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US 2022/0403564 A1Published application
Systems and methods for continuous fabrication of woven composite materials
AssigneeGeorgia Tech Research Corporation
InventorsChristopher Marc Oberste, Phillip Sung Tse Cheng, Ben Wang
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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.
Claims36
A method 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;
- and
- inserting one or more polymer impregnated or coated weft filaments between one or more warp filaments;
- and
- consolidating the woven composite material by heat and pressure to form a consolidated woven composite;
- wherein the method is a method of continuously forming the consolidated woven composite from the composite weave material.
4 more elements
A method comprising:
- trimming a part portion of a consolidated woven composite, the consolidated woven composite formed from a woven composite material of repeating units created by a repeated sequence of warp and weft filament movements;
- and
- overmolding the trimmed part portion of the consolidated woven composite to form a finished component.
A method comprising:
- feeding one or more layers of substrate material that is melt-compatible with one or more warp and/or weft filaments of a woven composite material created by a repeated sequence of warp and weft filament movements;
- and
- consolidating the substrate material concurrently with the woven composite material through the use of heat and pressure in a continuous process by a roller assembly to form a consolidated woven composite having a cohesive bond between the substrate material and the woven composite material.
A method 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 comprising weft heads;
- and
- consolidating the woven composite material by heat and pressure in a consolidation zone to form a consolidated woven composite;
- wherein each warp head is capable of independent vertical movement to adjust the height of the warp filament extending from the warp head toward a roller assembly in the consolidation zone;
- and
- wherein the method is a method of continuously forming the consolidated woven composite from the composite weave material.
6 more elements
Dependencies are inferred from the claim text.