WO2005061208A1 - Methods and systems for manufacturing a structure having organized areas - Google Patents
Methods and systems for manufacturing a structure having organized areas Download PDFInfo
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- WO2005061208A1 WO2005061208A1 PCT/US2004/042291 US2004042291W WO2005061208A1 WO 2005061208 A1 WO2005061208 A1 WO 2005061208A1 US 2004042291 W US2004042291 W US 2004042291W WO 2005061208 A1 WO2005061208 A1 WO 2005061208A1
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- preform
- beads
- stress
- steering
- matrix material
- Prior art date
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Classifications
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- 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
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
- B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
- B29B15/10—Coating or impregnating independently of the moulding or shaping step
- B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
- B29B15/122—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
- B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
- B29B15/10—Coating or impregnating independently of the moulding or shaping step
- B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
- B29B15/14—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length of filaments or wires
-
- 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
- B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
- B29C67/20—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for porous or cellular articles, e.g. of foam plastics, coarse-pored
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- 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
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
- B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
-
- 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
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/688—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks the inserts being meshes or lattices
Definitions
- the present invention relates to the design and manufacture of materials, and more particularly to a preform component used to generate voids, pores, or cavities in any material especially engineered materials.
- This invention relates in general to the ability to establish a plurality of organized voids in a material, and also to load bearing structures and structures that provide an enhanced trade-off between the stress that can be safely carried in relation to the amount of material required for the structure.
- voids have been created in materials using a number of existing foaming techniques. These foaming techniques produce materials having voids which are unorganized; i.e., the voids are randomly positioned as well as randomly placed. Moreover, a number of the voids in these materials are not enclosed - they are interconnected with adjacent voids.
- existing processes cannot produce materials having enclosed voids and/or voids in a truly organized position within a material.
- the present invention provides methods and apparatuses for creating organized vorasity (voids positioned in a predetermined arrangement) in any material.
- the voids created using these novel methods and apparatus may be of any size, shape, and spacing, and may also be interconnected or each may be entirely enclosed.
- the spacing of the voids in a particular material may be symmetrical and/or asymmetrical to attain a desired material characteristic.
- the voids must be arranged in a particular symmetrical arrangement.
- materials with predetermined morphologies that incorporate voids including the patented stress-steering materials that utilize a plurality of symmetrically arrayed, uniform voids to resolve forces imposed on a structure primarily into a compressive rather than tensile stress, may be manufactured using the unique and novel components and methods according to the present invention.
- the preforms, examples of voided structures, as well as the manufacturing apparatuses and methods according to the present invention are also disclosed in a corresponding provisional application, No. 60/291,904, filed May 17, 2001. entitled, "Preform For Manufacturing A Material Having A Plurality of Voids And Method Of Making The Same", the entire disclosure of which is incorporated herein by reference.
- voids are incorporated into a material through the use of either a preform material component or texturizing, or a combination of the two.
- the voids may be created in a material using known manufacturing methods.
- a beaded preform for forming a plurality of voids in an engineered material includes a plurality of adjacently positioned beads.
- a method for manufacturing a beaded preform for forming a plurality of voids in a engineered material includes extruding a preform material out a first opening to produce ar extruded preform material and calendaring the extruded preform material to form a plurality of adjacently positioned beads thereon.
- a method for manufacturing a coated, beaded preform for forming a plurality of voids in an engineered material includes providing a first flow of an extruding coating material to die, providing a beaded preform within the first flow, where the beaded preform is coated with the coating material, and extruding the first flow with the beaded preform from an opening to form a tow.
- a method for producing an engineered material having a plurality of voids includes guiding a plurality of beaded preforms into a supply of a first material, coating the plurality of beaded preforms with the first material, shaping the coated preforms into a predetermined form and consolidating the form.
- a method for producing an engineered structure comprised of a plurality of organized voids using a continuous casting apparatus includes guiding a beaded preform comprising a plurality of adjacently positioned beads into a matrix material, the material matrix held in a first container, guiding the matrix material into a space having a predetermined distance, whereby a product is foraied having a predetermined thickness substantially equal to the distance.
- a method for forming a composite having a plurality of organized voids arranged therein includes imparting a first array of first voids upon a first laminate, whereby openings to the first voids are formed on a first side of the first laminate, and assembling the first laminate with a second laminate.
- a laminate for assembly into a composite material includes a texture comprising a plurality of recesses on a first side, where the recesses correspond to a plurality of projections on a second side of the laminate.
- a method of manufacturing an engineered material having a plurality of organized voids includes guiding a beaded preform comprising a plurality of spaced apart beads within a continuous cast of molten material.
- a method of manufacturing an engineered material having a plurality of organized voids includes providing a beaded preform comprising a strand of adjacently positioned beads into any one of the following manufacturing processes: [0027] additive manufacturing, atomistic manufacturing, layered manufacturing including fused deposition modeling, stereo-lithography, optical fabrication, solid base (ground) curing, plasma spray forming, sputtering, vapor deposition, [0028] deformation and forming including bulk deformation processes including impression-die forging, open-die forging, coining, piercing, hubbing, fullering and edging, roll forging, ring rolling, direct extrusion, indirect extrusion, hydrostatic extrusion and impact extrusion, [00
- FIG. 1 illustrates a first, closed cell architecture of a stress steering structure created by preforms according to the present invention, in which all of the figurative TRDs have a void at their respective centers.
- FIG. 2 illustrates a second, open-cell architecture of a stress steering structure created by preforms according to the present invention, in which every other figurative TRD is removed.
- FIG. 3 illustrates a third, combination, open-cell, closed cell architecture of a stress steering structure created by preforms according to the present invention, in which figurative TRDs have a void at their respective centers.
- FIG. 1 illustrates a first, closed cell architecture of a stress steering structure created by preforms according to the present invention, in which all of the figurative TRDs have a void at their respective centers.
- FIG. 2 illustrates a second, open-cell architecture of a stress steering structure created by preforms according to the present invention, in which every other figurative TRD is removed.
- FIG. 3 illustrates a
- FIG. 4 illustrates a fourth, combination, open-cell, closed cell architecture of a stress steering structure created by preforms according to the present invention, in which figurative TRDs have a void at their respective centers.
- FIG. 5 A illustrates a string of pearls which resemble a preform according to the present invention.
- FIG. 5B illustrates a schematic view of a beaded filament preform according to a first embodiment of the present invention.
- FIG. 6 A illustrates a schematic view of the beaded filament preform according to the first embodiment of the present invention, having a single sized bead positioned at a first spacing.
- FIG. 5 A illustrates a string of pearls which resemble a preform according to the present invention.
- FIG. 5B illustrates a schematic view of a beaded filament preform according to a first embodiment of the present invention.
- FIG. 6 A illustrates a schematic view of the beaded filament preform according to the first embodiment of the present invention, having a single sized bead
- FIG. 6B illustrates a schematic view of the beaded filament preform according to the first embodiment of the present invention, having a larger sized bead interspaced between a smaller sized bead.
- FIG. 6C illustrates a schematic view of the beaded filament preform according to the first embodiment, having a larger sized bead interspaced between a smaller sized bead, and positioned adjacent thereto.
- FIG. 7 A illustrates a schematic view of the beaded filament preform according to the first embodiment of the present invention, where filaments are horizontally arranged in a grouping typical of a laminate material.
- FIG. 7B illustrates a schematic view of the beaded filament preform according to the first embodiment of the present invention, where filaments are diagonally arranged in a grouping typical of a laminate material.
- FIG. 7C illustrates a schematic view of the beaded filament preform according to the first embodiment of the present invention, where filaments are horizontally arranged in a grouping typical of a laminate material, and where two different sized beads are used.
- FIG. 7D illustrates a schematic view of the beaded filament preform according to the first embodiment of the present invention, similar to FIG. 7C, except the filaments are diagonally arranged.
- FIG. 7C illustrates a schematic view of the beaded filament preform according to the first embodiment of the present invention, where filaments are diagonally arranged.
- FIG. 8 illustrates a schematic view of the beaded filament preform according to the first embodiment of the present invention, illustrating beads of a filament prior to processing within a material having an oblong shape so that a properly shaped spherical void will be formed as a result.
- FIG. 9 illustrates a cross-sectional view of an engineered material manufactured by assembling together a plurality of filaments according to the first embodiment of the present invention.
- FIG. 10 illustrates a cross-sectional view of another engineered material manufactured by assembling together a plurality of filaments according to the first embodiment of the present invention.
- FIG. 11 A illustrates a cylindrical tow using a filament preform according to the first embodiment of the present invention.
- FIG. 11 A illustrates a cylindrical tow using a filament preform according to the first embodiment of the present invention.
- FIG. 12A illustrates a laminate manufactured by assembling a plurality of tows as illustrated in FIG. 11 A.
- FIG. 12B illustrates a laminate manufactured by assembling a plurality of tows as illustrated in FIG. 1 IB.
- FIG. 13A illustrates a plurality of tows, as shown in FIG. 11 A, assembled to form a fabric.
- FIG. 13B illustrates a plurality of tows, as shown in FIG. 1 IB, assembled to form a fabric.
- FIG. 12A illustrates a laminate manufactured by assembling a plurality of tows as illustrated in FIG. 11 A.
- FIG. 13B illustrates a plurality of tows, as shown in FIG. 1 IB, assembled to form a fabric.
- FIG. 13C illustrates a plurality of tows and laminates assembled together to form a fabric.
- FIG. 13D illustrates a plurality of laminates.
- FIG. 14 illustrates beaded filaments and mats aligned for processing to form a laminate/fabric.
- FIG. 15 illustrates an first extrusion spinning process for manufacturing the beaded filament preform according to the present invention.
- FIG. 16 illustrates a second extrusion process for manufacturing the beaded filament preform according to the present invention.
- FIG. 17 illustrates a first extrusion process for manufacturing the beaded mat preform according to the present invention.
- FIG. 18 illustrates a second extrusion process for manufacturing the beaded mat preform according to the present invention.
- FIG. 19 illustrates a first extrusion process for manufacturing a tow according to the present invention.
- FIG. 20 illustrates a second extrusion process for manufacturing a tow according to the present invention.
- FIG. 21 illustrates a first extrusion process for manufacturing a laminate with the preform mat according to the present invention.
- FIG. 22 illustrates a second extrusion process for manufacturing a laminate with the preform mat according to the present invention.
- FIG. 23 illustrates a preform according to the present invention used to produce a material using a continuous casting process.
- FIGS. 24-25 illustrate a preform according to the present invention used to produce a laminate or fabric using a pultrusion process.
- FIGS. 26 illustrates a texturized material according to a second embodiment of the present invention with a first organization of dimples.
- FIG. 27 illustrates a texturized material according to a second embodiment of the present invention with a second organization of dimples.
- FIG. 28 illustrates a texturized material according to a second embodiment of the present invention with a third organization of dimples.
- FIG. 29 illustrates various structures capable of being manufactured using the preform materials according to the first and second embodiments of the present invention.
- FIG. 30 illustrates a process diagram for acrylic manufacture.
- FIG. 31 illustrates a beaded filament and a beaded mat.
- FIG. 32 illustrates aggregates of beaded filaments serving as preforms to the voids formed with an entire product.
- FIG. 33 illustrates the different grades of carbon fiber.
- FIG. 34 illustrates the processing sequence for PAN and mesophase-pitch- based beaded filaments.
- FIG. 35 illustrates a manufacturing process of PAN-based beaded filaments.
- a beaded preform according to the present invention is a precursor component for incorporation into a material to form predetermined symmetrical or asymmetrical positioned or otherwise organized voids, or pores, to establish, for example, a material having organized vorasity.
- An example of such a material is a stress steering structure for resolving imposed loads primarily into compressive stress. Two-dimensional cross-sections of such three-dimensional stress steering structures are shown in FIGS. 1-4.
- the preforms may be sacrificial (i.e., preliminary), permanent, or a combination thereof.
- the bead material which forms the voids is eliminated at some point after incorporation into the base material, generally during further processing.
- the bead material remains in the voids, although it may be altered or reformed in some way during processing.
- the beads of the preforms may be of any shape and size required to produce a desired engineered material, and may be hollow or solid, and any combination thereof. Generally, the beads are shaped such that they will produce a void having a particular void volume and/or shape after processing.
- the beaded preforms are preferably made in one of two basic forms: filaments and mats, either of which may be rigid or flexible.
- a filament 2 preform according to the present invention is similar to a strand of beads (FIG. 5 A) and comprises a strand 4 of spaced apart beads 6 (FIG. 5B).
- the spacing may be asymmetrical, but is generally organized and/or symmetrical, with a pattern of predetermined distances.
- the beads may be equally sized, randomly sized, or (also) a repeating pattern of particularly shaped beads as shown in FIGS. 6A-6C.
- Mats 8 are two-dimensional arrays of assembled filaments 2 as shown in FIGS.
- FIG. 8 illustrates a beaded filament having oblong shaped beads.
- the beads are formed in such shapes so that when incorporated into a particular material, the voids, and thus the beads themselves if permanent, end up having a spherical shape after processing.
- Such processing which benefits from these types of filaments may be a casting process, where high temperatures and/or compression rolling effect the shape of the preform, and thus, the shape of the void created whether or not the preform is sacrificial or not.
- Mats and filaments may be assembled to form a fabric, resulting in, for example, material cross-sections illustrated in FIGS. 9-10 having voids 12 and 14 (FIG. 9) and voids 16 (FIG. 10). As shown in FIG. 14, such a fabric laminate may include alternating layers of mats 8 and filaments 2 with a surface material 11 covering the top and bottom.
- Tows 18 (FIGS. 11 A- 1 IB) are formed by coating a filament 2, generally, with a type of matrix material (e.g., thermosetting resin) 3.
- laminates 20 are generally formed by coating a mat with a matrix material, or may be manufactured by assembling a plurality of tows 2 (FIGS.
- Tows and laminates, as well as filaments and mats, may also include cutting and positioning guides (e.g., recesses, protrusions), so that they may be easily cut, arranged and assembled for a particular application in intermediate and final product materials.
- Intermediate and final products may be manufactured from composites 22 of tows and laminates (FIGS. 13A-13D, and 14). For example, one way a composite fabric may be made is by weaving, knitting, and otherwise assembling together a plurality of tows, a plurality of laminates, or a combination thereof.
- Composites, including fabrics, may be continuous (e.g., tapes) and discontinuous and may be manufactured for both intermediate materials and finished products. For example, composites may be manufactured into slabs, blooms, billets, panels, boards, and sheets (see FIG. 29).
- the void pattern of material e.g., a stress steering structure
- the structure and material of the beads and coatings may be comprised of stress steering structures (i.e., voided structures) such that, the advantages of the stress steering structures are now captured at three levels.
- a void created by a preform component may be used to house devices for intelligent materials for use in intelligent structures.
- sensors, actuators, MEMS, and other devices may be incorporated within a void of a structural element of a bridge, or a wing of an aircraft, for example, to supply information regarding the performance of the element/bridge or to induce an internal force on the structure to change its shape or change a characteristic of the element (e.g., change the shape of the wing of an aircraft to create more lift).
- the device may be used in place of one or more of the beads in a filament or mat or incorporated in one or more of the beads.
- FIGS. 15-18 Applicant has provided a comprehensive list of manufacturing processes which may be used to manufacture the preforms according to the present invention, examples of which are illustrated in FIGS. 15-18. These include various casting, deformation, and forming processes for metals; blow molding, compression molding (cold/hot), transfer molding, cold molding, injection molding, reaction injection molding, thermoforming, rotational molding, and foam molding for plastics; pressure casting, slip casting, isostatic pressing, plasma spray forming, roll pressing, injection molding, and gelcasting for ceramics; and infiltration casting, filament winding, and isostatic pressing for composites. [0097] One example of producing the novel preforms according to the present invention is shown in FIG. 15 and is described as follows. [0098] Filaments: As shown in FIGS.
- filaments may be produced by a spinning process 31, in which extruded material is forced through a die 32 (spinneret) containing many small holes 34. The beads are added thereafter by shape rolling 36, or preferably by inline drawing 38 and calendaring operations on the filaments with embossed rollers 40. Drawing thins the filaments thereby increasing their tensile strength in anticipation of further processing. The finished filaments are gathered on a take up spool 39. Filaments may also be produced by using rotary extrusion as shown in FIG. 16. [0099] Mats: Mats generally begin as extruded tape castings with beading added inline by calendaring with embossed rollers (as preferably done with filaments) as shown in FIGS. 17-18.
- Tows generally begin as beaded filaments and are generally formed inline in an extruding operation, for example, by coating filaments with an extruded matrix material as shown in FIGS.
- Laminates generally begin as mats (or filaments/tows) and are generally formed inline in extruding operations as shown in FIGS. 21-22, for example, by coating mats with an extruded matrix material.
- the coating material may also contain reinforcement material and may also be another form of composite.
- the coating material may also be applied in multiple layers, be functionally graded material, and be organized in a hierarchical structure.
- unconsolidated laminates may be superimposed and fused or otherwise bonded to form composites, other preforms, and structures such as fabrics. These combinations may be formed mechanically via inter-laminate connectors or mechanical fasteners (e.g., snap fits or tongues and grooves), or may be bonded via an adhesive, fusion bonding and welding (e.g., ultrasonic, microwave, rf welding, induction). It is worth noting that during the bonding process, sacrificial preforms are generally eliminated.
- Plastic-matrix preform laminates may be melted slightly on their surfaces to achieve consolidation. In addition to being heated, superimposed metal-matrix preform laminates may be subjected to compression rolling to enhance consolidation as well as the quality of the final product.
- Laminates and fabrics according to the present invention may be manufactured using the filaments and mats in, for example, a pultrusion process as shown in FIG. 24, a continuous casting process as shown in FIG. 23, and a continuous extrusion process as shown in FIG. 25. [00105] Accordingly, all of the aforementioned processes to manufacture the preforms according to the present invention may be continuous or batch processes and may be automated to produce continuous or discontinuous preforms of high quality and uniformity.
- An embodiment of the invention relates to a preform for forming a plurality of organized voids in a matrix material, the preform comprising a two-dimensional array of a plurality of beads, wherein at least a subset of the plurality of beads include a first center-to-center distance along a first axis and a second center-to-center distance along a second axis, wherein the beads are provided on a filament in at least one dimension, and wherein the beads have a bead material comprising polyacrylonitrile, carbon fiber, graphite, or combinations thereof.
- Preferred embodiments relating to the preform are as described above.
- Another embodiment of the invention relates to a preform for forming a plurality of organized areas in a matrix material to form a stress-steering structure, the preform comprising a two-dimensional array of a plurality of beads, wherein (a) the beads include a bead material which is less stiff relative to the matrix material, allowing the stress steering structure to operate in a stress-steering manner; (b) at least a subset of the plurality of beads include a first center-to-center distance along a first axis and a second center-to-center distance along a second axis, wherein the beads are provided on a filament in at least one dimension; and (c) the bead material is polyacrylonitrile, carbon fiber, graphite, or a combination thereof.
- a stress-steering material comprising a preform for forming a plurality of organized voids in a matrix material, the preform comprising a two-dimensional array of a plurality of beads, wherein at least a subset of the plurality of beads include a first center-to-center distance along a first axis and a second center-to-center distance along a second axis, wherein the beads are provided on a filament in at least one dimension, and wherein the beads have a bead material comprising polyacrylonitrile, carbon fiber, graphite, or combinations thereof.
- the bead material or beaded filament may include carbon-based materials, including polyacrylonitrile, carbon fiber, and graphite. Carbon-based materials may be used to form the bead materials and beaded filaments of the preforms, which may be used to establish the organized voids in nearly any matrix material in nearly any manufacturing technology. To maximize the stress-steering properties of the resulting engineered material, cohesion between the bead/filament material and the matrix material is preferably minimized and most preferably eliminated. While cohesion is minimized or eliminated, the bead/filament material may still contact the matrix material.
- PAN Polyacrylonitrile
- PAN which is made from the acrylonitrile monomer, is used principally for making fibers. When made into a fiber, PAN is called acrylic and is characterized by its softness and ease of coloring. The fiber may be used in a variety of products, such as sweaters and carpets. [00111] PAN is also a precursor material to carbon fiber and graphite materials.
- Carbon fiber is produced from PAN by first oxidizing the PAN material. As known by those of skill in the art, this may be performed by heating the PAN for a sufficient period of time to a temperature ranging from about 250° C to about 300° C in an atmosphere of air. This process evolves hydrogen from the material and adds less volatile oxygen. Oxidation converts PAN from a thermoplastic to a thermoset. [00112] Typically, oxidized PAN has a carbon level in the range of 60-65%.
- the PAN polymer changes from a ladder structure to a stable ring structure, and the fiber changes color from white to brown to black.
- the PAN becomes inflammable (fireproof) and thermally stabilized (or oxygen stabilized).
- the preform exhibits at least some of the properties of the beaded material or beaded filament.
- the preform becomes insusceptible to burning, melting, softening, and/or dripping.
- Subjecting the oxidized PAN to temperatures above 300° C induces progressive partial carbonization of the oxidized PAN, up to a temperature of about 3000° C, when the oxidized PAN is fully evolved to nearly 100% carbon.
- the oxidized PAN may be heated for a second period of time to a temperature ranging from 300° C to about 3000° C, preferably from about 1000° C to about 2500° C. Raising the temperature above 2500° C creates the possibility of graphite formation.
- the temperature used to treat the oxidized PAN will depend on whether the PAN contains additional chemical components as well as on the properties desired in the resulting material.
- the carbonization process should take place in an inert atmosphere, for example, a carbon gas atmosphere.
- the second heating process creates carbon chains generally characterized as long and wide.
- the carbon chain material is considered a carbon fiber material, and exhibits properties attributable to carbon-based materials that have been exposed to carbonization temperatures.
- the resulting carbon fiber may be subjected to surface treatments, sizing treatments, or other treatments known to those of skill in the art to obtain additional or custom properties of the carbon fiber.
- Graphite may be produced by heating the carbon fibers to a temperature at least about 200° C above the carbonization temperature. Graphitization should occur no later than when the temperature exceeds 2500° C. Graphite is softer than carbon fiber and relatively weak because of the crystalline order of the material and closer spacing between the monoplanes and stacks of molecules. As is known to those in the art, the graphite structure can be compared to a deck of cards with individual layers able to easily slide off the deck.
- the melting point of the matrix material makes certain bead material or beaded filament preferential for use with certain matrix materials.
- the preferences lie in the ease of forming a preform containing both the bead material or beaded filament and the matrix material. For instance, if the matrix material has a melt temperature below about 300° C, which is the case for most plastics, oxidized PAN or carbon fiber is preferably used as the bead material or beaded filament in the preform. If the matrix material has a melt temperature above 300° C, carbonized PAN or graphite is preferably used as the bead material or beaded filament material in the preform.
- preforms made of oxidized PAN, carbon fiber, or graphite may be used with all matrix materials, regardless of the melting point of the matrix material.
- the degree of carbonization can be tuned to the melt temperatures of respective matrix materials and preforms and the manufacturing environment in which the products and structures are produced. During the manufacturing of the beaded filaments, the bead material and beaded filaments tend to shrink — at times up to about 50% by weight — as a function of temperature during pyrolysis, i.e., the progressive oxidation-carbonization- graphitization process.
- Longitudinal shrinkage may be restrained by putting the beaded filaments in tension, as is done, for example, by utilizing a stretching procedure during stabilization.
- shrinkage may be accommodated by design, i.e., the physical and chemical parameters of the beaded filaments prior to pyrolysis.
- design i.e., the physical and chemical parameters of the beaded filaments prior to pyrolysis.
- a combination of both design and induced tension are used to restrain longitudinal shrinkage.
- Beaded materials or beaded filaments made with PAN, carbon fibers, or graphite are generally lightweight, having specific densities ranging from about 1.4 g/cc to about 1.8 g/cc.
- the beaded materials and filaments also exhibit high strength and high modulus properties; good chemically stability; strong resistance to acids, bases, and solvents; small coefficients of linear expansion; good dimensional stability; and strong conductivity. Additionally, the inertness of the beaded materials or filaments makes them suitable for various medical applications, e.g., hip and knee replacements, as well as other medical uses known to those of skill in the art. [00120] While the above methods of producing oxidized and carbonized PAN are the preferred methods, it should be noted that oxidized and carbonized beaded material or filaments can be made from almost anything that yields a quality char upon pyrolysis, i.e., decomposition by heating.
- the starting material should contain enough carbon so that the resultant bead material or filament is both physically and economically attractive.
- spinning involves forming the precursor material (e.g., PAN precursor) into a filament using variants of standard textile fiber manufacturing processes.
- Stabilization includes stretching the starting precursor (e.g., via a continuous tow) and shaping it during solidification by adding beads in a predetermined format via calendaring or other means to create the beads.
- the stabilization step may include a stretching step that helps develop the highly oriented molecular structure that makes the precursor stronger and more robust for subsequent treatment and use in the preform products and structures.
- Particular configurations e.g., specific bead sizes and spacing, may also be formulated. See Figure 35. Oxidation and carbonization have been discussed above.
- Application of a sizing or a variety of sizings, or coatings, depending on the application to the beaded material or beaded filament is the final step before spooling.
- the primary purpose of the application step is to (a) preclude bonding of the bead or filaments with the respective matrix materials, (b) preclude absorption of the respective matrix materials by the beads during the product manufacture, and (c) minimize damage during handling.
- Filaments, mats, tows, laminates, and fabrics according to the present invention may be used to create materials, including stress steering materials, in a variety of additional manufacturing processes. For convenience, Applicant has provided the following list of manufacturing processes in which preforms according to the present invention may be used.
- Additive Manufacturing atomistic manufacturing; layered manufacturing including fused deposition modeling, stereo- litography, optical fabrication, solid base (Ground) curing, plasma spray forming, sputtering, vapor deposition;
- Deformation and forming bulk deformation processes including impression-die forging, open-die forging, coining, piercing, hubbing, fullering and edging, roll forging, ring rolling, direct extrusion, indirect extrusion, hydrostatic extrusion and impact extrusion; sheet metal forming processes including shearing, bulging, rubber forming, high-energy-rate forming, superplastic forming, deep drawing, embossing; material removal including cutting, grinding, electrical discharge machining, water-jet machining, abrasive-jet machining, chemical machining and electrochemical machining and grinding; [00125] Casting: permanent molds including slush casting, pressure casting, insert molding, centrifugal casting and infiltration casting; expendable molds including vacuum casting
- the preforms according to the present invention are ideally suited for producing engineered materials using a continuous material manufacturing process, i.e., continuous (preform) casting and continuous extrusion manufacturing processes.
- Continuous preform casting utilizes two long established manufacturing processes used for casting a continuous tape of material—pultrusion and continuous casting.
- these manufacturing processes produce materials having a constant cross-section with shapes including round, rectangular, tabular, plate, sheet, and structural products.
- the processes are modified to include preform fixtures for channeling filaments and/or mats into proper alignment with a matrix material (and optional continuous, reinforcement such as fibers).
- the fixtures may also be used to contour the preform/matrix combination.
- the production flow in continuous preform casting may be uninterrupted from the introduction of the preforms into a molten material to the output of engineered products.
- the initial feedstock is a fluid (or a melt): molten metals, mononler solutions, slips, and slurries.
- Post casting processes vary depending on the choice of the matrix material, with ceramics being sintered and metals being generally rolled.
- the use of graphite as the bead material in preforms is well suited to establish stress-steering architectures in continuous casting processes for high-temperature matrix materials, such as aluminum, steel, cast iron, and titanium, as well as other metals and metal alloys.
- the matrix material may also be a plastic, a ceramic, or other metal and non- metal materials known to those of skill in the art. Relative to the matrix material, graphite is a softer material that results in a final product operating in a better stress-steering manner. PAN and carbon fiber material may also be used as the bead material for preforms to produce steer-steering materials with improved properties.
- the following is an example of a continuous casting process. In the continuous casting process, for example, as illustrated in FIG. 23, a continuous mat 8 (and/or filament) is fed into a tundish 60 of a casting apparatus 57 where molten material 59 and the mat flow out of the tundish through a water-cooled, continuous mold 62.
- the mold generally determines the thickness and/or profile of the resulting material, but not the length, and may be positioned vertically, horizontally or at another angle, depending on the desired material flow.
- the mat/material composition flows down a discharge rack 63 and is cooled.
- the cast can be further processed into final form, through various inline applications of heat and mechanical force (e.g., pinch rolling 64, reheating 66) to give it the desired shape, size, physical properties, and surface qualities.
- inline applications include pinch rolling, reheating/cooling, and the like.
- a sizing area 67 sizes the slab of material to a particular size, whereby a cut-off torch 65 (or other cutting device appropriate for the particular cast material) is used to cut the slab into a plurality of pieces.
- a cut-off torch 65 or other cutting device appropriate for the particular cast material
- the size, shape, alignment, and composition of the beaded preforms according to the present invention for inclusion in such a casting process may be structured and organized in anticipation of alterations resulting from the process to achieve the desired array of voids in the final product. To that end, it is preferable that characteristics of the preforms substantially match with the mechanics of the continuous processing process to produce the desired product.
- preforms can be organized for extreme (or bulk) deformation processes, these are equally well suited for near net shape casting, or thin-slab casting, for example.
- metals are known materials which are used in a continuous casting process
- continuous casting of plastics and ceramics can be achieved through a variation of the basic tape casting process.
- a liquid resin material usually acrylic syrup
- the gasket retains the liquid resin and defines the thickness of the tape.
- a similar process may be used to produce metal and ceramic tapes, as well as combination tapes that are a mix or alloy of all three types of basic materials, i.e., metals, plastics, and ceramics.
- Laminates and fabrics according to the present invention may be easily manufactured using this process by using a preform fixture to supplement, or in place of, the gasket.
- Preforms according to the present invention may also be fabricated as expendable patterns in mold casting. A pattern, or copy, in one piece or in sections, of a product to be made by casting is used to establish the shape and dimensions of the mold cavity. While the matrix materials of patterns are expendable, these patterns contain the beaded preforms according to the present invention (that may be either sacrificial or permanent). Among the casting processes that may use expendable preform patterns are lost foam and investment casting as explained below. , [00140] In conventional lost foam casting, the pattern is made of expendable polystyrene (EPS) beads.
- EPS expendable polystyrene
- PS preform slabs may be made by continuous preform casting or continuous extrusion processes using a PS solution as feedstock. The slabs may be formed by introducing a foaming agent into a PS solution, or melt, that then is properly integrated with beaded filaments and/or mats to form a continuous tape.
- the tape may pass between belts or plates with a specific gap between them while the foaming agent expands the tape to fill the gap, fixing the dimensions of the tape.
- This PS continuous tape may be cooled and cut into the slabs.
- the slabs may be partially or fully expanded, depending on the choice of subsequent casting procedures.
- the beaded filaments and/or mats are aligned in the PS solution or melt to reconcile the degree of expansion with the geometry of the void array desired in the final product.
- slabs may be converted into EPS preform patterns in heated molds or dies that burn away excess material from the slabs to conform each one to the shape of the desired pattern.
- a slab can be expanded within a heated mold to conform to the shape of the mold caVity, or an oversized slab can be forged in a heated die to the desired shape.
- pattern shapes may be cut out of the slabs using conventional woodworking equipment and, if necessary, these shapes may be assembled with glue to form the final pattern.
- Squeeze Casting is a combination of casting and forging. In this process, forging means squeezing, or pressing, an unconsolidated feedstock into a predetermined shape. In squeeze casting, casting preform feedstock according to the present invention is placed in the bottom section of a preheated die. A heated upper die then descends, applying pressure throughout the duration of consolidation of the feedstock.
- thermo-mechanical processing of the casting feedstock during squeezing produces a forged microstructure that has enhanced ductility over the original cast microstructure.
- a liquid (or thixotropic material) is forced around a preform pattern(s) in a mold.
- Thixotropic materials eliminate the need to introduce a precise amount of molten metal into the die since chunks of solid matrix material are used and these have been heated into a semi-solid (liquid plus solid) state.
- the thixotropic material Because of the properties of the thixotropic material, it can be handled mechanically, like a solid, but shaped at low pressures because it flows like a liquid when agitated or squeezed.
- An additional advantage of the material is that the absence of a turbulent flow minimizes gas pickup and entrapment.
- solidification shrinkage and related undesirable porosity is reduced. For example, semi-solid metal flows in a viscous manner, allowing thin-cast sections to be filled rapidly without jetting and spraying of liquid metal that would normally occur.
- Pultrusion Although the continuous preform casting process may be used to form intermediate and final products composed of plastics, metals, and ceramics, plastic resins are typically the matrix material used in pultrusion. Pultrusion is a cost-effective automated process for continuous production of composite materials of constant cross-sectional area such as round, rectangular, tabular, plate, sheet, and structural products. Recent innovations, however, have also allowed pultrusion fabrication of composites with varying cross-sectional areas. [00149] Pultrusion may be used to manufacture both laminates and fabrics containing the preforms according to the present invention (FIG. 24). Accordingly, fixtures 73 are provided in a pultrusion system to properly align the preforms with the matrix material consistent with the profile and architecture of the desired product.
- pultrusion as shown in FIGS. 24-25 generally includes a fiber delivery system 69, a resin bath 74, preform fixtures/heated die 76, synchronized pullers 78, and a cut-off device 80 (e.g., torch, saw, and the like).
- a cut-off device 80 e.g., torch, saw, and the like.
- One or more bundles of continuous filaments 2 are guided through delivery fixtures 73 that align the preforms with a matrix material and contour the combination of components into a desired shape.
- the composition may then be pulled through one or more heated dies 76 (fixed or floating) for further shaping, compacting, and solidifying of the matrix material and for eliminating sacrificial filaments, mats, and/or weaves. Thereafter, the fabricated material is cooled and cut to length for further fabrication into intermediate and finished products.
- Continuous Extrusion may be' used in coordination with pultrusion
- laminates may be formed through either post extrusion coating of beaded filaments and mats with a matrix material, or post extrusion addition of texture to a tape.
- the tape may be either texturized with patterns that are applied by (for example) calendaring, or excised through (for example) selective laser burnout.
- Batch processing technologies also may be used to fabricate preforms according to the present invention, as well as engineered intermediate goods and consumer products including those having a stress steering structure.
- Such batch processes include additive manufacturing (AM) and particulate manufacturing technology.
- AM additive manufacturing
- the former is solely a batch process, while the latter may also be a continuous process.
- AM provides the capability to incorporate actual voids, versus void precursors, into fabrics in a one-step process.
- Additive Manufacturing is a family of processes that involve creating 3D objects by automatically placing 2D layers of material on top of each other under computer control. The advantage is that a structure's geometric complexity has little impact on the fabrication process.
- AM processes reproduce preforms layer-by-layer in an uninterrupted sequence.
- a fabric according to the present invention may be produced as a series of alternating layers of solid mass and layers containing either beads (sacrificial or permanent) or actual voids.
- An attractive and powerful feature of AM as used in conjunction with the present invention is the capability to endow products with varying macro- and microstructures.
- this technology may be employed to incorporate actual voids and preform materials in fabrics, and to make heterogeneous and hierarchical compositions.
- AM technology utilizing 3D printing may also be used which brings the potential for production of intermediate and finished fabrics according to the present invention to create functional parts and products made out of plastic, metal, and ceramic powders.
- Particulate manufacturing technology is a process by which fine powdered materials (metals, plastics, and ceramics, among others) are blended, pressed into a desired shape (compacted), and then heated (sintered) in a controlled atmosphere to bond the contacting surfaces of the particles and establish the desired properties.
- Properly sized, shaped, and positioned, filaments and mats according to the present invention may be incorporated in this process by surrounding the preforms with powdered material and compacting this composition into a "green" fabric for later sintering into a final engineered product.
- One advantage of this process is the ability of the assembled material to keep its shape before and during sintering.
- the "green" fabric may be heated just below the melting point of the matrix material, right below its liquid melt point. Consequently, the compact would not loose its shape. Thus, the void space would be preserved because the compacted particles would melt only slightly and bond to form the final product.
- any sacrificial preforms may be eliminated.
- the sintered product may be re-pressed, which in general may make the product more accurate with a better surface finish.
- the voids also may be impregnated, for example, in an oil bath. This process is very similar to continuous casting as described above, except that the matrix material is a powder, not a melt.
- Particulate technology may be used to form fabrics to be used as expendable patterns for lost foam and investment casting, as well as preforms for squeeze casting. Particle technology, of course, is the basis of various ceramic and polymer resin processing techniques, including tape casting of ceramics and plastics.
- the voids for engineered structures may also be provided by incorporating a texture onto a laminate. Examples of such textures are illustrated in FIGS. 26-28. As shown, dimples 78 are imparted onto a surface of a material. Such dimples may be involve the entire thickness of the material, in that, dimples are present on one side (i.e., shallow openings), and corresponding protruding areas on the other side of the material. [00166] Generally, to produce preferred symmetrical voids according to the present invention using texturizing, a pattern of texture may be incorporated into one or both surfaces of a laminate, depending on the void array to be realized in the final engineered product. Texturizing may also impart tape cutting and laminate stacking guides so that the laminates may be assembled into a composite and final products more easily (as with tows and laminate detailed above). [00167] Textures may be added to laminates through imprinting and excising
- void precursors in laminate surfaces may be the result of (1) localized material compression which redistributes material out-of-plane (e.g., forged indentures), or (2) redistribution of the material of the laminate in-plane (e.g. by shape rolling).
- a thixotropic laminate material is used during the imprinting of the texture.
- the laminate is imprinted when the laminar material is heated to a "green" state so that the material easily redistributes itself. In a continuous casting or molding process, this is readily accomplished in situ during the casting of metal, plastic, and ceramics.
- metals like aluminum and steel e.g., foils
- plastics could be imprinted inline, for example, during plastic film casting
- ceramics could be imprinted inline during tape casting when the tape is in a green, unfired state.
- Assuring material redistribution is not a concern when excising laminates to create the textured patterns through, for example, selective laser burnout or chemical etching.
- An advantage of texturizing tape castings to produce patterned laminates is the ability to consolidate tapes using heat, pressure, and dwell time to form a monolithic composite structure comprising many layers (which may be of different base compositions to produce functionally-graded products, for example). This advantage may be enhanced by drawing and texturizing the unconsolidated tapes as a continuation of the tape casting line while the tapes are still heated.
- Composites formed of textured laminates are generally preferably formed using mechanical and adhesive joining as well as welding. This is especially true of texturized metals, although metals may be heated and compressed to achieve consolidation. Texturized ceramic laminates, on the other hand, must be sintered.
- Texturized plastic laminates may be welded, as well, using microwave, ultrasonic, rf, and induction techniques. Induction welding uses the heat generated by a metal filler in the plastic moving through a magnetic field to heat the plastic material. [00173] While the system of the present invention has been described with reference to the above manufacturing materials, processes, and systems, it should be apparent to those skilled in the art that the present invention may be used/made with other materials, processes, and systems not specifically referenced here. [00174] Having described the invention with reference to the presently preferred embodiments, it should be understood that numerous changes in construction may be introduced without departing from the true spirit of the invention as defined in the appended claims.
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Abstract
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US53145403P | 2003-12-18 | 2003-12-18 | |
US60/531,454 | 2003-12-18 | ||
US10/899,882 | 2004-07-26 | ||
US10/899,882 US7927528B2 (en) | 2001-05-17 | 2004-07-26 | Preform for manufacturing a material having a plurality of voids and method of making the same |
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WO2005061208A1 true WO2005061208A1 (en) | 2005-07-07 |
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PCT/US2004/042291 WO2005061208A1 (en) | 2003-12-18 | 2004-12-17 | Methods and systems for manufacturing a structure having organized areas |
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Publication number | Priority date | Publication date | Assignee | Title |
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FR2931100A1 (en) * | 2008-05-16 | 2009-11-20 | Onera (Off Nat Aerospatiale) | CELLULAR MATERIAL BASED ON BALLS AND METHOD FOR PRODUCING SUCH MATERIAL |
WO2018228739A1 (en) * | 2017-06-14 | 2018-12-20 | Thyssenkrupp Presta Ag | Fiber composite material for a component with reduction of the fiber-matrix adhesion for the targeted guiding of structure-borne noise and increasing the damping |
CN111361180A (en) * | 2020-02-14 | 2020-07-03 | 大连交通大学 | Carbon fiber fine structure component and preparation method thereof |
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US2920354A (en) * | 1957-08-14 | 1960-01-12 | Viso S A | Process for making spaced reinforcements on shaped elongate structures from fiber-forming materials |
US20020172817A1 (en) * | 2001-05-17 | 2002-11-21 | Owens Charles R. | Preform for manufacturing a material having a plurality of voids and method of making the same |
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US2920354A (en) * | 1957-08-14 | 1960-01-12 | Viso S A | Process for making spaced reinforcements on shaped elongate structures from fiber-forming materials |
US20020172817A1 (en) * | 2001-05-17 | 2002-11-21 | Owens Charles R. | Preform for manufacturing a material having a plurality of voids and method of making the same |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2931100A1 (en) * | 2008-05-16 | 2009-11-20 | Onera (Off Nat Aerospatiale) | CELLULAR MATERIAL BASED ON BALLS AND METHOD FOR PRODUCING SUCH MATERIAL |
WO2009150314A2 (en) * | 2008-05-16 | 2009-12-17 | ONERA (Office National d'Etudes et de Recherches Aérospatiales) | Method for preparing a cellular material based on hollow metal beads |
WO2009150314A3 (en) * | 2008-05-16 | 2010-08-19 | ONERA (Office National d'Etudes et de Recherches Aérospatiales) | Method for preparing a cellular material based on hollow metal beads |
US8663812B2 (en) | 2008-05-16 | 2014-03-04 | Onera (Office National D'etudes Et De Recherche Aerospatiales) | Method for preparing a cellular material based on hollow metal beads |
WO2018228739A1 (en) * | 2017-06-14 | 2018-12-20 | Thyssenkrupp Presta Ag | Fiber composite material for a component with reduction of the fiber-matrix adhesion for the targeted guiding of structure-borne noise and increasing the damping |
CN111361180A (en) * | 2020-02-14 | 2020-07-03 | 大连交通大学 | Carbon fiber fine structure component and preparation method thereof |
CN111361180B (en) * | 2020-02-14 | 2021-02-19 | 大连交通大学 | Carbon fiber structural component and preparation method thereof |
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