Interlaced three-dimensional printed composites and machines for fabricating same
AssigneeGeorgia Tech Research Corporation
InventorsChristopher Marc Oberste, Ben Wang, Kan Wang
Life of this patent
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Abstract
A machine for fabricating three-dimensional interlaced composite components including a frame, a deposition surface, a first set of two or more warp heads, a second set of two or more of warp heads, and a weft inserter. An interlaced composite component including a first set of two or more warp filaments parallel to each other and a first set of two or more weft filaments parallel to each other. Warp filaments are interlaced with, and bonded to, weft filaments. Warp filaments and weft filaments are interlaced in at least two different weave patterns. Warp filaments and weft filaments are continuous, and the weave patterns transition from one pattern to another.
Claims21
A three-dimensional interlaced composite fabricated by a machine comprising a frame, a deposition surface, a first set of two or more warp heads adapted to deposit a first set of warp filaments on the deposition surface in a first warp direction, and move parallel to one another within a first plane, a second set of two or more of warp heads adapted to deposit a second set of warp filaments on the deposition surface in a second warp direction, and move parallel to one another within the first plane, wherein the second set of warp heads do not move collinearly with the first set of warp heads, and a weft inserter adapted to deposit a first and second set of weft filaments on the deposition surface in a weft direction, and traverse a length of the deposition surface in the warp direction, wherein the weft direction is different than at least one of the first and second warp directions;
- wherein the three-dimensional interlaced composite is fabricated by the machine by:
- depositing onto the deposition surface the first set warp filaments;
- inserting, on top of the first set of warp filaments, the first set of weft filaments being parallel to one another and substantially coplanar;
- depositing, on top of the first set of weft filaments, the second set of warp filaments;
- and
- inserting, on top of the second set of warp filaments, the second set of weft filaments being parallel to one another and substantially coplanar;
- wherein the three-dimensional interlaced composite is formed when at least one of the warp filaments passes over at least one of the weft filaments and passes under at least another of the weft filaments;
- and
- wherein the three-dimensional interlaced composite comprises:
- the first and second set of warp filaments;
- and
- the first and second set of weft filaments;
- wherein one or more of the warp filaments of the first and second set of warp filaments comprise reinforcing fibers that are pre-impregnated and therefore saturated with resin.
An interlaced composite component comprising:
- two or more warp filaments parallel to each other;
- and
- two or more weft filaments parallel to each other;
- wherein one or more of the warp filaments comprise reinforcing fibers that are pre-impregnated and therefore saturated with resin;
- wherein at least a portion of the warp filaments are interlaced with at least a portion of the weft filaments at locations of interlacing;
- wherein at least a portion of the locations of interlacing, the interlaced warp filament and the interlaced weft filament are bonded to one another only at such portions of locations of interlacing;
- wherein at least a portion of the warp filaments and at least a portion of the weft filaments are interlaced in at least two different weave patterns selected from the group consisting of plain weave, twill weave, and satin weave;
- wherein at least a portion of the warp filaments and at least a portion of the weft filaments are continuous and the weave patterns transition from one pattern to another;
- and
- wherein each location of bonding of the interlaced composite component is a location of interlacing.
An interlaced composite component comprising:
- a first set of warp filaments at least a portion of which are parallel to each other;
- a first set of weft filaments at least a portion of which are parallel to each other;
- a second set of warp filaments at least a portion of which are parallel to each other;
- and
- a second set of weft filaments at least a portion of which are parallel to each other;
- wherein at least a portion of the weft filaments of the first set of weft filaments are substantially coplanar;
- wherein at least a portion of the weft filaments of the second set weft filaments are substantially coplanar, and positioned either directly above or directly below at least a portion of the first set of weft filaments;
- wherein at least a portion of the warp filaments of the first set of warp filaments alternate between being interlaced with, and bonded to, at least a portion of the weft filaments of the first set of weft filaments and at least a portion of the weft filaments of the second set of weft filaments;
- wherein at least a portion of the warp filaments of the second set of warp filaments alternate between being interlaced with, and bonded to, at least a portion of the weft filaments of the first set of weft filaments and at least a portion of the weft filaments of the second set of weft filaments;
- and
- wherein either or both:
- in at least a portion of the composite, weft filaments of both the first set of weft filaments and the second set of weft filaments remain unbonded from one another;
- and
- at least a portion of the warp filaments of the second set warp filaments are positioned either directly above or directly below at least a portion of the first set of warp filaments.
An interlaced composite component comprising:
- a first set of two or more warp filaments parallel to each other and separated from one another by a warp gap;
- and
- a first set of two or more weft filaments parallel to each other and separated from one another by a weft gap;
- wherein at least a portion of the warp filaments of the first set of warp filaments are interlaced with at least a portion of the weft filaments of the first set of weft filaments at locations of interlacing;
- wherein at at least a portion of the locations of interlacing, the interlaced warp filament of the first set of warp filaments and the interlaced weft filament of the first set of weft filaments are bonded to one another only at such portions of locations of interlacing;
- wherein the warp and weft gaps define one or more openings in the composite component configured to one or both limit crack propagation and buckling;
- wherein each location of bonding of the interlaced composite component is a location of interlacing;
- wherein at least a portion of the warp filaments of the first set of warp filaments comprise reinforcing fibers that are pre-impregnated and therefore saturated with resin;
- and
- wherein at least a portion of the weft filaments of the first set of weft filaments comprise reinforcing fibers that are pre-impregnated and therefore saturated with resin.
An interlaced composite component comprising:
- warp filaments;
- and
- weft filaments;
- wherein either or both of the warp and weft filaments comprise reinforcing fibers that are pre-impregnated and therefore saturated with resin;
- wherein the warp filaments are interlaced with the weft filaments at locations of interlacing;
- and
- wherein at least a portion of the locations of interlacing, the interlaced warp filament and the interlaced weft filament are bonded to one another at such portions of locations of interlacing via activation of at least a portion of the resin of either or both the warp filament and the weft filament.
An interlaced composite component comprising:
- first and second sets of warp filaments;
- and
- first and second sets of weft filaments;
- wherein one or more of the filaments of the warp and weft filaments comprise reinforcing fibers that are pre-impregnated and therefore saturated with resin;
- wherein at least a portion of the weft filaments of the first set of weft filaments are substantially coplanar;
- wherein at least a portion of the weft filaments of the second set weft filaments are substantially coplanar, and positioned either directly above or directly below at least a portion of the first set of weft filaments;
- wherein at least a portion of the warp filaments of the first set of warp filaments are interlaced with, and bonded to, at least a portion of the weft filaments of both of the first set and the second set of weft filaments;
- wherein at least a portion of the warp filaments of the second set of warp filaments are interlaced with, and bonded to, at least a portion of the weft filaments of both of the first set and the second set of weft filaments;
- and
- wherein either or both:
- in at least a portion of the composite, weft filaments of both the first set of weft filaments and the second set of weft filaments remain unbonded from one another;
- and
- at least a portion of the warp filaments of the second set warp filaments are positioned either directly above or directly below at least a portion of the first set of warp filaments.
Dependencies are inferred from the claim text.