公开(公告)号：US20240083823A1

公开(公告)日：2024-03-14

申请号：US18508839

申请日：2023-11-14

Applicant: Northrop Grumman Systems Corporation

Inventor： Talbot P. Thrasher ,  Timothy E. Dominick

IPC: C04B35/83 ,  B29C64/118 ,  B29C64/30 ,  B33Y10/00 ,  B33Y40/00 ,  B33Y80/00 ,  C04B35/622 ,  C04B35/628 ,  C04B35/64

CPC classification number: C04B35/83 ,  B29C64/118 ,  B29C64/30 ,  B33Y10/00 ,  B33Y40/00 ,  B33Y80/00 ,  C04B35/6224 ,  C04B35/62272 ,  C04B35/62844 ,  C04B35/62886 ,  C04B35/64 ,  B29K2071/00

Abstract: Methods for fabricating high-temperature composite structures (e.g., structures comprising carbon-carbon composite materials or ceramic composite matrix (CMC) materials and configured for use at temperature at or exceeding about 2000° F. (1093° C.)) include forming precursor structures by additive manufacturing (“AM”) (e.g., “3D printing”) with a filament drawn from a spool. The precursor structures are exposed to high temperatures to pyrolyze a precursor matric material of the initial 3D printed structure. A liquid resin is used to impregnate the pyrolyzed structure, to densify the structure into a near-net final shape. Use of expensive and time-consuming molds and post-processing machining may be avoided. Large, unitary, integrally formed parts conducive for use in high-temperature environments may be formed using the methods of the disclosure.

公开(公告)号：US11701816B2

公开(公告)日：2023-07-18

申请号：US17122343

申请日：2020-12-15

Applicant: NORTHROP GRUMMAN SYSTEMS CORPORATION

Inventor： Eric G. Barnes ,  Talbot P. Thrasher ,  Timothy E. Dominick

IPC: B29C64/118 ,  B29C64/188 ,  B33Y40/20 ,  B33Y10/00 ,  B33Y70/10 ,  B29K101/12 ,  B29K307/04

CPC classification number: B29C64/118 ,  B29C64/188 ,  B33Y40/20 ,  B29K2101/12 ,  B29K2307/04 ,  B33Y10/00 ,  B33Y70/10

Abstract: A method for fabricating a composite part using a 3D printing machine. The method includes forming the part by depositing a plurality of part layers in a consecutive manner on top of each other where each layer is deposited by laying down rows of filaments made of a thermoplastic composite material. Reinforcing Z-pins are then inserted through the part layers to provide reinforcement of the part in the Z-direction. A plurality of additional part layers are deposited in a consecutive manner on top of each other on the part layers including the reinforcing Z-pins where each additional part layer is also deposited by laying down rows of filaments made of a thermoplastic composite material. Reinforcing Z-pins are also inserted through the additional part layers to provide reinforcement of the part in the Z-direction.

公开(公告)号：US20220184880A1

公开(公告)日：2022-06-16

申请号：US17122343

申请日：2020-12-15

Applicant: NORTHROP GRUMMAN SYSTEMS CORPORATION

Inventor： Eric G. Barnes ,  Talbot P. Thrasher ,  Timothy E. Dominick

IPC: B29C64/118 ,  B29C64/188 ,  B33Y40/20

Abstract: A method for fabricating a composite part using a 3D printing machine. The method includes forming the part by depositing a plurality of part layers in a consecutive manner on top of each other where each layer is deposited by laying down rows of filaments made of a thermoplastic composite material. Reinforcing Z-pins are then inserted through the part layers to provide reinforcement of the part in the Z-direction. A plurality of additional part layers are deposited in a consecutive manner on top of each other on the part layers including the reinforcing Z-pins where each additional part layer is also deposited by laying down rows of filaments made of a thermoplastic composite material. Reinforcing Z-pins are also inserted through the additional part layers to provide reinforcement of the part in the Z-direction.

公开(公告)号：US11814324B2

公开(公告)日：2023-11-14

申请号：US16516104

申请日：2019-07-18

Applicant: Northrop Grumman Systems Corporation

Inventor： Talbot P. Thrasher ,  Timothy E. Dominick

IPC: C04B35/83 ,  B33Y10/00 ,  B33Y40/00 ,  B33Y80/00 ,  B29C64/118 ,  B29C64/30 ,  C04B35/622 ,  C04B35/628 ,  C04B35/64 ,  B29K71/00 ,  B29K81/00

CPC classification number: C04B35/83 ,  B29C64/118 ,  B29C64/30 ,  B33Y10/00 ,  B33Y40/00 ,  B33Y80/00 ,  C04B35/6224 ,  C04B35/62272 ,  C04B35/62844 ,  C04B35/62886 ,  C04B35/64 ,  B29K2071/00 ,  B29K2081/04 ,  C04B2235/422 ,  C04B2235/5232 ,  C04B2235/5248 ,  C04B2235/5252 ,  C04B2235/6026 ,  C04B2235/616 ,  C04B2235/656

Abstract: Methods for fabricating high-temperature composite structures (e.g., structures comprising carbon-carbon composite materials or ceramic composite matrix (CMC) materials and configured for use at temperature at or exceeding about 2000° F. (1093° C.)) include forming precursor structures by additive manufacturing (“AM”) (e.g., “3D printing”). The precursor structures are exposed to high temperatures to pyrolyze a precursor matric material of the initial 3D printed structure. A liquid resin is used to impregnate the pyrolyzed structure, to densify the structure into a near-net final shape. Use of expensive and time-consuming molds and post-processing machining may be avoided. Large, unitary, integrally formed parts conducive for use in high-temperature environments may be formed using the methods of the disclosure.