• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    DEPOSITION MANUFACTURING METHOD, AND, TERMINAL ACTUATOR A fiber-reinforced polymer part is manufactured by rasterizing a deposition head over a substrate, and additively forming partial characteristics through the extrusion of a polymer having a continuous reinforcement admitted from the deposition head on a substrate
    公开号:BR102015023863B1
    申请号:R102015023863-0
    申请日:2015-09-16
    公开日:2020-07-28
    发明作者:Gregg Robert Bogucki；Gregory James Schoepen Hickman；Michael William Hayes
    申请人:The Boeing Company；
    IPC主号:
    专利说明:

    1. Field:
    [001] The present description in general refers to additive manufacturing techniques, and deals more particularly with a method and apparatus for the deposition of fiber reinforced polymers, such as thermoplastic polymers. 2. Basics:
    [002] Additive manufacturing is a process in which physical parts are produced directly from a 3-D (three-dimensional) CAD (computer-aided design) file. In a type of additive fabrication known as fused deposition modeling (FDM®) and sometimes referred to as 3-D printing, a portion is produced by extruding small beads of thermoplastic polymer material to form layers of material that solidify after being extruded from a nozzle. The extrusion nozzle can be moved along a path or “rasterized” by a numerically controlled mechanism to build the part from the bottom upwards on a construction platform, one layer at a time.
    [003] Parts produced by known additive manufacturing processes, such as FDM®, may not be suitable for use in some applications that require high structural performance, such as in the aerospace industry. In order to achieve greater structural performance, thermoplastic parts used in these applications typically require the use of an admitted reinforcement such as staple or continuous fibers. However, the integration of a continuous fiber reinforcement for an extruded thermoplastic polymer during melt deposition modeling is still not practical until now.
    [004] It is known to introduce staple reinforcement fibers (for example, "cut") in an extruded polymer. For example, a process known as PUSHTRUSION® was developed to mold reinforced polymer composites using a direct line molding and composition process, where the mold filler comprises extruded polymer granules or yarns reinforced with staple fibers. However, the PUSHTRUSION® process uses large, heavy industrial equipment that must provide granules or polymer filaments reinforced by staple fiber for molding, and is not suitable for use in additive manufacturing processes such as FDM.
    [005] Appropriately, there is a need for an additive manufacturing process such as FDM that allows integration of a reinforcement into a layered polymer rim to form characteristics of a part. There is also a need for a terminal actuator to carry out the process described above that allows the admission of a continuous reinforcement in a liquefied polymer since the terminal actuator has characteristics of the part. SUMMARY
    [006] The disclosed modalities provide a method and apparatus for making reinforced polymer parts using an additive manufacturing technique. The reinforcement can be continuous and is integrated into a melted edge of the polymer when the polymer is being deposited in layers to form characteristics of the part, similar to melted deposition modeling. The modalities allow the manufacture of parts having higher structural performance requirements. High resolution deposition of continuously reinforced polymers is made possible.
    [007] According to a disclosed modality, a deposition manufacturing method is provided. The method comprises establishing a pressurized stream of a molten polymer through a tube, admitting a fiber reinforcement within the pressurized stream, and depositing a polymer rim and fiber reinforcement from the tube on a substrate. Fiber reinforcement is permitted by feeding it into the tube. The fiber reinforcement may comprise a filament, tow, a wick or a thread. The fiber reinforcement can be admitted by feeding one of a dry fiber reinforcement and a pre-impregnated fiber reinforcement to the tube. The fiber reinforcement can be heated. In a variation, a plurality of discontinuous fiber reinforcements can be coupled to a chain, and the chain can be admitted by stretching it to the pressurized chain. The method may also include encapsulating the fiber reinforcement in a polymer having a melting temperature that is greater than the melting temperature of the polymer in the pressurized stream. A desired polymer viscosity can be maintained by applying a variable amount of heat to the tube along its length. Optionally, the method may additionally include depositing a polymer rim on the substrate on which the polymer is devoid of fiber reinforcement. The pressurized current is established by injecting the polymer under pressure into the tube. The injection of the polymer under pressure in the tube includes establishing a pressure differential between an upstream end and a downstream end of the tube. The method may also include drawing the fiber reinforcement through the tube along with the polymer using the pressurized stream and / or capillary action. Fiber reinforcement can be admitted by inserting it to an end upstream of the tube. The polymer is introduced into the tube in an annular manner around the fiber reinforcement
    [008] According to another modality, a method is provided for the manufacture of a composite part. A deposition head is rasterized onto a substrate. Part characteristics are formed additively through the extrusion of a polymer having a reinforcement from the deposition head on a substrate. The method may include admitting a discontinuous reinforcement to the polymer, or alternatively admitting a continuous reinforcement to the polymer. In a variation, features can be extruded that are stripped of reinforcement. Extrusion includes introducing the polymer and reinforcement at an upstream end of a tube, forcing the polymer to pass through the tube to an end downstream of the tube, and removing the reinforcement through the tube to the downstream end of the tube using the polymer flow through the tube to stretch the reinforcement along with the polymer flow. The method may also include using capillary action to help remove the reinforcement through the tube. The polymer is introduced by injecting the polymer under pressure around the reinforcement. Extrusion includes forcing the polymer and the reinforcement admitted through a die. The method may also include cutting the polymer and reinforcement during the rasterization of the deposition head.
    [009] According to yet another modality, a terminal actuator is provided to perform the deposition of a fiber reinforced polymer. The terminal actuator includes a supply of a continuous fiber reinforcement, and a supply of a flowing polymer. A deposition head is provided having a polymer inlet and a material supply end configured to receive a supply of continuous fiber reinforcement. The deposition also includes a deposition end configured to deposit a polymer rim having continuous fiber reinforcement admitted therein. The end actuator may additionally comprise a heater to heat the intake barrel, including at least one heating coil having a plurality of coil turns that vary in number over a length of the intake barrel. The deposition head includes an intake barrel configured to support continuous fiber reinforcement. The intake barrel includes a convergence region where the continuous fiber reinforcement and the flowing polymer converge. The intake barrel may also include an extrusion die coupled with the deposition end. The intake barrel may additionally include a capillary tube coupled with the convergence region and configured to be used for continuous fiber reinforcement in the polymer.
    [0010] The characteristics, functions, and advantages can be achieved independently of the various modalities of the present description or can be combined in other modalities in which additional details can be observed with reference to the following description and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS
    [0011] The new characteristics that are believed to be characteristic of the illustrative modalities are defined in the attached claims. The illustrative modalities, however, as well as a preferred mode of use, objectives and additional advantages thereof, will be better understood with reference to the following detailed description of an illustrative embodiment of the present description when read in conjunction with the accompanying drawings, in which :
    [0012] Figurei is an illustration of a global and diagrammatic block of the apparatus for making a fiber-reinforced part using an additive manufacturing technique;
    [0013] Figure IA is an illustration of the area designated as “FIG. IA ”in Figure 1, parts of an extruded bead being broken to reveal a fiber reinforcement admitted in the polymer;
    [0014] Figure 2 is an illustration of a cross-sectional view of a deposition head that forms part of the apparatus shown in Figure 1;
    [0015] Figure 3 is an illustration of a sectional view taken along line 3-3 in Figure 2.
    [0016] Figure 4 is an illustration of an enlarged view of the section designated as “FIG. 4 "in Figure 2;
    [0017] Figure 5 is an illustration of a flow diagram of an embodiment of a deposition method;
    [0018] Figure 6 is an illustration of a flow diagram of a method of manufacturing a composite part;
    [0019] Figure 7 is an illustration of a bottom perspective view of a deposition head network for the deposition of a fiber reinforced polymer;
    [0020] Figure 8 is an illustration of a flow diagram of aircraft production and service methodology.
    [0021] Figure 9 is an illustration of an aircraft block diagram. DETAILED DESCRIPTION
    [0022] Referring to Figure 1, the modalities discussed comprise a terminal actuator 20 that can be rasterized through three-dimensional space by a substrate 23 such as a platform 24 by any suitable manipulator 30. The manipulator 30 can comprise, for example, and without limitation, a numerically controlled gantry mechanism (not shown), and an articulated robotic arm (not shown) or a similar mechanism. Both terminal actuator 20 and manipulator 30 are operated by combining a controller 32 and construction programs 38 or similar software. Controller 32 may comprise, without limitation, a programmed general purpose or special purpose computer, such as a PC (personal computer) or a PLC (programmable logic controller).
    [0023] The terminal actuator 20 accumulates a part of three-dimensional fiber reinforced polymer 26, layer 22 by layer 22 on the platform 24 which moves downwards 28 since each layer of reinforced polymer 22 is completed. Polymer part 26, sometimes referred to here as a composite part 26, is defined by one or more CAD (computer aided design) files 34 which are converted to STL (stereolithography) 36 files defining the surfaces of part 26 Using the STL files 36, and one or more construction programs 38, controller 32 controls the operation of terminal actuator 20 and manipulator 30. Manipulator 30 rasterizes terminal actuator 20 on platform 24 to deposit cast edges 44 of soft fiber reinforced polymer that subsequently solidifies. As shown in Figure 1A, each of the molten edges 44 comprises an extruded polymer 80 having a continuous fiber reinforcement 76 admitted thereto. When the reinforced polymer solidifies, layers 22 fuse to form the various characteristics of the fiber-reinforced composite part 26.
    [0024] The terminal actuator 20 includes a deposition head 40 that can be provided with an extrusion nozzle or die 42 through which a fiber-reinforced molten rim 44 of reinforced polymer is deposited on platform 24, or on an underlying layer 22 As mentioned above, the lip 44 includes a fiber reinforcement 76 (Figures 1, 2, 3 and 4) which is admitted to the extruded polymer 80 when the lips 44 are extruded to form layers 22 which then solidify and fuse. The extrusion nozzle 42 can have a nozzle opening 42a (Figure 2) to extrude a polymer flange 44 having admitted fiber reinforcement 76. The nozzle opening 42a can have the desired cross-sectional shape such as, without limitation, a circular, square, elliptical, ribbon or rectangular cross-sectional shape.
    [0025] The terminal actuator 20 additionally comprises a fiber supply and supply 48, a supply of pressurized polymer 50 and one or more suitable heaters 52. The supply of polymer 50 may include one or more control valves and pressure regulators (not shown) as may be necessary to control the flow and pressure of polymer that is supplied to the deposition head 40. The heater 52 heats the polymer until it liquefies and can flow, and still provides heat to the deposition head 40 to maintain the desired polymer viscosity up to polymer 80 and admitted fiber reinforcement 76 comes out of the extrusion nozzle 42. The desired polymer viscosity can depend on a variety of factors, including without limitation, the temperature at which the polymer is heated, the amount of heat absorption by fiber reinforcement 76, the particular polymer 80 being used and its shear rate, the ability of fiber reinforcement 76 to be wetted by the polymer 80, the desired extrusion rate of the deposition head 40 and the rate at which the terminal actuator 20 is rasterized onto the substrate 23. In general, however, polymer 80 must have a viscosity that is low enough to wet the reinforcement fiber 76 and be extruded from the deposition head 40.
    [0026] Optionally, heater 52 can be used to heat fiber reinforcement 76 before and / or when it is being fed to the deposition head 40 and becomes admitted to polymer 80. Terminal actuator 20 can also include a cutter suitable 46 which cuts the fiber-reinforced polymer 44 after a layer 22 has been deposited. The cutter 46 may comprise, for example, and without limitation, a laser cutter, an ultrasonic knife or a mechanical cutter such as a guillotine blade (all not shown) that cuts through both the polymer 80 and the admitted fiber reinforcement 76 .
    [0027] The polymer 80 supplied to the deposition head 40 can be any phase-changing polymer that reduces viscosity when heated to at least its glass transition temperature, and then solidifies and hardens when cooled. For example, and without limitation, the polymer 80 withdrawn to the deposition head 40 from the polymer supply 50 may comprise any suitable crystalline or amorphous thermoplastic polymer, thermoset or a thermoplastic copolymer.
    [0028] The fiber reinforcement 76 which is allowed in polymer 80 may comprise one or more fiber filaments, tow, wicks, or threads that are compatible with polymer 80, such as metal, glass, ceramic or metal fibers, or combination of such fibers. The fiber reinforcement 76 may be in the form of, without limitation, one or more tow, wicks or threads, each comprising a plurality of individual filaments. In some embodiments, for example, reinforcement 76 may comprise a single tow, wick or yarn comprising a linear weight between 2 and 16 tex, where a "tex" is the mass in grams of 1,000 meters of a tow segment, wick or wire. The fiber reinforcement 76 can be a dry fiber reinforcement or it can be a pre-impregnated fiber reinforcement.
    [0029] The tow, wick or yarn can comprise dry filaments, however in some embodiments, the tow can be pre-impregnated with a polymer that is the same as or that is different from the polymer 80 taken from the supply of polymer 50. Also it may be possible to form a reinforcement filament by encapsulating a tow, wick or yarn in a first polymer that has a relatively high melting temperature, and then feeds the encapsulated tow through the deposition head 40 where it is admitted within a second polymer 80 which it has a melting temperature that is lower than that of the first polymer. In other embodiments, fiber reinforcement 76 may comprise staple fiber reinforcements (for example, cut fibers) that may or may not be aligned and are coupled, as with a binder, to a chain (not shown) that can be stretched or “ pulled ”through the deposition head 40 by a flow stream of polymer 80 in which the chain of staple fiber reinforcements 76 is allowed.
    [0030] Attention is now directed to Figures 2, 3 and 4 which show details of the deposition head 40 comprising the forming part of the terminal actuator 20.0 deposition head 40 includes an elongated intake barrel 66 having a material supply end 70, and a material deposition end 72 from which a molten rim 44 (Figure 1) of the fiber-reinforced polymer is extruded and deposited, as explained above. Inlet barrel 66 includes an inner capillary tube 68 having the first upstream end 68a, and a second downstream end 68b opposite the upstream end 68a. Capillary tube 68 extends longitudinally from the material deposition end 72 of the intake barrel 66 to a convergence region 86 where fiber reinforcement 76 is introduced into and converges with a polymer 80 flow stream which is introduced into the intake barrel 66 upstream of the convergence region 86.
    [0031] When fiber reinforcement 76 is introduced into the flow stream of polymer 80, viscous interaction between fiber reinforcement 76 and polymer 80 pulls fiber reinforcement 76 to the upstream end 68a of, and then through the tube capillary 68. With the entry into the convergence region 86, the fiber reinforcement 76 becomes admitted into the flow stream of polymer 80 and is carried along with polymer 80 through capillary tube 68 to the material deposition end72 of the barrel. intake 66 where polymer 80 and admitted fiber reinforcement 76 are extruded as a bead 44.
    [0032] The downstream end 68b of capillary tube 68 can be coupled with an extrusion die 42 in order to extrude a polymer rim 44 having a desired cross-sectional shape. In some applications, extrusion die 42 may not be necessary. Capillary tube 68 has an internal diameter “D” that will depend on a variety of factors, including the application of particular deposition, the print resolution of part 26 (Figure 1) being manufactured and the fiber reinforcement volume fraction76 that is desired. The volume fraction of fiber reinforcement76 contained in the polymer is a function of both the inner diameter “D” of capillary tube 68, and the number and diameter of fibers that make up fiber reinforcement 76. The length of capillary tube 68 can also affect the amount of polymer interaction allowed for fiber that is required to move fiber reinforcement 76 through capillary tube 68.
    [0033] The material supply end 70 of the intake barrel 66 is provided with a centrally located guide tube 74 in which the fiber reinforcement 76 can be fed longitudinally from the fiber supply and supply 48 ( Figure 1). The downstream end 74a of the guide tube 74 is tapered and includes a central opening 82 (Figures 3 and 4) which is coaxially aligned with the capillary tube 68. After being fed into the guide tube 74, the fiber reinforcement 76 is guided through the opening 82, in axial alignment with the capillary tube 68, and enters the convergence region 86 where it converges with, is exposed to and becomes wetted by the molten polymer flowing over the outside of the guide tube 74 to the tube capillary 68. When the fiber reinforcement 76 enters the convergence region 86, it becomes admitted in the polymer 80 which flows through the convergence region 86 to the capillary tube 68.
    [0034] The material supply end 70 of the intake barrel 66 additionally includes an annular polymer passageway 69 surrounding the guide tube 74. In one embodiment, flowing molten polymer 80 can be introduced into the transit passageway of annular polymer 69 through a polymer inlet 69a at the material supply end 70 (as shown), in a direction generally parallel to the direction in which fiber reinforcement 76 is fed to guide tube 74. Alternatively, in another embodiment (not shown), the flowing molten polymer 80 can be fed across the side of the intake barrel 66 to the passage path 69 in a direction that is transverse to the direction in which the fiber reinforcement 76 is fed into the guide tube 74.
    [0035] Polymer 80 is injected from the supply of polymer 50 to the inlet of polymer 69a at a pressure "PI", and flows through the annular passage path 69. The annular passage path 69 tapers and converges with the tapered end 74a of the guide tube 74, causing the flowing polymer 80 to pass from and over the fiber reinforcement 76 to the upstream end 68a of capillary tube 68. The pressure "PI" is greater than the atmospheric pressure " Pa ”at the material deposition end72 of the intake barrel 66, consequently a pressure differential of PI-Pa exists between the opposite ends 68a, 68b of the capillary tube 68. This pressure differential helps to remove and admit the fiber reinforcement 76 in the flowing polymer 80.
    [0036] The heater 52 shown in Figure 1 may include one or more electric heating coils 52a that both surround and are admitted to the intake barrel 66 as shown in Figure 2. The electrical heating coils 52a provide the necessary heat to maintain the polymer 80 in a fluent state with a desired viscosity. It may be desirable to maintain the temperature of the intake barrel 66 at the material supply end 70 at a temperature that is higher than the temperature at the material deposition end72 in order to ensure that the fiber reinforcement 76 is properly wetted as it is initially withdrawn into capillary tube 68. In order to vary the amount of heat supplied to polymer 80 while traveling along the length of the intake barrel 66 and thereby controlling the viscosity of polymer 80, heating coils 52a can have a greater number of coil turns at the material supply end 70 in the intake barrel 66 compared to the number of coil turns at the material tip 72.
    [0037] In use, one or more fiber reinforcements 76 are loosely fed to the guide tube 74 such that they are not positioned in any substantial amount of compression, i.e. they are not forced into the guide tube 74, and consequently the bending of the fiber reinforcements 76 is avoided. As previously mentioned, the intake barrel 66 is heated to a temperature that keeps polymer 80 able to flow and ensures that substantially complete fiber reinforcement 76 is wetted. Polymer 80 under pressure P1 is introduced into polymer inlet 69a, filling the annular passage path69, and establishing a flow of polymer 80 through the convergence region 86 to the upstream end 68a of the capillary tube 68. The pressure differential polymer PI-Pa established between the polymer inlet 69a and the end of deposition of material 72 maintains the flow of polymer 80 to capillary tube 68. In other words, polymer 80 seeks to balance by flowing from polymer inlet 69a at a relatively high pressure PI to the deposition end of material 72 at relatively pressure minor Pa.
    [0038] The flow of polymer 80 through the convergence region 86 produced by the pressure differential PI-Pa, causes polymer 80 to "pick up" and remove fiber reinforcement 76 along with the flow of polymer 80 to the end a upstream 68a of capillary tube 68 where it becomes admitted in polymer 80. Additionally, fiber reinforcement 76 is stretched through capillary tube 68 by the capillary action produced by intermolecular forces between polymer 80 and the surrounding capillary tube 68. When the reinforcement of fiber 76 is drawn into capillary tube 68, fiber reinforcement 76 becomes admitted into the polymer stream 80 and is extruded and then deposited together with polymer 80 on a molten rim 44 (Figure 1) for successive layer 22 part 26 when the terminal actuator 20 is rasterized onto the substrate 23.
    [0039] When a layer 22 or other functionality of part 26 has been formed, cutter 46 cuts off edge 44, and the polymer supply 50 can be turned off until terminal actuator 20 is ready to deposit the next layer 22. Cutting the flange 44 results in the cutting of both polymer 80 and the fiber reinforcement 76 admitted to polymer 80. In some applications, it may be possible to temporarily interrupt the feeding of fiber reinforcement 76 in order to deposit edges 44 which are purely polymer 80 ( without fiber reinforcements) in order to form layers 22 that do not contain a reinforcement.
    [0040] Attention is now directed to Figure 5 which vastly illustrates a deposition manufacturing method that employs a terminal actuator 20 of the type described above. Starting at 54, a pressurized stream of polymer 80 is established through a tube 68 which can be a capillary tube. The pressurized stream of polymer 80 can be established by establishing a pressure differential between polymer inlet 69a (Figure 2) and the downstream end 68b of capillary tube 68. In 56, a fiber reinforcement 76 is admitted into the pressurized polymer stream. In some embodiments, the method may optionally include heating fiber reinforcement 76 before being admitted to the pressurized stream of polymer 80. In 58, a rim 44 of polymer 80 having fiber reinforcement 76 admitted to it is deposited from the tube on a substrate23. The pressurized stream of polymer 80 can be established by supplying polymer 80 to the upstream end 68a of capillary tube 68 at a Pique pressure that is greater than the pressure Pa at which the polymer exists to downstream end 68b of capillary tube 68 and is deposited from the material deposition end 72.
    [0041] Figure 6 broadly illustrates a method of manufacturing a composite part 26 by the additive manufacturing technique described above. In 60, a deposition head 40 is rasterized onto a substrate 23. In 62, characteristics of the composite part 26 are formed additively through the extrusion of a polymer 80 having a continuous fiber reinforcement admitted 76 from the deposition head 40 to the substrate 23. The extrusion of polymer 80 together with the continuous admitted fiber reinforcement 76 can be achieved by the flow of a pressurized stream of polymer 80 through a capillary tube 68 generated by a pressure differential PI-Pa, between one end a upstream 68a and a downstream end 68b of capillary tube 68.
    [0042] In some applications, in order to increase manufacturing speed, it may be necessary or desirable to employ a terminal actuator 20 having more than a single deposition head 40. Referring to Figure 7, a plurality of deposition heads 40 it can be grouped in an arrangement 88 in a single terminal actuator 20 (Figure 1). Each of the deposition heads 40 can include an extrusion nozzle 42 from which a rim (not shown) of the fiber-reinforced polymer can be deposited on a substrate 23 (Figure 1) to additively form features of the part.
    [0043] Modalities of the description can find use in a variety of potential applications, particularly in the transport industry, including, for example, aerospace, marine, automotive and other applications where part of fiber-reinforced polymer can be used. Thus, in reference now to Figures 8 and 9, modalities of the description can be used in the context of an aircraft manufacturing and service method 90 as shown in Figure 8 and an aircraft 92 as shown in Figure 9. Aircraft applications of the modalities discussed they can include, for example, without limitation, prototype components, low production racing parts and reinforced structures that can be difficult or costly to manufacture using conventional processes. During pre-production, example method 90 may include specification and design 94 for aircraft 92 and search for material 96. During production, component and subset 98 manufacturing and system integration 100 for aircraft 92 occurs. During the manufacture of component and subset 98, the disclosed method and apparatus can be employed to produce components or subsets that are then integrated as part of system 100 integration. In addition, the modalities can be used to produce components that allow other components assembled and / or integrated. Next, aircraft 92 can undergo certification and design 102 in order to be placed in service 104. While in service 104 by a consumer, aircraft 92 is scheduled for routine maintenance and service 106, which may also include modification, reconfiguration , reform, and so on. The modalities discussed can be used to manufacture parts or components that are used to repair or replace components as part of maintenance and service 106.
    [0044] Each of the method 90 processes can be carried out or transported by a system integrator, a third party, and / or an operator (for example, a customer). For the purposes of this description, a system integrator may include without limitation any number of aircraft manufacturers and main system subcontractors; a third party may include without limitation any number of vendors, subcontractors and suppliers; and an operator can be an airline, leasing company, military entity, service organization, and so on.
    [0045] As shown in Figure 9, aircraft 92 produced by example method 90 may include a fuselage 108 with a plurality of systems 110 and an interior 112. Examples of high-level systems 110 include one or more of a propulsion system 114, an electrical system 116, a hydraulic system 122 and an environmental system 120. Any number of other systems may be included. Although an example of aerospace is shown, the principles of the description can be applied to other industries, such as the marine and automotive industries. The discussed modalities can be used to manufacture parts or components of low production running fiber reinforced polymer or custom design prototype used in fuselage 108, any of the systems 110 or the interior 112.
    [0046] Systems and methods admitted here may be employed during any one or more of the stages of the service and production method 90. For example, components or subassemblies corresponding to the production process 98 may be manufactured or produced in a manner similar to the components or subsets produced while aircraft 120 is in service. In addition, one or more apparatus modalities, method modalities, or a combination thereof can be used during production stages 98 and 100, for example, substantially expediting assembly or reducing the cost of an 92 aircraft. Similarly, one or more more of the apparatus modalities, method modalities, or a combination of them can be used while the aircraft 92 is in service, for example, and without limitation, for maintenance and service 106.
    [0047] As used here, the phrase “at least one of”, when used with a list of items, means that different combinations of one or more of the items listed can be used and only one of each item in the list may be needed . For example, “at least one of item A, item B, and item C” can include, without limitation, item A, item A and item B, or item B. This example can also include item A, item B, and item C or item B and item C. The item can be a particular object, thing, or category. In other words, at least one means that any combination of items and number of items can be used from the list, but not all items on the list are necessary.
    [0048] Thus, in summary, according to a first aspect of the present invention, there is provided: Al. A method of manufacturing deposition, comprising: establishing a pressurized stream of a polymer through a tube; admit a fiber reinforcement within the pressurized chain; and depositing a polymer rim and fiber reinforcement from the tube on a substrate. A2. Also provided is the method of manufacturing the deposition of paragraph A1, wherein admitting fiber reinforcement includes feeding at least one of a tow, a wick and a thread in the tube. A3. Also provided is the deposition manufacturing method of paragraph A1, wherein admitting fiber reinforcement includes feeding one of a dry fiber reinforcement and a pre-impregnated fiber reinforcement into the tube. A4. Also provided is the deposition manufacturing method of paragraph A1, wherein admitting fiber reinforcement includes feeding one of a continuous fiber reinforcement and a batch fiber reinforcement into the tube. A5. Also provided is the method of manufacturing the deposition of paragraph A1, further comprising: heating the fiber reinforcement. A6. Also provided is the method of manufacturing the deposition of paragraph A1, further comprising: coupling together a plurality of discontinuous fiber reinforcements in a chain, and in which admitting a fiber reinforcement includes stretching the chain into the pressurized chain. A7. Also provided is the method of manufacturing the deposition of paragraph A1, further comprising: encapsulating the fiber reinforcement in a polymer having a melting temperature that is greater than the melting temperature of the polymer in the pressurized stream thereof. A8. Also provided is the method of making the deposition of paragraph A1, further comprising: maintaining a desired viscosity of the polymer by applying a variable amount of heat to the tube over a length of the tube. A9. Also provided is the method of manufacturing the deposition of paragraph A1, further comprising: depositing a polymer rim on the substrate, wherein the polymer is devoid of fiber reinforcement. AIO. Also provided is the deposition manufacturing method of paragraph A1, in which establishing the pressurized current includes injecting the polymer under pressure into the tube. A1 1. Also provided is the method of manufacturing the deposition of paragraph AIO, in which injecting the polymer under pressure into the tube includes establishing a pressure differential between an upstream end and a downstream end of the tube. Al2. Also provided is the method of manufacturing the deposition of the AIO paragraph, further comprising: stretching the fiber reinforcement through the pipe using the pressurized current. Al3. Also provided is the method of manufacturing the deposition of the AIO paragraph, further comprising: stretching the fiber reinforcement through the tube using capillary action. A14. Also provided is the method of manufacturing the deposition of the AIO paragraph, in which admitting fiber reinforcement includes introducing fiber reinforcement at one end upstream of the tube. A15. Also provided is the deposition manufacturing method of paragraph A14, in which introducing the polymer into the upstream end of the tube includes introducing the polymer in an annular manner around the fiber reinforcement.
    [0049] In accordance with a further aspect of the present invention, B1 is provided. A method of manufacturing a composite part, comprising: rasterizing a deposition head over a substrate; and additively forming characteristics of the composite part through the extrusion of a polymer having a reinforcement from the deposition head on the substrate. B2. Also provided is the method of paragraph Bl, further comprising: admitting a discontinuous reinforcement in the polymer. B3. Also provided is the method of paragraph Bl, further comprising: admitting a continuous reinforcement in the polymer. B4. Also provided is the method of paragraph Bl, in which additively forming characteristics of the composite part includes discontinuing the extrusion of the polymer having the reinforcement and continuing the extrusion of the polymer which is devoid of the reinforcement from the deposition head on the substrate. B5. Also provided is the method of paragraph Bl, in which extruding the polymer having the reinforcement includes: introducing the polymer having the reinforcement at one end upstream of a tube, forcing the polymer to flow through the tube to one end downstream of the tube , and stretching the reinforcement through the pipe to the downstream end of the pipe using the flow through the pipe to stretch the reinforcement along with the flow through the pipe. B6. Also provided is the method of paragraph B5, further comprising: using capillary action to help stretch the reinforcement through the tube. B7. Also provided is the method of paragraph B5, in which introducing a polymer having the reinforcement includes injecting the polymer under pressure around the reinforcement. B8. Also provided is the method of paragraph Bl, wherein the extrusion includes forcing the polymer having the reinforcement through a tube and a matrix. B9. Also provided is the method of paragraph Bl, further comprising: cutting the polymer having the reinforcement during the rasterization of the deposition head. Cl. A terminal actuator for carrying out the deposition of a fiber-reinforced polymer, comprising: providing a continuous fiber reinforcement; a supply of a flowing polymer; and a deposition head having a polymer inlet and a material supply end configured to receive a supply of continuous fiber reinforcement, the deposition head additionally including a deposition end configured to deposit a polymer rim having the reinforcement of continuous fiber admitted to it. C2. Also provided is the terminal actuator of paragraph Cl, in which the deposition head includes: an intake barrel configured to accommodate continuous fiber reinforcement in the polymer, the intake barrel including a convergence region in which the continuous fiber reinforcement and the flowing polymer converge. C3. Also provided is the terminal actuator of paragraph C2, in which the intake barrel additionally includes an extrusion die coupled with the deposition end. C4. Also provided is the terminal actuator of paragraph C2, in which the intake barrel additionally includes a capillary tube coupled with the convergence region and configured to admit continuous fiber reinforcement in the polymer. C5. Also provided is the terminal actuator of paragraph C4, in which: the capillary tube includes an upstream end coupled with the convergence region and a downstream end configured to extrude the polymer having the continuous fiber reinforcement admitted therein. C6. Also provided is the terminal actuator of paragraph C2, further comprising: a heater to heat the intake barrel, the heater including at least one heating coil having a plurality of coil turns that vary in number over a length of the barrel of admission.
    [0050] The description of the different illustrative modalities has been presented for the purposes of illustration and description, and is not intended to be exhaustive or limited to the modalities in the disclosed form. Many modifications and variations will be apparent to those skilled in the art. In addition, different illustrative modalities can provide different advantages compared to other illustrative modalities. The selected modality or modalities are chosen and described in order to better explain the principles of the modalities, their practical application, and to allow other experts in the art to understand the description for various modalities with various modifications as are suitable for the particular intended use.
    权利要求:
    Claims (8)
    [0001]
    1. A deposition manufacturing method, characterized by the fact that it comprises: establishing a pressurized stream of a first polymer (80) through a tube (68), in which the first polymer has a first melting temperature; admit a carbon nanotube reinforcement within the pressurized stream, where the carbon nanotube reinforcement is pre-impregnated with a second polymer that has a second melting temperature, where the second melting temperature is higher than the first melting temperature melting, and where the admission is carried out above the first melting temperature, but below the second melting temperature, in which, as a result of the admission, a combined polymer is formed; maintaining a third temperature at a material supply end (70) of an intake barrel (66) containing the tube (68) at a temperature higher than a fourth temperature at a material deposition end (72) of the barrel admission (66); and depositing a rim (44) of the combined polymer from the tube (68) on a substrate (23).
    [0002]
    2. Deposition fabrication method according to claim 1, characterized by the fact that admitting carbon nanotube reinforcement includes feeding a carbon nanotube wire into the tube.
    [0003]
    3. Deposition manufacturing method according to claim 1, characterized by the fact that admitting carbon nanotube reinforcement includes feeding carbon nanotubes aligned in the tube.
    [0004]
    4. A deposition manufacturing method according to claim 1, characterized by the fact that admitting carbon nanotube reinforcement includes feeding a continuous length of carbon nanotubes mechanically interlocked in the pressurized stream.
    [0005]
    5. Deposition manufacturing method according to claim 1, characterized by the fact that it also comprises the step of: pulling the carbon nanotube reinforcement through the tube using the pressurized current and the capillary action.
    [0006]
    6. Deposition manufacturing method according to claim 1, characterized by the fact that it further comprises the step of: pre-impregnating the carbon nanotube reinforcement with a polymer, and in which admitting the carbon nanotube reinforcement includes food reinforcement of carbon nanotube in the pressurized stream.
    [0007]
    7. A deposition manufacturing method according to claim 1, characterized by the fact that it also comprises the step of: heating the carbon nanotube reinforcement for a glass transition of the first polymer.
    [0008]
    8. Deposition manufacturing method according to claim 1, characterized in that the first polymer is different from the second polymer.
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    法律状态:
    2016-10-04| B03A| Publication of a patent application or of a certificate of addition of invention [chapter 3.1 patent gazette]|
    2018-09-18| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-12-17| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-05-26| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2020-07-28| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 16/09/2015, OBSERVADAS AS CONDICOES LEGAIS. |
    2020-11-24| B16C| Correction of notification of the grant|Free format text: REF. RPI 2586 DE 28/07/2020 QUANTO AO ENDERECO. |
    优先权:
    申请号 | 申请日 | 专利标题
    US14/489972|2014-09-18|
    US14/489,972|US9931778B2|2014-09-18|2014-09-18|Extruded deposition of fiber reinforced polymers|
    US14/602,964|US10118375B2|2014-09-18|2015-01-22|Extruded deposition of polymers having continuous carbon nanotube reinforcements|
    US14/602964|2015-01-22|
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