Systems and methods for designing and manufacturing optimized irregular objects having composite materials and the resulting objects

Abstract

The present invention relates to: a system and method for designing and manufacturing irregular objects made of composite materials, optimized in weight and load capacity; a system for designing and manufacturing objects; and an object obtained by the method. Using a 3D computer design program and a computational computer program, a digital design of an object made of composite materials with component fragments of a specific shape and orientation is obtained, which object is optimized to be lightweight while meeting the required specific mechanical properties and / or structural properties. Subsequently, a mold is obtained based on the design, and the parameters of the digital design are converted into instructions so that one or more automatic manufacturing machines deposit material fragments (preferably wood) on the mold in a specific orientation, which is calculated to minimize the weight of the object and optimize its load-bearing capacity. Optionally, one or more adhesives can be deposited on the mold. The deposited material is then pressed into the mold. Finally, the newly manufactured object is obtained by removing the newly manufactured object from the mold.

Description

Technical Field

[0001] Systems and methods for designing and manufacturing optimized irregular objects having novel composite materials and the resulting objects.

[0002] In the field of construction and manufacturing of load-bearing objects without any shape restrictions, the need to manufacture such objects with less material, lighter weight, lower energy consumption and lower carbon emissions has become an important pursuit in the relevant industries for both economic and sustainability reasons.

[0003] In this context, there are different industries that rely on new technologies and lightweight materials to meet sustainability goals, such as reducing energy consumption (as in the case of the transport industry) and using raw materials more efficiently (as in the case of the construction industry). Background Art

[0004] Currently, there are digital design and manufacturing processes that help manufacturers develop objects with specific machine and structural requirements. In this context, there are digital design tools that help make it easier to design three-dimensional objects, such as computer-aided design (CAD) computer programs. There are also computer programs for structural calculations. At the same time, there are machines operated with computer numerical control (CNC) systems for automatic manufacturing, subtractive manufacturing and additive manufacturing to manufacture the designs. For example, document US5121329A (D1) teaches about an additive manufacturing system for a three-dimensional design of an object in a CAD-type computer program, and teaches the subsequent step of sending commands to a CNC-type machine, so that the CNC-type machine manufactures a three-dimensional object by extruding thermoplastic materials deposited in overlapping layers until a three-dimensional object of thermoplastic material designed in the CAD program is obtained.

[0005] As for materials that can be used to make lightweight objects, aluminum and plastics reinforced with carbon fiber or glass fiber are widely used. Although these materials can be light and the aforementioned computer programs can help optimize their shape, these materials are by no means sustainable, as their production process is very intensive in CO2 emissions.

[0006] On the other hand, in the field of sustainable construction, some wood-based products are also known, which are indeed renewable and whose production process generates less CO2 than other materials, such as plywood, molded wood, and oriented strand board (OSB) particle board. For example, document US4364984A (D2) describes an OSB board and its structural features based on layers of oriented wood particles that are superimposed and pressed to obtain the board.

[0007] Composite materials based on other plant fibers such as jute, flax, and some hybrid composite materials containing a certain percentage of plant fibers combined with carbon fibers are also known. These technologies are good solutions for non-structural applications, but due to their low mechanical properties and / or their high weight, they do not achieve the structural properties of the above-mentioned materials. They also have important limitations in productivity, since their manufacture requires a labor-intensive process, and in addition, they have limitations due to the restricted anisotropy, considering that the woven textile materials with the most commonly used compounds for reinforcement have a specific orientation in their fibers (usually orthogonal or with specific angles), which results in an orientation of the fibers that does not effectively follow the path of the stresses to which the object is subjected. This translates into a reduction in the structural properties of the object and / or its greater weight.

[0008] On the other hand, plywood composites made from wood chips have very high shape restrictions during the molding process and do not allow small radii of curvature. The plywood composites are also orthotropic, which reduces their efficiency and increases the weight of these parts. This makes them suitable only for applications where weight is not an important variable.

[0009] In short, the most sustainable alternatives available for manufacturing lightweight objects fail to meet high machine and / or structural performance requirements, and the options that do meet machine and / or structural performance requirements are unsustainable.

[0010] Therefore, there is a need for new methods, systems and materials for manufacturing lightweight objects.

[0011] In this context, our invention of new systems and methods for designing and manufacturing optimized irregular objects provides a solution to the demand for new composite materials and the resulting objects for lightweight objects with high structural performance that is more sustainable than currently used materials such as aluminum, stamped metal or reinforced plastics and at the same time has higher machine and / or structural performance than other wood composite technologies. Summary of the invention

[0012] Our invention overcomes the limitations of known methods and materials by integrating digital design, digital simulation, digital structural analysis, weight optimization, automated manufacturing of lightweight structural objects, and new composite materials into a unified and automated process. Our system and method are thus able to optimize objects with mechanical and / or structural requirements on two criteria: the first is regarding the optimization of the shape, while the second is regarding the optimization of the orientation of the fibers or fragments of the material so that their orientation effectively follows the path of the stresses to which the object is subjected. This combination of variable control allows us to produce irregular elements with high mechanical and / or structural properties, allowing the manufacture of objects with three-dimensional designs of complex geometries and integrating various functions, with higher strength and less weight than objects currently produced using other technologies and / or materials.

[0013] Our invention consists of a system consisting of at least one computer with one or more computer programs for design, calculation and analysis, one or more machines for depositing materials operated with computerized numerical control, one or more material fragments, a binder, at least one mold and at least one press.

[0014] The system and method for designing and manufacturing an optimized irregular object with a novel composite material and the resulting object include: obtaining the form requirements and structural requirements of the part to be manufactured; defining the measurable physical parameters of the part to be manufactured; using a specialized computer program to perform N times of design, simulation, analysis, redesign, simulation and analysis in a data feedback loop until an optimized three-dimensional digital design is obtained; converting the optimized three-dimensional digital design into digital instructions; obtaining a mold according to the obtained three-dimensional design; sending the digital instructions to a deposition machine; depositing material fragments (preferably wood) in the mold in a specific orientation calculated to optimize the pressure of the resulting object; optionally, depositing an adhesive in the mold according to the digital instructions; pressing the fragments and the adhesive in the mold; and finally opening the mold to obtain a finished object having lightweight properties and high mechanical and / or structural properties. If the particles used are made of wood, it will also be a sustainable and renewable object.

[0015] One example of an application of the invention is in seats in public transportation vehicles such as buses and trains. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 is an exemplary diagram of possible configurations of chips, preferably wood chips, obtained after a process of designing and optimizing the orientation of the chips.

[0017] Figure 2 is an exemplary perspective view of a seat design preferably for use in a bus or train.

[0018] Figure 3 is an exemplary diagram of one possible type of mold having two parts, similar to that used for Figure 2 The mold of the seat.

[0019] Figure 4 is an illustrative diagram of generally irregularly shaped wood chips or sawdust.

[0020] Figure 5 is an exemplary diagram of typical wood chips with regular width.

[0021] Figure 6 is a flow chart of a method for designing and manufacturing an optimized irregular object.

[0022] It should be noted that the drawings are not drawn to scale, and for illustrative purposes, elements, their components and steps are represented by the same reference numerals in all drawings. It should also be noted that the drawings are intended only to facilitate the description of some preferred embodiments, and do not show other possible embodiments or every aspect of the described embodiments, and therefore the drawings do not limit the scope of the present disclosure. DETAILED DESCRIPTION

[0023] Because currently available materials and manufacturing systems and methods lack the characteristics of combining high machine and / or structural performance with lightweight properties, and / or lack the characteristics of lower environmental impact and sustainability, it may be desirable to develop new systems and methods for designing and manufacturing optimized irregular objects with new composite materials and the resulting objects, which are dedicated to manufacturing objects that combine the characteristics of high machine and / or structural performance with lightweight properties, and have lower environmental impact and sustainability characteristics, and which can be widely used in a variety of industries that have a growing demand for objects with these properties, such as construction, transportation, furniture, appliances, etc.

[0024] For example, in one of the applications mentioned herein, the transportation industry and its need to reduce the weight of vehicle parts in order to save fuel and / or energy and thus emit less CO2 is mentioned.

[0025] Figure 1 An example of what a fragment (10) of a portion of a part manufactured using the system and method proposed in the present invention may look like is shown.

[0026] Figure 2By way of example, a seat for a bus or train with optimized design and materials is shown, the seat comprising wood chips (20) and wood chip layers (21) in a specific order and orientation determined by our digital irregular design optimization process. In other embodiments of the invention, the resulting object can have a single layer or multiple layers, with a thickness greater in some areas of the object than in others, depending on the form of the object and machine requirements.

[0027] Figure 3 By way of example, a possible type of mould (in this case having 2 parts) is shown, which is similar to that which can be used to manufacture e.g. Figure 2 The mold of the seat. Figure 3 In the figure, we can see the lower part of the mold (30), the upper part of the mold (31), and the movement vector of the force (32) used to press the deposited material between the parts of the mold. In another embodiment, the lower part of the mold can be moved, applying a force upward to press the deposited material against the upper part of the mold. In another embodiment, the two parts of the mold can be moved towards each other until the deposited material is pressed. In other embodiments, it can be composed of a vacuum mold. In other embodiments, the mold can have more than 2 parts.

[0028] Figure 4 Examples of wood fragments (40) or wood chips with irregular shapes and surfaces are shown. It should be noted that the proportions and shapes of the fragments are not limited to those shown in these exemplary figures. In some embodiments, the size of these fragments will be as small as sawdust particles. In other embodiments, it will be long pieces or large pieces of wood or another material. In other embodiments, it will be irregular fragments like chips. In other embodiments, the size and / or shape and / or material of these fragments can be different. In other embodiments, the material of these fragments will be plant, and / or animal, and / or mineral, and / or metal-derived materials.

[0029] Figure 5 An example of wood pieces with regular width (50) is shown.

[0030] Figure 6 A flow chart (60) of a system and method for designing and manufacturing an optimized irregular object having a novel composite material and the resulting object is shown. The method begins at box (61).

[0031] In block (61), the form and structural requirements of the object to be manufactured are obtained. In this step, information is received about the characteristics of the desired object, as well as its shape, maximum and minimum dimensions, mechanical property requirements, maximum weight and other quantifiable variables that the object must have once completed. For example, Figure 1Following the embodiment shown, the objects that may be required are seats for a specific model of bus, each bus must accommodate 30 seats, they must support people weighing up to 100 kg, each seat must weigh no more than 0.5 kg and must have a specific shape to attach to the construction of the bus.

[0032] In box (62), based on the information obtained in the previous step about the requirements of the object, the parameters that the object must meet are defined. Continuing with the example of the previous paragraph, in this step, the requirements are converted into specific shape parameters and into numerical parameters (such as width, height, thickness, weight, vertical loads to be supported, traction and other loads to be supported) with specific maximum and minimum values ​​for the object.

[0033] In box (63), the parameters defined in the previous step (62) are input into one or more computer programs and converted into an initial digital design, which is then subjected to N times of digital simulation, analysis of results and redesign in a feedback loop until an optimized digital three-dimensional design that meets all formal and structural requirements is obtained in the most efficient way. This process defines: the general shape of the design for the object; the type and size of the fragments to be used; the material of the fragments (preferably wood); the size of the fragments; the adhesive to be used; and, very importantly, the orientation of the fragments in terms of the shape of the fragments, and the orientation of their fibers, strands or components.

[0034] In block (64), the optimized digital three-dimensional design is converted into operating instructions for a mechanical device by a computer program, and the mechanical device is operated using computer numerical control (CNC).

[0035] In block (65), a mold specific to the optimized design obtained by the previous processing is obtained.

[0036] In box (66), digital instructions are sent to the CNC machine to place the selected material in the mold. These instructions are: 3D coordinate data and the orientation of each piece to be deposited at said coordinates, details of whether adhesive is to be used, and if so, the 3D coordinate data and the corresponding amount of adhesive to be deposited at the corresponding coordinates relative to the mold.

[0037] In box (67), the instructions sent to the CNC mechanism are executed. It is during this step that the chips and adhesive are deposited on the mold.

[0038] In block (68), a step of pressing the deposited material is started. In this step, the material deposited in the mold is pressed with force.

[0039] In block (69), the parts of the mold are separated to obtain the finished product.

Claims

1. A method for manufacturing an optimized irregular object made of composite material, the optimized irregular object having been previously designed using a computer program for performing N times of design, simulation, analysis results, redesign, simulation and analysis results in a data feedback loop to obtain an optimized 3D design and converting the digital information of the design into digital instructions for a mechanical device operated using a computerized numerical control CNC, wherein: The composite material includes material fragments and a binder; Characterized in that the method comprises the following steps: (a) providing a mold having at least two parts, the mold being dedicated to an optimized design obtained by a design process for object design; (b) depositing said adhesive and said material fragments in a lower portion of said mold in accordance with said digital instructions at intentional and specific coordinates and orientations such that said orientations effectively follow the path of the pressure to which the object is subjected; (c) pressing the fragments and the adhesive between the parts of the mold, wherein the fragments of material and the adhesive form a pressed layer; (d) separating the portions of the mold to remove the completed object.

2. The method according to claim 1, characterized in that After step (b) of depositing the adhesive and the material fragments and before pressing the fragments and the adhesive, the method further comprises: depositing one or more layers of the adhesive and the material fragments on the layer formed in step (b) with intentional and specific coordinates and orientations according to the digital instructions and in accordance with the form requirements and machine requirements of the object to form a multilayer composite material.

3. The method according to claim 2, characterized in that Each layer of the adhesive and the material fragments in the plurality of layers may have its own specific coordinates and orientation that are the same as or different from the coordinates and orientation of the other layers.

4. The method according to any one of the preceding claims, characterized in that The thickness of the material layer of the object obtained is greater in some areas of the object than in other areas, depending on the formal requirements of the object and the machine requirements.

5. The method according to claim 1, characterized in that The portions of the mold are brought together to apply a force to press the deposited material between the portions.

6. The method according to claim 1, characterized in that The material fragments include at least one material from the group consisting of plant-derived materials, animal-derived materials, synthetic-derived materials, mineral-derived materials, and metal materials.

7. The method according to claim 1, characterized in that The material fragments are irregular in shape and size.

8. The method according to claim 1, characterized in that The material fragments include a combination of at least two regular shapes and / or sizes.

9. The method according to claim 1, characterized in that: The material fragments are any one of the group consisting of: regular shape and regular size, regular shape and irregular size, irregular shape and regular size.

10. The method according to claim 1, characterized in that The adhesive comprises at least one adhesive selected from the group consisting of adhesives and thermoplastic materials.

11. The method according to claim 1, characterized in that: Pressing is performed without heating.

12. The method according to claim 1, characterized in that Pressing is performed by heating.

13. A system for manufacturing an optimized irregular three-dimensional object made of composite materials, the optimized irregular three-dimensional object has been previously designed using a computer program, the computer program is used to perform N times of design, simulation, analysis results, redesign, simulation and analysis results in a data feedback loop to obtain an optimized 3D design, and convert the digital information of the design into digital instructions for a mechanical device, the mechanical device is operated using a computerized numerical control CNC, wherein, The composite material includes material fragments and a binder; Characterized in that the system comprises: (a) a computer storing one or more of said computer programs for design, calculation and analysis, and said computer being configured to send digital instructions to a deposition machine; (b) a mould having at least two parts, said mould being dedicated to an optimised design obtained by a design process for said object; (c) one or more machines for depositing materials, configured to deposit said binder and said material fragments on the lower part of said mold in specific coordinates and orientations according to said digital instructions, such that said orientations effectively follow the path of the pressure to which the object is subjected; (d) a press configured to press the fragments and the binder between the portions of the mold, wherein the fragments of material and the binder form a pressed layer.

14. The system according to claim 13, characterized in that The portions of the mold are configured to apply a force to compress the deposited material between the portions.

15. The system according to claim 13, characterized in that The material fragments include at least one material from the group consisting of plant-derived materials, animal-derived materials, synthetic-derived materials, mineral-derived materials, and metal materials.

16. The system according to claim 13, characterized in that The adhesive comprises at least one adhesive selected from the group consisting of adhesives and thermoplastic materials.

17. An optimized irregular three-dimensional object made of composite material, the optimized irregular three-dimensional object has been previously designed using a computer program, the computer program is used to perform N times of design, simulation, analysis results, redesign, simulation and analysis results in a data feedback loop to obtain an optimized 3D design, and convert the digital information of the design into digital instructions for a mechanical device, the mechanical device is operated using a computerized numerical control CNC, wherein, The composite material includes material fragments and a binder; Features: (a) said material fragments are in intentional and specific coordinates and orientations according to said digital instructions, such that said orientations effectively follow the path of the pressure experienced by the object; (b) combining a bonding material with the material fragments; (c) The material fragments and the binder form a pressed layer of a composite material having high mechanical and / or high structural properties in a specific orientation.

18. The three-dimensional object according to claim 17, characterized in that The three-dimensional object comprises a plurality of pressed layers of a composite material consisting of fragments of the material and the binder, wherein the fragments of the material in the plurality of layers are placed at intentional and specific coordinates and orientations according to the digital instructions.

19. The three-dimensional object according to any one of claims 17 and 18, characterized in that The material fragments contained in the composite material include at least one material from the group consisting of plant-derived materials, animal-derived materials, synthetic-derived materials, mineral-derived materials, and metal materials.

20. The three-dimensional object according to claim 17, characterized in that The adhesive comprises at least one adhesive selected from the group consisting of adhesives and thermoplastic materials.

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