US 6,214,279 B1 · Apparatus and process for freeform fabrication of composite reinforcement preforms

Abstract

A solid freeform fabrication process and apparatus for making a three-dimensional reinforcement shape. The process comprises the steps of (1) operating a multiple-channel material deposition device for dispensing a liquid adhesive composition and selected reinforcement materials at predetermined proportions onto a work surface; (2) during the material deposition process, moving the deposition device and the work surface relative to each other in an X-Y plane defined by first and second directions and in a Z direction orthogonal to the X-Y plane so that the materials are deposited to form a first layer of the shape; (3) repeating these steps to deposit multiple layers for forming a three-dimensional preform shape; and (4) periodically hardening the adhesive to rigidize individual layers of the preform. These steps are preferably executed under the control of a computer system by taking additional steps of (5) creating a geometry of the shape on the computer with the geometry including a plurality of segments defining the preform shape and each segment being preferably coded with a reinforcement composition defining a specific proportion of different reinforcement materials; (6) generating programmed signals corresponding to each of the segments in a predetermined sequence; and (7) moving the deposition device and the work surface relative to each other in response to these programmed signals. Preferably, the system is also operated to generate a support structure for any un-supported feature of the 3-D preform shape.

Claims29

Dependent claims

A process for fabricating a net-shape reinforcement preform for a composite material part, in a layer-by-layer manner comprising

(a) providing a work surface lying substantially parallel to an X-Y plane of an X-Y-Z Cartesian coordinate system defined by three mutually perpendicular X-, Y- and Z-axes;
(b) positioning a material deposition device at a predetermined initial distance from said work surface, said deposition device comprising at least a reinforcement dispensing tool and an adhesive dispensing tool;
(c) operating and moving said material deposition device relative to said work surface along selected directions in said X-Y plane to deposit first layer of selected reinforcement and adhesive compositions onto said work surface, said first layer being of a predetermined cross-sectional shape on said X-Y plane and a predetermined thickness in said Z-axis direction;
(d) moving said material deposition device away from said work surface along said Z-axis direction by a predetermined distance,
(e) operating and moving said material deposition device to deposit another layer of selected reinforcement and adhesive compositions of another predetermined cross-sectional shape and thickness, and
(f) repeating steps (d) and (e) to deposit multiple layers of reinforcement and adhesive compositions for forming said net-shape reinforcement preform.

3 more elements

Solid freeform fabrication apparatus for making a three-dimensional reinforcement preform shape, comprising:

(a) a material deposition device comprising
a liquid adhesive dispensing tool that comprises (1) at least a flow channel being supplied with a hardenable liquid adhesive composition, (2) at least one nozzle having, on one end, a fluid passage in flow communication with said at least one channel and, on another end, a discharge orifice of a predetermined size, and (3) actuator means located in control relation to said channel for activating delivery of said liquid adhesive composition through said discharge orifice;
a reinforcement dispensing tool that comprises (1) at least a flow channel being supplied with a solid reinforcement composition, (2) at least one nozzle having, on one end, a flow passage in flow communication with said flow channel and, on another end, a discharge orifice of a predetermined size, and (3) valve means located in control relation with said flow channel;
(b) an object-supporting work surface at a predetermined initial distance from said discharge orifices to receive said liquid adhesive and reinforcement compositions therefrom;
(c) motion devices coupled to said work surface and said material deposition device for moving said material deposition device and said work surface relative to each other in a plane defined by first and second directions and in a third direction orthogonal to said plane to deposit said liquid adhesive and reinforcement compositions into a three-dimensional shape.

2 more elements

A process for making multi-reinforcement a three-dimensional preform shape of spatially tailored material compositions, comprising the steps of

creating a geometry of said shape on a computer, said geometry including a plurality of segments defining said shape;
each of said segments being coded with a specific reinforcement composition;
evaluating the geometry data files representing said shape to locate any un-supported feature of the shape, followed by defining a support structure for the un-supported feature and creating a plurality of segments defining said support structure;
generating program signals corresponding to each of said segments for both said preform shape and said support structure in a predetermined sequence;
providing a material deposition device capable of (a) dispensing a liquid adhesive composition, (b) dispensing, for each spatial location, a selected reinforcement composition for said shape, and (c) dispensing support material for building said support structure;
operating said material deposition device to deposit adhesive, reinforcement and support material compositions onto an object-supporting work surface;
during said deposition step, moving said material deposition device and said work surface in response to said programmed signals relative to each other in a plane defined by first and second directions and in a third direction orthogonal to said plane in a predetermined sequence of movements such that said material compositions are deposited in free space as a plurality of segments sequentially formed so that the last deposited segment overlies at least a portion of the preceding segment in contact therewith to thereby form said support structure and said multi-reinforcement three-dimensional preform shape.

4 more elements

Dependencies are inferred from the claim text.

Apparatus and process for freeform fabrication of composite reinforcement preforms

Life of this patent

Apparatus and process for freeform fabrication of composite reinforcement preforms

Life of this patent

Abstract

Claims29