JP6475232B2 - 繊維強化付加製造方法 - Google Patents
繊維強化付加製造方法 Download PDFInfo
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- JP6475232B2 JP6475232B2 JP2016518010A JP2016518010A JP6475232B2 JP 6475232 B2 JP6475232 B2 JP 6475232B2 JP 2016518010 A JP2016518010 A JP 2016518010A JP 2016518010 A JP2016518010 A JP 2016518010A JP 6475232 B2 JP6475232 B2 JP 6475232B2
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- filament
- fiber
- reinforced composite
- fiber reinforced
- matrix material
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- B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
- B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
- B29C70/523—Pultrusion, i.e. forming and compressing by continuously pulling through a die and impregnating the reinforcement in the die
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
- B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
- B29C70/525—Component parts, details or accessories; Auxiliary operations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
- B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
- B29C70/525—Component parts, details or accessories; Auxiliary operations
- B29C70/528—Heating or cooling
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y70/00—Materials specially adapted for additive manufacturing
- B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2025/00—Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
- B29K2025/04—Polymers of styrene
- B29K2025/08—Copolymers of styrene, e.g. AS or SAN, i.e. acrylonitrile styrene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2063/00—Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2071/00—Use of polyethers, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2077/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2079/00—Use of polymers having nitrogen, with or without oxygen or carbon only, in the main chain, not provided for in groups B29K2061/00 - B29K2077/00, as moulding material
- B29K2079/08—PI, i.e. polyimides or derivatives thereof
- B29K2079/085—Thermoplastic polyimides, e.g. polyesterimides, PEI, i.e. polyetherimides, or polyamideimides; Derivatives thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3076—Aircrafts
- B29L2031/3085—Wings
Landscapes
- Engineering & Computer Science (AREA)
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- Robotics (AREA)
- Textile Engineering (AREA)
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- Extrusion Moulding Of Plastics Or The Like (AREA)
Description
本出願は、米国特許法第119条(e)項に基づき、2013年6月5日付けの米国仮出願第61/831,600号、2013年7月17日付けの米国仮出願第61/847,113号、2013年9月15日付けの米国仮出願第61/878,029号、2013年9月24日付けの米国仮出願第61/881,946号、及び2013年11月10日付けの米国仮出願第61/902,256号の利益を主張し、それらの開示全体を参照により本明細書に組み込む。
Claims (19)
- フィラメントのマトリックス材料内を延在する少なくとも一つの軸方向繊維ストランドを含む、未溶融の繊維強化複合フィラメントを供給するステップと、
前記繊維強化複合フィラメントをある供給速度で供給するステップと、
前記マトリックス材料を前記フィラメント内で介在的に溶融するため、前記マトリックス材料の溶融温度よりも高い温度まで横方向圧力区域で前記繊維強化複合フィラメントを加熱するステップと、
前記繊維強化複合フィラメントが結合配列で部分に堆積される際に、しごき加工リップを用いて前記しごき加工リップの底部からその下の前記部分の頂部までの高さが前記繊維強化複合フィラメントの直径未満であることを確保することで前記繊維強化複合フィラメントを前記部分に堆積する方向に押圧して前記繊維強化複合フィラメントの前記溶融したマトリックス材料及び前記少なくとも一つの軸方向繊維ストランドにしごき力を加えるステップと、
結合配列を前記部分から分離するのに必要な張力よりも低い中立から正の張力を、前記しごき加工リップと前記部分との間にある前記繊維強化複合フィラメント内で維持する印刷速度で、前記部分に隣接した前記しごき加工リップを並進させるステップとを含む、部分を付加製造する方法。 - 未溶融の繊維強化複合フィラメントを供給する前記ステップが、前記マトリックス材料内にエアギャップを実質的に有さない、未溶融の空隙がないフィラメントを供給するステップを含み、前記繊維強化複合フィラメントを供給する前記ステップが、前記繊維強化複合フィラメントの座屈を防ぐ遊びはめ区域に沿って、未溶融の繊維強化複合材を供給するステップを含む、請求項1に記載の方法。
- 前記マトリックス材料が、約10〜100MPaの未溶融最大抗張力及び10MPa未満の溶融最大抗張力を有する熱可塑性樹脂を含み、前記少なくとも一つの軸方向ストランドが、約200〜100000MPaの最大抗張力を有するストランド材料を含む、請求項1に記載の方法。
- 前記繊維強化複合フィラメントを非接触区域内で加熱するステップと、主に前記フィラメントに沿って延在する前記少なくとも一つの軸方向繊維ストランド内の張力によって、前記しごき加工リップと前記部分との間で前記繊維強化複合フィラメントの前記中立から正の張力を維持するため、前記供給速度及び前記印刷速度の少なくとも一つを制御するステップとを更に含む、請求項3に記載の方法。
- 遊びはめ区域、前記非接触区域、前記横方向圧力区域内で、結合配列が前記工作物に取り付けられる際に、前記繊維強化複合フィラメントの実質的に一定の断面積を維持するステップを更に含む、請求項1に記載の方法。
- 前記フィラメントが、2.56x10E-5cm2超過及び5.08x10E-3cm2未満の断面積を有する、請求項5に記載の方法。
- 前記少なくとも一つの軸方向ストランドが、任意の断面積中に100〜6000の平行な連続軸方向ストランドを含む、請求項5に記載の方法。
- 前記遊びはめ区域又は前記しごき加工リップの一方で若しくは一方に隣接して、前記繊維強化複合フィラメントを切断するステップを更に含む、請求項1に記載の方法。
- 前記横方向圧力区域の前記繊維強化複合フィラメントを前記部分の第1の部分に対する接続から引き離すステップと、
自由空間を通して前記横方向圧力区域を並進させるステップと、
前記繊維強化複合フィラメントを前記部分の第2の部分に再接続するためにしごき加工するステップとを更に含む、請求項1に記載の方法。 - マトリックス材料内にエアギャップを実質的に有さない、フィラメントの前記マトリックス材料内を延在する少なくとも一つの軸方向繊維ストランドを含む、未溶融の空隙がない繊維強化複合フィラメントを供給するステップと、
前記未溶融の繊維強化複合材を、前記繊維強化複合フィラメントの座屈を防ぐ遊びはめ区域に沿って、ある供給速度で供給するステップと、
前記繊維強化複合フィラメントを、横方向圧力区域で部分に接触するように挿通するステップと、
前記繊維強化複合フィラメントの端部を溶融位置に至らせるように、前記横方向圧力区域を前記部分に対してかつそれに隣接して印刷速度で並進させるステップと、
前記溶融位置で前記マトリックス材料を前記フィラメント内で介在的に溶融するステップとを含む、
部分を付加製造する方法であり、
前記溶融するステップが、前記繊維強化複合フィラメントが結合配列で前記部分に押圧される際に、前記マトリックス材料の前記溶融温度よりも高い温度まで加熱したしごき加工リップを用いて前記しごき加工リップの底部からその下の前記部分の頂部までの高さが前記繊維強化複合フィラメントの直径未満であることを確保することで前記繊維強化複合フィラメントを前記部分に堆積する方向に押圧して前記繊維強化複合フィラメントの前記溶融したマトリックス材料及び前記少なくとも一つの軸方向繊維ストランドにしごき力を加えることによって、前記繊維強化複合フィラメントの前記溶融したマトリックス材料及び前記少なくとも一つの軸方向繊維ストランドをしごき加工するステップを更に含み、
前記横方向圧力区域を並進させる前記ステップが、結合配列を前記部分から分離するのに必要な張力よりも低い中立から正の張力を、前記しごき加工リップと前記結合配列との間にある前記繊維強化複合フィラメント内で維持する印刷速度で、前記しごき加工リップを並進させる、方法。 - 前記部分の頂部からの前記しごき加工リップの高さを、前記フィラメントの直径未満であるように制御するステップを更に含む、請求項10に記載の方法。
- 前記マトリックス材料が、約0.1〜5GPaの未溶融弾性係数及び0.1GPa未満の溶融弾性係数を有する熱可塑性樹脂を含み、前記少なくとも一つの軸方向繊維ストランドが、約5〜1000GPaの弾性係数を有するストランド材料を含む、請求項10に記載の方法。
- 前記繊維強化複合材を前記しごき加工の直ぐ上流の非接触区域内で加熱するステップと、主に前記フィラメントに沿って延在する前記少なくとも一つの軸方向繊維ストランド内の軸方向圧縮力を介して、前記非接触区域内の前記フィラメントに沿って圧縮を誘発するように、前記供給速度及び前記印刷速度の少なくとも一方を制御するステップとを更に含む、請求項10に記載の方法。
- 前記繊維強化複合フィラメントを圧縮し、熱及び圧力を加えることによってしごき加工されるしごき加工リップの横方向下方で前記部分に当接する前記フィラメントの端部を並進させるように、前記供給速度及び前記印刷速度の少なくとも一方を制御するステップを更に含む、請求項13に記載の方法。
- 前記遊びはめ区域が、前記繊維強化複合フィラメントの周りに遊びはめを形成する少なくとも一つのチャネルを含み、前記繊維強化複合材が、前記少なくとも一つのチャネル全体を通して前記マトリックス材料のガラス遷移温度よりも低い温度で維持される、請求項14に記載の方法。
- 前記遊びはめ区域で又はそれに隣接して前記未溶融繊維強化フィラメントを切断するステップを更に含む、請求項10に記載の方法。
- 前記非接触区域を画成するキャビティの加熱された壁に前記フィラメントが触れるのを防ぐステップを更に含む、請求項10に記載の方法。
- 前記横方向圧力区域内の加熱されたしごき加工リップに前記フィラメントを触れさせて、前記フィラメントの前記マトリックス材料を溶融するステップを更に含む、請求項10に記載の方法。
- 前記溶融したマトリックス材料及び前記少なくとも一つの軸方向繊維ストランドを前記横方向圧力区域の前記部分内へと押圧して、横方向及び垂直方向の結合配列を形成するステップと、
前記しごき加工リップを用いて前記溶融したマトリックス材料及び前記少なくとも一つの軸方向繊維ストランドにしごき力を加え、前記部分自体からの垂直反力として、前記溶融したマトリックス材料及び前記少なくとも一つの軸方向繊維ストランドに反対方向の整形力を加えることによって、少なくとも二つの側面で前記結合配列を扁平にするステップとを更に含む、請求項10に記載の方法。
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US61/847,113 | 2013-07-17 | ||
US201361878029P | 2013-09-15 | 2013-09-15 | |
US61/878,029 | 2013-09-15 | ||
US201361881946P | 2013-09-24 | 2013-09-24 | |
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US201361902256P | 2013-11-10 | 2013-11-10 | |
US61/902,256 | 2013-11-10 | ||
US14/222,318 | 2014-03-21 | ||
US14/222,318 US20140291886A1 (en) | 2013-03-22 | 2014-03-21 | Three dimensional printing |
PCT/US2014/041161 WO2014197732A2 (en) | 2013-06-05 | 2014-06-05 | Methods for fiber reinforced additive manufacturing |
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US20140232035A1 (en) * | 2013-02-19 | 2014-08-21 | Hemant Bheda | Reinforced fused-deposition modeling |
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