Multi-Channel Nozzle for Composite Ribbon Manufacturing
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Solution Overview
Problem
Existing manufacturing processes, such as extrusion and pultrusion, face challenges in achieving the required strength and form precision in composite structures, with issues in wetting and bonding between fibers and matrix materials.
Innovation Solution
An additive manufacturing system with a multi-channel nozzle that includes a housing, fiber guide, die, and cure enhancer, allowing for the convergence and curing of matrix-wetted reinforcements, enabling the creation of high-strength composite structures with precise shapes and improved bonding between fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If extrusion manufacturing is used to produce continuous structures, then manufacturing efficiency is improved, but the resulting structures lack sufficient strength
Solution Approach 1:
The invention uses composite materials by combining continuous fiber reinforcements with a liquid matrix material. The fiber guide receives multiple continuous reinforcements (fibers) that are then impregnated with matrix material as they pass through the die, creating a composite structure that maintains both manufacturing efficiency and enhanced structural strength through the synergistic combination of fiber strength and matrix binding.
2Strength
If pultrusion manufacturing is used to produce high-strength structures, then structural strength is improved, but the resulting structures lack the required form precision
Solution Approach 1:
The invention segments the reinforcement delivery system into multiple separate channels within the fiber guide, with each channel receiving and guiding individual continuous reinforcements. This segmentation allows for precise control and positioning of each fiber bundle as it exits the die, enabling accurate formation of complex cross-sectional shapes while maintaining the high strength benefits of continuous fiber reinforcement.
3Strength
If conventional multi-fiber pultrusion is used to manufacture high-strength structures, then structural strength is improved, but adequate wetting and bonding between adjacent fibers becomes problematic
Solution Approach 1:
The invention introduces matrix material as an intermediary substance that is applied to wet and bond the adjacent fiber reinforcements together. The matrix material serves as a mediator between the discrete fiber bundles, ensuring adequate wetting and bonding as the fibers pass through the die and are impregnated with the liquid matrix, thereby improving interfacial adhesion and overall composite reliability.
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 continuous manufacture of composite structures with desired cross-sectional shapes and increased strength by ensuring thorough wetting and bonding of reinforcements, resulting in enhanced structural integrity and precision.
Implementation Method 1
a cure enhancer configured to cure the matrix in the composite material during discharge of the ribbon from the die
Implementation Method 2
a fiber guide located inside the housing and configured to separately receive a plurality of continuous reinforcements
Implementation Method 3
a die located inside the housing and configured to receive the plurality of continuous reinforcements from the fiber guide and to cause the plurality of continuous reinforcements to converge
Implementation Method 4
ensuring thorough wetting and bonding of reinforcements
Data Source
AI summary
A system is disclosed for use in additively manufacturing a composite structure. The system may include a matrix reservoir, and a fiber guide configured to separately receive a plurality of matrix-wetted reinforcements from the matrix reservoir. The system may also include a die configured to receive the plurality of matrix-wetted reinforcements from the fiber guide and to cause the plurality of matrix-wetted reinforcements to converge into a ribbon. The system may additionally include a cure enhancer configured to cure the matrix in the composite material during discharge of the ribbon from the die, and a support configured to move the die in multiple dimensions during discharge of the ribbon.