Systems and methods for continuous fabrication of woven composite materials
AssigneeWEAV3D, Inc.
InventorsChristopher Oberste, Phillip Sung Tse Cheng
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Abstract
A machine and method are presented for continuously forming a woven composite with controllable internal fabric geometry. The machine may include one or more spools for dispensing one or more warp filaments, a roller assembly configured to receive a composite weave, a warp rack having warp heads for engaging the warp filaments and vertically adjusting position to dynamically create a weave pattern in response to the insertion of one or more weft filaments by a weft inserter stack.
Claims20
A method of continuously forming a consolidated woven composite comprising:
- forming a woven composite material of repeating units created by a repeated sequence of warp and weft filament movements comprising:
- receiving one or more polymer impregnated or coated warp filaments from a warp rack comprising warp heads;
- and
- inserting one or more polymer impregnated or coated weft filaments between one or more warp filaments with a weft inserter, at least one of the warp or weft filaments comprising a transmission material;
- and
- consolidating the woven composite material by heat and pressure to form a consolidated woven composite,
- wherein the forming and consolidating of the woven composite material is performed on a single machine.
A method of continuously forming a consolidated woven composite, comprising:
- forming a woven composite material of repeating units by a repeated sequence of warp and weft filament movements comprising:
- receiving one or more polymer impregnated or coated warp filaments from a warp rack comprising warp heads;
- and
- inserting one or more polymer impregnated or coated weft filaments between one or more warp filaments, at least one of the warp or weft filaments comprising a transmission material;
- and
- consolidating the woven composite material by heat and pressure to form a consolidated woven composite,
- wherein each warp head is capable of independent vertical movement to adjust the height of the warp filament exiting from the respective warp head.
A method of continuously forming a consolidated woven composite comprising:
- forming a woven composite material of repeating units created by a repeated sequence of warp and weft tape movements comprising:
- receiving one or more polymer impregnated or coated warp tapes from a warp rack comprising warp heads, at least a first warp tape including a first plurality of reinforcing fibers and a second warp tape including a first transmission element;
- and
- inserting one or more polymer impregnated or coated weft tapes between one or more warp tapes, at least a first weft tape including a second plurality of reinforcing fibers;
- and
- consolidating the woven composite material by heat and pressure to form a consolidated woven composite,
- wherein the forming and consolidating of the woven composite material is performed on a single machine.
Dependencies are inferred from the claim text.