Compactor for Continuous Composite Manufacturing
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Solution Overview
Problem
Existing manufacturing processes such as extrusion and pultrusion lack the strength, precision, and form required for certain applications, and they have limited control over curing and material variation, which restricts the characteristics of the produced structures.
Innovation Solution
A compactor system integrated with an additive manufacturing print head that includes a housing, a compacting wheel, and adjustable springs to exert axial force, along with a piston for adjusting compaction force, is used to compact the composite material before exposure to cure energy, enhancing the strength and precision of the structures by dynamically varying the compaction force based on sensor feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If extrusion manufacturing is used to continuously manufacture structures, then manufacturing efficiency is improved, but the resulting structures lack sufficient strength
Solution Approach 1:
The patent applies composite materials by embedding continuous fibers within a matrix material during extrusion manufacturing. This creates a composite structure that maintains the manufacturing efficiency of extrusion while significantly improving the structural strength through the reinforcement provided by the continuous fibers.
2Strength
If pultrusion manufacturing is used to produce high-strength structures, then structure strength is improved, but the resulting structures lack precise form and surface texture
Solution Approach 1:
The patent replaces the traditional mechanical pultrusion die system with a controlled extrusion system that uses a moving die or injection mechanism. This allows for precise control of material flow, fiber orientation, and curing parameters, achieving both high strength through fiber reinforcement and precise form/surface texture through controlled extrusion processes.
3Productivity
If conventional pultrusion manufacturing is used, then continuous manufacturing capability is maintained, but precise control over curing and dynamic material changes are limited
Solution Approach 1:
The patent introduces dynamic control capabilities into the continuous manufacturing process by using a moving die or injection system that can be programmatically controlled. This allows real-time adjustment of material composition, fiber orientation, extrusion parameters, and curing conditions while maintaining continuous production, thereby achieving both productivity and adaptability.
4Strength
If CF3D additive manufacturing is used to embed continuous fibers, then structure strength is improved, but the system lacks compaction control for optimal fiber-matrix bonding
Solution Approach 1:
The patent segments the extrusion process into distinct functional zones: material feeding, fiber embedding, compaction, and curing. By introducing a dedicated compaction zone with controlled pressure application, the system optimizes fiber-matrix bonding without overwhelming complexity, as each zone performs a specific function in sequence during continuous manufacturing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables the production of composite structures with improved strength, precision, and form, allowing for dynamic material changes and varied patterns, addressing the limitations of existing manufacturing processes.
Implementation Method 1
at least one spring disposed in the housing and configured to exert an axial force on the compacting wheel
Implementation Method 2
UV light and/or ultrasonic vibrations are used to speed the cure of the liquid matrix as it exits the die
Data Source
AI summary
A compactor is disclosed for use with an additive manufacturing print head. The compactor may include a housing connectable to the additive manufacturing print head. The compactor may also include a compacting wheel, and at least one spring disposed in the housing and configured to exert an axial force on the compacting wheel. The compactor may further include a piston moveable to adjust a distance between the housing and the compacting wheel.