossiere, Joseph E.; Skubic, Robert L., High temperature modeling apparatus.
Dyksterhouse Robert (Marathon FL) Dyksterhouse Joel A. (Marathon FL) Handermann Alan C. (Matthews NC) Western Edward D. (Fort Mill SC), Improved preimpregnated material comprising a particulate thermosetting resin suitable for use in the formation of a sub.
Mikulak, James K.; Deckard, Carl R., Method for building three-dimensional models in extrusion-based additive manufacturing systems using core-shell semi-crystalline consumable filaments.
Mikulak, James K.; Deckard, Carl R.; Zinniel, Robert L., Method for building three-dimensional objects in extrusion-based additive manufacturing systems using core-shell consumable filaments.
deAngelis Alfredo O. (241 Freeman St. #1 Brookline MA 02146), Method of three-dimensional rapid prototyping through controlled layerwise deposition/extraction and apparatus therefor.
※ AI-Helper는 부적절한 답변을 할 수 있습니다.