公开(公告)号：US20100173118A1

公开(公告)日：2010-07-08

申请号：US11745350

申请日：2007-05-07

申请人： David W. Johnson ,  Scott A. Garrett ,  Stephen G. Moyers ,  James M. Hook

发明人： David W. Johnson ,  Scott A. Garrett ,  Stephen G. Moyers ,  James M. Hook

IPC分类号： B32B3/02 ,  B32B5/12

CPC分类号： E04C2/296 ,  B29C70/086 ,  B29C70/088 ,  B29C70/24 ,  B32B5/02 ,  E01C9/086 ,  Y10S411/904 ,  Y10T29/49957 ,  Y10T428/233 ,  Y10T428/23914 ,  Y10T428/24174 ,  Y10T428/249923 ,  Y10T428/249924 ,  Y10T428/249942 ,  Y10T428/31504

摘要： A method and apparatus for forming an improved pultruded and clinched Z-axis fiber reinforced composite laminate structure. The upper and lower skins and the core are pulled automatically through tooling where the skin material is wetted-out with resin and the entire composite laminate is preformed in nearly its final thickness. The preformed composite laminate continues to be pulled into an automatic 3-dimensional Z-axis fiber deposition machine that deposits “groupings of fiber filaments” at multiple locations normal to the plane of the composite laminate structure and cuts each individual grouping such that an extension of each “grouping of fiber filaments” remains above the upper skin and below the lower skin. The preformed composite laminate then continues to be pulled into a secondary wet-out station. Next the preformed composite laminate travels into a pultrusion die where the extended “groupings of fiber filaments” are all bent over above the top skin and below the bottom skin producing a superior clinched Z-axis fiber reinforcement as the composite laminate continues to be pulled, catalyzed, and cured at the back section of the pultrusion die. The composite laminate continues to be pulled by grippers that then feed it into a gantry CNC machine that is synchronous with the pull speed of the grippers and where computerized machining, drilling, and cutting operations take place. This entire method is accomplished automatically without the need for human operators.

摘要翻译： 一种用于形成改进的拉挤和夹紧Z轴纤维增强复合层压结构的方法和装置。 上下皮和芯通过模具被自动拉出，其中皮肤材料用树脂润湿，并且整个复合层压板以几乎最终的厚度预成型。 预成型的复合层压板继续被拉入自动的三维Z轴纤维沉积机，其在与复合层压结构的平面垂直的多个位置处沉积“纤维丝组”，并且切割每个单独的组，使得 每个“纤维丝组”保留在上皮肤上方和下皮肤之下。 然后将预制复合层压材料继续拉入二次浸湿站。 接下来，预制的复合层压板进入拉挤模具，其中延伸的“纤维丝”分组全部在顶部皮肤上方并在底部皮肤之下弯曲，从而在复合层压板继续拉伸时产生优良的切割Z轴纤维增强件， 催化并在拉挤模头的后部固化。 复合层压板继续由夹具拉出，然后将其送入龙门数控机床，与机器的拉速同步，并进行计算机化的加工，钻孔和切割操作。 这种整个方法是自动完成的，而不需要人类操作者。

公开(公告)号：US07387147B2

公开(公告)日：2008-06-17

申请号：US11530859

申请日：2006-09-11

申请人： David W. Johnson ,  Scott A. Garrett ,  James M. Hooks ,  Stephen G. Moyers

发明人： David W. Johnson ,  Scott A. Garrett ,  James M. Hooks ,  Stephen G. Moyers

IPC分类号： B32B37/00

CPC分类号： B32B5/18 ,  B29C31/08 ,  B29C70/086 ,  B29C70/088 ,  B29C70/24 ,  B29C70/521 ,  B29K2105/04 ,  B32B3/12 ,  B32B5/02 ,  B32B5/08 ,  B32B5/22 ,  B32B5/24 ,  B32B7/08 ,  B32B21/04 ,  B32B2250/03 ,  B32B2250/40 ,  B32B2262/0269 ,  B32B2262/101 ,  B32B2262/106 ,  B32B2305/024 ,  E01C9/086 ,  E04C2/296

摘要： A method of inserting z-axis reinforcing fibers into a multi-layer composite laminate. Layers of material made up of z-axis fiber and y-axis fibers are automatically transported into a z-fiber deposition machine having a housing with upper and lower surfaces. Z-axis apertures are formed in the respective upper and lower surfaces. An elongated solid rod having a tapered front tip is aligned in close proximity to the aperture in the bottom surface. The rod is first rotated by a motor and then actuated upwardly completely through the thickness of the layer of x-y material by an actuator. A first hollow tube having a z-axis is axially aligned with the aperture in the top surface and a fiber bundle is threaded downwardly through a first hollow tube to a position adjacent its bottom end. The z-fiber deposition machine has structure to feed a predetermined length of the fiber bundle downwardly through the first hollow tube so that it follows the pathway in the x-y material formed by the rod which is now withdrawn downwardly through the aperture in the bottom wall. The z-axis fiber is thus deposited into the x-y material. The top end of the z-axis fiber is then severed and the x-y material is then advanced a predetermined distance to complete the cycle and is, thus, set to be repeated.

摘要翻译： 将z轴增强纤维插入多层复合层压板的方法。 由z轴纤维和y轴纤维构成的材料层自动输送到具有上表面和下表面的壳体的z-纤维沉积机中。 在相应的上表面和下表面中形成Z轴孔。 具有锥形前端的细长实心杆对准在底表面中的孔附近。 杆首先由马达旋转，然后通过致动器完全通过x-y材料层的厚度向上致动。 具有z轴的第一空心管与顶表面中的孔轴向对准，并且纤维束向下穿过第一中空管到靠近其底端的位置。 z-纤维沉积机具有通过第一中空管向下馈送预定长度的纤维束的结构，使得其沿着由杆形成的x-y材料中的路径，该路径现在通过底壁中的孔向下取出。 因此，z轴光纤沉积到x-y材料中。 然后切断z轴光纤的顶端，然后将x-y材料前进预定距离以完成循环，并因此被设置为重复。

公开(公告)号：US07217453B2

公开(公告)日：2007-05-15

申请号：US10744630

申请日：2003-12-23

申请人： David W Johnson ,  Scott A. Garrett ,  Stephen G. Moyers

发明人： David W Johnson ,  Scott A. Garrett ,  Stephen G. Moyers

IPC分类号： D04H1/00 ,  B32B27/04

CPC分类号： E04C2/296 ,  B29C70/086 ,  B29C70/088 ,  B29C70/24 ,  B32B5/02 ,  E01C9/086 ,  Y10S411/904 ,  Y10T29/49957 ,  Y10T428/233 ,  Y10T428/23914 ,  Y10T428/24174 ,  Y10T428/249923 ,  Y10T428/249924 ,  Y10T428/249942 ,  Y10T428/31504

摘要： A method and apparatus for forming an improved pultruded and clinched Z-axis fiber reinforced composite laminate structure. The upper and lower skins and the core are pulled automatically through tooling where the skin material is wetted-out with resin and the entire composite laminate is preformed in nearly its final thickness. The preformed composite laminate continues to be pulled into an automatic 3-dimensional Z-axis fiber deposition machine that deposits “groupings of fiber filaments” at multiple locations normal to the plane of the composite laminate structure and cuts each individual grouping such that an extension of each “grouping of fiber filaments” remains above the upper skin and below the lower skin. The preformed composite laminate then continues to be pulled into a secondary wet-out station. Next the preformed composite laminate travels into a pultrusion die where the extended “groupings of fiber filaments” are all bent over above the top skin and below the bottom skin producing a superior clinched Z-axis fiber reinforcement as the composite laminate continues to be pulled, catalyzed, and cured at the back section of the pultrusion die. The composite laminate continues to be pulled by grippers that then feed it into a gantry CNC machine that is synchronous with the pull speed of the grippers and where computerized machining, drilling, and cutting operations take place. This entire method is accomplished automatically without the need for human operators.

摘要翻译： 一种用于形成改进的拉挤和夹紧Z轴纤维增强复合层压结构的方法和装置。 上下皮和芯通过模具被自动拉出，其中皮肤材料用树脂润湿，并且整个复合层压板以几乎最终的厚度预成型。 预成型的复合层压板继续被拉入自动的三维Z轴纤维沉积机，其在与复合层压结构的平面垂直的多个位置处沉积“纤维丝组”，并且切割每个单独的组，使得 每个“纤维丝组”保留在上皮肤上方和下皮肤之下。 然后将预制复合层压材料继续拉入二次浸湿站。 接下来，预制的复合层压板进入拉挤模具，其中延伸的“纤维丝”分组全部在顶部皮肤上方并在底部皮肤之下弯曲，从而在复合层压板继续拉伸时产生优良的切割Z轴纤维增强件， 催化并在拉挤模头的后部固化。 复合层压板继续由夹具拉出，然后将其送入龙门数控机床，与机器的拉速同步，并进行计算机化的加工，钻孔和切割操作。 这种整个方法是自动完成的，而不需要人类操作者。

公开(公告)号：US08002919B2

公开(公告)日：2011-08-23

申请号：US12140121

申请日：2008-06-16

申请人： David W. Johnson ,  Scott A. Garrett ,  James H. Hook ,  Stephen G. Moyers

发明人： David W. Johnson ,  Scott A. Garrett ,  James H. Hook ,  Stephen G. Moyers

IPC分类号： B32B37/00

CPC分类号： B32B5/18 ,  B29C31/08 ,  B29C70/086 ,  B29C70/088 ,  B29C70/24 ,  B29C70/521 ,  B29K2105/04 ,  B32B3/12 ,  B32B5/02 ,  B32B5/08 ,  B32B5/22 ,  B32B5/24 ,  B32B7/08 ,  B32B21/04 ,  B32B2250/03 ,  B32B2250/40 ,  B32B2262/0269 ,  B32B2262/101 ,  B32B2262/106 ,  B32B2305/024 ,  E01C9/086 ,  E04C2/296

摘要： A method of inserting z-axis reinforcing fibers into a multi-layer composite laminate. Layers of material made up of z-axis fiber and y-axis fibers are automatically transported into a z-fiber deposition machine having a housing with upper and lower surfaces. Z-axis apertures are formed in the respective upper and lower surfaces. An elongated solid rod having a tapered front tip is aligned in close proximity to the aperture in the bottom surface. The rod is first rotated by a motor and then actuated upwardly completely through the thickness of the layer of x-y material by an actuator. A first hollow tube having a z-axis is axially aligned with the aperture in the top surface and a fiber bundle is threaded downwardly through a first hollow tube to a position adjacent its bottom end. The z-fiber deposition machine has structure to feed a predetermined length of the fiber bundle downwardly through the first hollow tube so that it follows the pathway in the x-y material formed by the rod which is now withdrawn downwardly through the aperture in the bottom wall. The z-axis fiber is thus deposited into the x-y material. The top end of the z-axis fiber is then severed and the x-y material is then advanced a predetermined distance to complete the cycle and is, thus, set to be repeated.

摘要翻译： 将z轴增强纤维插入多层复合层压板的方法。 由z轴纤维和y轴纤维构成的材料层自动输送到具有上表面和下表面的壳体的z-纤维沉积机中。 在相应的上表面和下表面中形成Z轴孔。 具有锥形前端的细长实心杆对准在底表面中的孔附近。 杆首先由马达旋转，然后通过致动器完全通过x-y材料层的厚度向上致动。 具有z轴的第一空心管与顶表面中的孔轴向对准，并且纤维束向下穿过第一中空管到靠近其底端的位置。 z-纤维沉积机具有通过第一中空管向下馈送预定长度的纤维束的结构，使得其沿着由杆形成的x-y材料中的路径，该路径现在通过底壁中的孔向下取出。 因此，z轴光纤沉积到x-y材料中。 然后切断z轴光纤的顶端，然后将x-y材料前进预定距离以完成循环，并因此被设置为重复。

公开(公告)号：US20080314017A1

公开(公告)日：2008-12-25

申请号：US11771919

申请日：2007-06-29

申请人： David W. Johnson ,  Scott A. Garrett ,  Stephen G. Moyers

发明人： David W. Johnson ,  Scott A. Garrett ,  Stephen G. Moyers

IPC分类号： D01H9/04

CPC分类号： D01H9/04 ,  B65H49/18 ,  B65H2701/31 ,  B65H2701/37

摘要： A method of maintaining the location of a fiber doff inner-diameter-tow at a point of payout within a constant inertial reference frame includes providing a flat fiber tow payout system with a center-pull doff of flat fiber tow that pays out at a point of payout along an inner diameter of the center-pull doff with rotation of the center-pull doff about a vertically oriented axis of rotation, the flat fiber tow payout system including a constant inertial reference frame for payout of the flat fiber tow along the inner diameter of the center-pull doff without twisting the flat fiber tow; and accelerating and stopping rotation of the center-pull doff with the flat fiber tow payout system so as to maintain payout of the flat fiber tow along the inner diameter of the center-pull doff in the constant inertial reference frame, preventing twisting of the flat fiber tow.

摘要翻译： 维持在恒定惯性参考系内的支付点处的纤维道夫内径丝束的位置的方法包括提供平坦的纤维拖曳支付系统，该系统具有在一点支付的扁平纤维丝束的中心拉拔脱落 沿着中心拉拔道夫的内径沿着垂直取向的旋转轴线旋转中心拉夫道夫的平坦纤维丝束支付系统包括用于沿着内部的平坦纤维束支撑的恒定的惯性参考系 直径的中心拉夫德夫没有扭曲平纤维丝束; 并且利用扁平纤维丝束支撑系统来加速和停止中心拉拔道夫的旋转，以便在恒定的惯性参考系中保持扁平纤维束沿着中心拉夫德夫的内径的支出，从而防止平面 纤维束

公开(公告)号：US08123510B1

公开(公告)日：2012-02-28

申请号：US12409389

申请日：2009-03-23

申请人： David W. Johnson ,  Scott A. Garrett ,  Stephen G. Moyers

发明人： David W. Johnson ,  Scott A. Garrett ,  Stephen G. Moyers

IPC分类号： B29C47/16

CPC分类号： B29C70/526 ,  B29K2101/12

摘要： A thermoplastic pultrusion die system for pultruding a thermoplastic composite includes a first pultrusion die member; a second pultrusion die member; a die cavity gap formed between the first pultrusion die member and the second pultrusion die member; and a die cavity gap adjustment mechanism that imparts movement to at least one of the first pultrusion die member and the second pultrusion die member to vary the die cavity gap within a very tight die cavity gap tolerance.

摘要翻译： 用于拉挤热塑性复合材料的热塑性拉挤模具系统包括第一拉挤模具构件; 第二拉挤模具构件; 形成在第一拉挤模具构件和第二拉挤模具构件之间的模腔间隙; 以及模腔间隙调节机构，其向第一拉挤模具构件和第二拉挤模具构件中的至少一个施加运动，以在非常紧密的模腔间隙容限内改变模腔间隙。

公开(公告)号：US07846528B2

公开(公告)日：2010-12-07

申请号：US11745350

申请日：2007-05-07

申请人： David W. Johnson ,  Scott A. Garrett ,  Stephen G. Moyers ,  James M. Hook

发明人： David W. Johnson ,  Scott A. Garrett ,  Stephen G. Moyers ,  James M. Hook

IPC分类号： B32B7/00

CPC分类号： E04C2/296 ,  B29C70/086 ,  B29C70/088 ,  B29C70/24 ,  B32B5/02 ,  E01C9/086 ,  Y10S411/904 ,  Y10T29/49957 ,  Y10T428/233 ,  Y10T428/23914 ,  Y10T428/24174 ,  Y10T428/249923 ,  Y10T428/249924 ,  Y10T428/249942 ,  Y10T428/31504

摘要： A method and apparatus for forming an improved pultruded and clinched Z-axis fiber reinforced composite laminate structure. The upper and lower skins and the core are pulled automatically through tooling where the skin material is wetted-out with resin and the entire composite laminate is preformed in nearly its final thickness. The preformed composite laminate continues to be pulled into an automatic 3-dimensional Z-axis fiber deposition machine that deposits “groupings of fiber filaments” at multiple locations normal to the plane of the composite laminate structure and cuts each individual grouping such that an extension of each “grouping of fiber filaments” remains above the upper skin and below the lower skin. The preformed composite laminate then continues to be pulled into a secondary wet-out station. Next the preformed composite laminate travels into a pultrusion die where the extended “groupings of fiber filaments” are all bent over above the top skin and below the bottom skin producing a superior clinched Z-axis fiber reinforcement as the composite laminate continues to be pulled, catalyzed, and cured at the back section of the pultrusion die. The composite laminate continues to be pulled by grippers that then feed it into a gantry CNC machine that is synchronous with the pull speed of the grippers and where computerized machining, drilling, and cutting operations take place. This entire method is accomplished automatically without the need for human operators.

摘要翻译： 一种用于形成改进的拉挤和夹紧Z轴纤维增强复合层压结构的方法和装置。 上下皮和芯通过模具被自动拉出，其中皮肤材料用树脂润湿，并且整个复合层压板以几乎最终的厚度预成型。 预成型的复合层压板继续被拉入自动的三维Z轴纤维沉积机，其在与复合层压结构的平面垂直的多个位置处沉积“纤维丝组”，并且切割每个单独的组，使得 每个“纤维丝组”保留在上皮肤上方和下皮肤之下。 然后将预制复合层压材料继续拉入二次浸湿站。 接下来，预制的复合层压板进入拉挤模具，其中延伸的“纤维丝”分组全部在顶部皮肤上方并在底部皮肤之下弯曲，从而在复合层压板继续拉伸时产生优良的切割Z轴纤维增强件， 催化并在拉挤模头的后部固化。 复合层压板继续由夹具拉出，然后将其送入龙门数控机床，与机器的拉速同步，并进行计算机化的加工，钻孔和切割操作。 这种整个方法是自动完成的，而不需要人类操作者。

公开(公告)号：US07690179B2

公开(公告)日：2010-04-06

申请号：US11771919

申请日：2007-06-29

申请人： David W. Johnson ,  Scott A. Garrett ,  Stephen G. Moyers

发明人： David W. Johnson ,  Scott A. Garrett ,  Stephen G. Moyers

IPC分类号： D06B23/08

CPC分类号： D01H9/04 ,  B65H49/18 ,  B65H2701/31 ,  B65H2701/37

摘要： A method of maintaining the location of a fiber doff inner-diameter-tow at a point of payout within a constant inertial reference frame includes providing a flat fiber tow payout system with a center-pull doff of flat fiber tow that pays out at a point of payout along an inner diameter of the center-pull doff with rotation of the center-pull doff about a vertically oriented axis of rotation, the flat fiber tow payout system including a constant inertial reference frame for payout of the flat fiber tow along the inner diameter of the center-pull doff without twisting the flat fiber tow; and accelerating and stopping rotation of the center-pull doff with the flat fiber tow payout system so as to maintain payout of the flat fiber tow along the inner diameter of the center-pull doff in the constant inertial reference frame, preventing twisting of the flat fiber tow.

摘要翻译： 维持在恒定惯性参考系内的支付点处的纤维道夫内径丝束的位置的方法包括提供平坦的纤维拖曳支付系统，该系统具有在一点支付的扁平纤维丝束的中心拉拔脱落 沿着中心拉拔道夫的内径沿着垂直取向的旋转轴线旋转中心拉夫道夫的平坦纤维丝束支付系统包括用于沿着内部的平坦纤维束支撑的恒定的惯性参考系 直径的中心拉夫德夫没有扭曲平纤维丝束; 并且利用扁平纤维丝束支撑系统来加速和停止中心拉拔道夫的旋转，以便在恒定的惯性参考系中保持扁平纤维束沿着中心 - 拉夫道夫的内径的支出，从而防止平面 纤维束

公开(公告)号：US20090071594A1

公开(公告)日：2009-03-19

申请号：US12140121

申请日：2008-06-16

申请人： David W. Johnson ,  Scott A. Garrett ,  James M. Hook ,  Stephen G. Moyers

发明人： David W. Johnson ,  Scott A. Garrett ,  James M. Hook ,  Stephen G. Moyers

IPC分类号： B29C70/06

CPC分类号： B32B5/18 ,  B29C31/08 ,  B29C70/086 ,  B29C70/088 ,  B29C70/24 ,  B29C70/521 ,  B29K2105/04 ,  B32B3/12 ,  B32B5/02 ,  B32B5/08 ,  B32B5/22 ,  B32B5/24 ,  B32B7/08 ,  B32B21/04 ,  B32B2250/03 ,  B32B2250/40 ,  B32B2262/0269 ,  B32B2262/101 ,  B32B2262/106 ,  B32B2305/024 ,  E01C9/086 ,  E04C2/296

摘要： A method of inserting z-axis reinforcing fibers into a multi-layer composite laminate. Layers of material made up of z-axis fiber and y-axis fibers are automatically transported into a z-fiber deposition machine having a housing with upper and lower surfaces. Z-axis apertures are formed in the respective upper and lower surfaces. An elongated solid rod having a tapered front tip is aligned in close proximity to the aperture in the bottom surface. The rod is first rotated by a motor and then actuated upwardly completely through the thickness of the layer of x-y material by an actuator. A first hollow tube having a z-axis is axially aligned with the aperture in the top surface and a fiber bundle is threaded downwardly through a first hollow tube to a position adjacent its bottom end. The z-fiber deposition machine has structure to feed a predetermined length of the fiber bundle downwardly through the first hollow tube so that it follows the pathway in the x-y material formed by the rod which is now withdrawn downwardly through the aperture in the bottom wall. The z-axis fiber is thus deposited into the x-y material. The top end of the z-axis fiber is then severed and the x-y material is then advanced a predetermined distance to complete the cycle and is, thus, set to be repeated.

摘要翻译： 将z轴增强纤维插入多层复合层压板的方法。 由z轴纤维和y轴纤维构成的材料层自动输送到具有上表面和下表面的壳体的z-纤维沉积机中。 在相应的上表面和下表面中形成Z轴孔。 具有锥形前端的细长实心杆对准在底表面中的孔附近。 杆首先由马达旋转，然后通过致动器完全通过x-y材料层的厚度向上致动。 具有z轴的第一空心管与顶表面中的孔轴向对准，并且纤维束向下穿过第一中空管到靠近其底端的位置。 z-纤维沉积机具有通过第一中空管向下馈送预定长度的纤维束的结构，使得其沿着由杆形成的x-y材料中的路径，该路径现在通过底壁中的孔向下取出。 因此，z轴光纤沉积到x-y材料中。 然后切断z轴光纤的顶端，然后将x-y材料前进预定距离以完成循环，并因此被设置为重复。

公开(公告)号：US08353694B1

公开(公告)日：2013-01-15

申请号：US13407629

申请日：2012-02-28

申请人： David W. Johnson ,  Scott A. Garrett ,  Stephen G. Moyers

发明人： David W. Johnson ,  Scott A. Garrett ,  Stephen G. Moyers

IPC分类号： B29C47/16

CPC分类号： B29C70/526 ,  B29K2101/12

摘要： A thermoplastic pultrusion die system for pultruding a thermoplastic composite includes a first pultrusion die member; a second pultrusion die member; a die cavity gap formed between the first pultrusion die member and the second pultrusion die member; and a die cavity gap adjustment mechanism that imparts movement to at least one of the first pultrusion die member and the second pultrusion die member to vary the die cavity gap within a very tight die cavity gap tolerance.

摘要翻译： 用于拉挤热塑性复合材料的热塑性拉挤模具系统包括第一拉挤模具构件; 第二拉挤模具构件; 形成在第一拉挤模具构件和第二拉挤模具构件之间的模腔间隙; 以及模腔间隙调节机构，其向第一拉挤模具构件和第二拉挤模具构件中的至少一个施加运动，以在非常紧密的模腔间隙容限内改变模腔间隙。