Systems and methods for continuous fabrication of woven composite materials
AssigneeWEAV3D, Inc.
InventorsChristopher Oberste, Phillip Sung Tse Cheng
Life of this patent
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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.
Claims21
-20. (canceled)
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.
A consolidated woven composite comprising:
- a plurality of warp tapes in a first linear direction, wherein at least a first warp tape includes reinforcing fibers impregnated with resin and is in surface contact with a first elongate transmission element external to the first warp tape, the first elongate transmission element comprising a material different from the reinforcing fibers;
- and
- a plurality of weft tapes in a second linear direction, wherein at least a first weft tape includes the reinforcing fibers impregnated with the resin and is in surface contact with a second elongate transmission element external to the first weft tape, the second elongate transmission element comprising the material different from the reinforcing fibers,
- wherein the first warp tape passes over the first weft tape and passes under at least another of the weft tapes, such that the first elongate transmission element is in communication with the second elongate transmission element.
A method for manufacturing a reinforced concrete composition, comprising the steps of:
- inserting a reinforcing material into a mold, wherein the reinforcing material comprises a polymer and a reinforcement fiber, and the polymer has a backbone comprising cyclohexane dimethanol (“CHDM”);
- inserting a polymer concrete mixture into the mold, wherein the mixture comprises an unsaturated polyester resin (“UPR”), aggregate, and a curing agent;
- and
- allowing the polymer concrete mixture to cure.
Dependencies are inferred from the claim text.