Patents Assigned to Continuous Composites Inc.
  • Publication number: 20210370594
    Abstract: A system is disclosed for use in additively manufacturing a composite structure. The system may include a head configured to discharge a continuous reinforcement at least partially coated with a matrix. The head may have a matrix reservoir, and a nozzle connected to an end of the matrix reservoir. The system may further include a support configured to move the head during discharging, and a supply of matrix. The system may also include at least one sensor configured to generate a signal indicative of a matrix characteristic inside of the head, and a controller configured to selectively affect the supply of matrix based on the signal.
    Type: Application
    Filed: August 13, 2021
    Publication date: December 2, 2021
    Applicant: Continuous Composites Inc.
    Inventor: Trevor David BUDGE
  • Patent number: 11173660
    Abstract: A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.
    Type: Grant
    Filed: April 9, 2021
    Date of Patent: November 16, 2021
    Assignee: Continuous Composites Inc.
    Inventor: Kenneth Lyle Tyler
  • Publication number: 20210346733
    Abstract: A respirator is disclosed for use in protecting a wearer from airborne contaminates. The respirator may include a body configured to seal against a face of a wearer and provide clearance for a nose, a mouth, and a chin of the wearer. The respirator may also include a frame connectable to the body. At least one of the body and the frame may be configured to receive and seal against a plurality of filter media having different shapes.
    Type: Application
    Filed: March 29, 2021
    Publication date: November 11, 2021
    Applicant: Continuous Composites Inc.
    Inventors: Nathan Andrew STRANBERG, Andrew John OVERBY
  • Publication number: 20210347119
    Abstract: A system is disclosed for use in additively manufacturing a composite structure. The system may include at least one support, and a print head operatively connected to the at least one support and configured to discharge composite material. The system may further include an auxiliary tool operatively connected to the at least one support and configured to receive the composite material discharged by the print head.
    Type: Application
    Filed: July 23, 2021
    Publication date: November 11, 2021
    Applicant: Continuous Composites Inc.
    Inventors: Nathaniel Isaak Stuart, Tyler B. Alvarado, Ryan C. Stockett
  • Patent number: 11167495
    Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a head having a matrix reservoir, a nozzle fluidly connected to the matrix reservoir and configured to discharge a composite material into a feature of an existing component. a guide configured to detect a location of the feature, and a cure enhancer configured to expose composite material discharging from the nozzle to a cure energy. The system may also include a support configured to move the head in multiple dimensions, and a controller in communication with the cure enhancer and the support. The controller may be configured to cause the support to move the head during discharge of the composite material into the feature based on the detected location of the feature.
    Type: Grant
    Filed: December 29, 2017
    Date of Patent: November 9, 2021
    Assignee: Continuous Composites Inc.
    Inventors: Blake L. Alfson, Ryan C Stockett, Kenneth Lyle Tyler
  • Patent number: 11161300
    Abstract: A print head is disclosed for use in an additive manufacturing system. The print head may include a receiving end configured to receive a matrix and a continuous reinforcement, and a discharging end configured to discharge the continuous reinforcement at least partially coated in the matrix. The print head may also include a compactor located at the discharging end and forming a tool center point for the print head.
    Type: Grant
    Filed: March 28, 2019
    Date of Patent: November 2, 2021
    Assignee: Continuous Composites Inc.
    Inventors: Trevor David Budge, Ryan C. Stockett, Tyler B. Alvarado, Kenneth Lyle Tyler, Colin Hugh Hambling, Brian Dunham, Nathan Andrew Stranberg
  • Patent number: 11161297
    Abstract: A method is disclosed for controlling an additive manufacturing system. The method may include causing a head to discharge composite material along a first trajectory, and activating a cure enhancer to at least partially cure composite material discharging from the head along the first trajectory. The method may also include selectively deactivating the cure enhancer as the head nears a corner location, moving the head to a second trajectory after the head reaches the corner location, and reactivating the cure enhancer after moving the head to the second trajectory.
    Type: Grant
    Filed: March 10, 2020
    Date of Patent: November 2, 2021
    Assignee: Continuous Composites Inc.
    Inventors: Kenneth Lyle Tyler, Blake L. Alfson, Josiah D. Coad, Kaleb Forrest Beebout
  • Patent number: 11135764
    Abstract: A method is disclosed for additively manufacturing a composite structure. The method may include directing a continuous reinforcement into a print head, and coating the continuous reinforcement with a first matrix component inside of the print head. The method may further include coating the continuous reinforcement with a second matrix component, discharging the continuous reinforcement through a nozzle of the print head, and moving the print head in multiple dimensions during the discharging. The first and second matrix components interact to cause hardening of a matrix around the continuous reinforcement.
    Type: Grant
    Filed: May 31, 2018
    Date of Patent: October 5, 2021
    Assignee: Continuous Composites Inc.
    Inventors: Tyler B. Alvarado, Trevor David Budge, Ryan C. Stockett, John Swallow
  • Patent number: 11135770
    Abstract: A system is disclosed for use in additively manufacturing a composite structure. The system may include a head configured to discharge a continuous reinforcement at least partially coated with a matrix. The head may have a matrix reservoir, and a nozzle connected to an end of the matrix reservoir. The system may further include a support configured to move the head during discharging, and a supply of matrix. The system may also include at least one sensor configured to generate a signal indicative of a matrix characteristic inside of the head, and a controller configured to selectively affect the supply of matrix based on the signal.
    Type: Grant
    Filed: November 6, 2018
    Date of Patent: October 5, 2021
    Assignee: Continuous Composites inc.
    Inventor: Trevor David Budge
  • Patent number: 11135769
    Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a head configured to discharge a continuous reinforcement that is at least partially coated with a matrix, and a housing trailing from the head and configured to at least partially enclose the continuous reinforcement after discharge. The system may also include a heat source disposed at least partially inside the oven, and a support configured to move the head during discharging.
    Type: Grant
    Filed: May 31, 2018
    Date of Patent: October 5, 2021
    Assignee: Continuous Composites inc.
    Inventors: Ryan C. Stockett, Kenneth Lyle Tyler
  • Publication number: 20210299956
    Abstract: An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a print head configured to discharge a material, a first structure, and a second structure. The first structure may be configured to move the print head within a plane during discharge of the material. The second structure may be configured to move the print head within the plane during material discharge, the second structure being movable together with the print head by the first structure.
    Type: Application
    Filed: March 9, 2021
    Publication date: September 30, 2021
    Applicant: Continuous Composites Inc.
    Inventor: Andrew John OVERBY
  • Patent number: 11130285
    Abstract: A print head is disclosed for use with an additive manufacturing system. The print head may include a nozzle tip, a first matrix source configured to selectively supply a structural matrix to the nozzle tip, and a second matrix source configured to selectively supply a temporary support matrix to the nozzle tip. The print head may also include a reinforcement supply configured to supply a continuous reinforcement through the nozzle tip only when the first matrix source is supplying the structural matrix to the nozzle tip.
    Type: Grant
    Filed: May 30, 2018
    Date of Patent: September 28, 2021
    Assignee: Continuous Composites Inc.
    Inventors: Kenneth Lyle Tyler, Ryan C. Stockett
  • Patent number: 11130284
    Abstract: A print head is disclosed for use in an additive manufacturing system. The print head may include a discharge outlet configured to discharge a continuous reinforcement, and an applicator disposed upstream of the discharge outlet and configured to apply a solid film to the continuous reinforcement prior to discharge. The print head may also include a cure enhancer configured to soften the solid film after discharge.
    Type: Grant
    Filed: February 19, 2019
    Date of Patent: September 28, 2021
    Assignee: Continuous Composites Inc.
    Inventor: Kenneth Lyle Tyler
  • Publication number: 20210283840
    Abstract: 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.
    Type: Application
    Filed: May 20, 2021
    Publication date: September 16, 2021
    Applicant: Continuous Composites Inc.
    Inventors: Trevor David Budge, Kenneth Lyle Tyler, Colin Hugh Hambling
  • Publication number: 20210283841
    Abstract: 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 movable to adjust a distance between the housing and the compacting wheel.
    Type: Application
    Filed: May 20, 2021
    Publication date: September 16, 2021
    Applicant: Continuous Composites Inc.
    Inventors: TREVOR DAVID BUDGE, Kenneth Lyle Tyler, Colin Hugh Hambling
  • Patent number: 11110655
    Abstract: 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.
    Type: Grant
    Filed: November 8, 2018
    Date of Patent: September 7, 2021
    Assignee: Continuous Composites Inc.
    Inventors: Trevor David Budge, Kenneth Lyle Tyler, Colin Hugh Hambling
  • Patent number: 11110656
    Abstract: A system is disclosed for use in additively manufacturing a composite structure. The system may include at least one support, and a print head operatively connected to the at least one support and configured to discharge composite material. The system may further include an auxiliary tool operatively connected to the at least one support and configured to receive the composite material discharged by the print head.
    Type: Grant
    Filed: February 19, 2019
    Date of Patent: September 7, 2021
    Assignee: Continuous Composites Inc.
    Inventors: Nathaniel Isaak Stuart, Tyler B. Alvarado, Ryan C. Stockett
  • Patent number: 11110654
    Abstract: A system is disclosed for use in additively manufacturing a composite structure. The system may include a head configured to discharge a continuous reinforcement. The system may further include an external applicator configured to apply a matrix to the discharged continuous reinforcement, and a cure enhancer configured to expose the matrix to a cure energy at a side of the external applicator opposite the head.
    Type: Grant
    Filed: February 19, 2019
    Date of Patent: September 7, 2021
    Assignee: Continuous Composites Inc.
    Inventors: Tyler B. Alvarado, Trevor David Budge, Ryan C. Stockett
  • Patent number: 11109453
    Abstract: A system is disclosed for additively manufacturing a structure. The system may include a feeder configured to feed a thin-film material through the system, and a cutter configured to cut out of the thin-film material a pattern associated with a shape of the structure at a particular layer within the structure. The system may also include a placer configured to place the pattern in at least one of a desired location and a desired orientation.
    Type: Grant
    Filed: February 15, 2018
    Date of Patent: August 31, 2021
    Assignee: Continuous Composites Inc.
    Inventors: Kenneth Lyle Tyler, Ryan C. Stockett, Trevor David Budge
  • Publication number: 20210260821
    Abstract: An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a housing, a supply module operatively mounted to the housing and configured to hold a supply of continuous reinforcement, an impregnation module operatively mounted to the housing and configured to wet the continuous reinforcement with a matrix, and a clamping module operatively mounted to the housing downstream of the supply module relative to movement of a reinforcement through the print head. The clamping module may be configured to selectively clamp the continuous reinforcement. The additive manufacturing system may also include a controller in communication with the support and the print head and configured to coordinate operations of the support and the print head to fabricate a three-dimensional structure.
    Type: Application
    Filed: February 24, 2021
    Publication date: August 26, 2021
    Applicant: Continuous Composites Inc.
    Inventors: Nathan Andrew STRANBERG, Andrew Michael Stulc, Brock Adam Jahner, Stephen Tyler Wilson