Patents by Inventor Kenneth Lyle Tyler

Kenneth Lyle Tyler has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Method and apparatus for continuous composite three-dimensional printing
    Patent number: 10759109
    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: July 2, 2019
    Date of Patent: September 1, 2020
    Assignee: Continuous Composites Inc.
    Inventor: Kenneth Lyle Tyler
  • Method and apparatus for continuous composite three-dimensional printing
    Patent number: 10744707
    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: May 2, 2019
    Date of Patent: August 18, 2020
    Assignee: Continuous Composites Inc.
    Inventor: Kenneth Lyle Tyler
  • Method and apparatus for continuous composite three-dimensional printing
    Patent number: 10744708
    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: July 2, 2019
    Date of Patent: August 18, 2020
    Assignee: Continuous Compostites Inc.
    Inventor: Kenneth Lyle Tyler
  • System and method for additively manufacturing a composite structure
    Patent number: 10723073
    Abstract: A system for additively manufacturing a composite part is disclosed. The system may include a vat configured to hold a supply of resin, and a build surface disposed inside the vat. The system may also include a print head configured to discharge a matrix-coated continuous reinforcement onto the build surface, and an energy source configured to expose resin on a surface of the matrix-coated continuous reinforcement to a cure energy.
    Type: Grant
    Filed: January 18, 2018
    Date of Patent: July 28, 2020
    Assignee: Continuous Composites Inc.
    Inventors: Kenneth Lyle Tyler, Ryan C. Stockett
  • Composite vehicle body
    Patent number: 10717512
    Abstract: A vehicle body may have an internal skeleton, and a skin fabricated in-situ over the internal skeleton. The internal skeleton may be fabricated via a first additive manufacturing system. The skin may be fabricated via a second additive manufacturing system that is different from the first additive manufacturing system.
    Type: Grant
    Filed: August 22, 2017
    Date of Patent: July 21, 2020
    Assignee: Continuous Composites Inc.
    Inventors: Kenneth Lyle Tyler, Ryan C. Stockett
  • CONTROL METHODS FOR ADDITIVE MANUFACTURING SYSTEM
    Publication number: 20200207012
    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: Application
    Filed: March 10, 2020
    Publication date: July 2, 2020
    Applicant: Continuous Composites Inc.
    Inventors: KENNETH LYLE TYLER, Blake L. Alfson, Josiah D. Coad, Kaleb Forrest Beebout
  • Head and system for continuously manufacturing composite hollow structure
    Patent number: 10668663
    Abstract: A head is disclosed for use with a manufacturing system. The head may have a housing configured to discharge a tubular structure reinforced with at least one continuous fiber and having a three-dimensional trajectory, and a cure enhancer operatively connected to the housing and configured to cure a liquid matrix in the tubular structure during discharge. The head may also have a nozzle configured to discharge a fill material into the tubular structure, and a wand extending from the housing to the nozzle.
    Type: Grant
    Filed: October 2, 2017
    Date of Patent: June 2, 2020
    Assignee: Continuous Composites Inc.
    Inventor: Kenneth Lyle Tyler
  • SYSTEM FOR ADDITIVE MANUFACTURING
    Publication number: 20200156316
    Abstract: A system is disclosed for additive manufacturing of a composite structure. The system may include an outlet through which a composite material is discharged, and a nose that is a component separate from the outlet and located at a distal end of the outlet. The nose may be biased axially relative to the outlet, from a retracted position to an extended position. The nose extends axially past the distal end of the outlet in the extended position.
    Type: Application
    Filed: September 24, 2019
    Publication date: May 21, 2020
    Applicant: Continuous Composites Inc.
    Inventors: KENNETH LYLE TYLER, ANDREW JOHN OVERBY, RYAN C. STOCKETT
  • Control methods for additive manufacturing system
    Patent number: 10647058
    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: June 2, 2017
    Date of Patent: May 12, 2020
    Assignee: Continuous Composites Inc.
    Inventors: Kenneth Lyle Tyler, Blake L. Alfson, Josiah D. Coad, Kaleb Forrest Beebout
  • Additive manufacturing system having shutter mechanism
    Patent number: 10632673
    Abstract: A system is disclosed for use in additively manufacturing a composite structure. The system may include a head configured to discharge a composite material including a matrix and continuous reinforcement. The system may also include a shutter mechanism mounted to the head and configured to grasp the continuous reinforcement after discharge from the head.
    Type: Grant
    Filed: June 1, 2017
    Date of Patent: April 28, 2020
    Assignee: Continuous Composites Inc.
    Inventor: Kenneth Lyle Tyler
  • Additive manufacturing system having adjustable curing
    Patent number: 10625467
    Abstract: A system is disclosed for use in additively manufacturing a composite structure. The system may include a head having a nozzle configured to discharge a composite material including a matrix and a reinforcement, and a cure enhancer configured to direct energy to the composite material to enhance curing of the matrix. The system may also include an optic adjustably positioned between the cure enhancer and the nozzle of the head.
    Type: Grant
    Filed: July 6, 2017
    Date of Patent: April 21, 2020
    Assignee: Continuous Composites Inc.
    Inventor: Kenneth Lyle Tyler
  • ADDITIVE MANUFACTURING SYSTEM HAVING IN-HEAD FIBER-TEASING
    Publication number: 20200108555
    Abstract: A head is disclosed for an additive manufacturing system having a support. The head may include a body connectable to and moveable by the support. The body may have a discharge end configured to discharge a composite material. The head may also include a wetting location inside the body at which a continuous reinforcement is wetted with a matrix to form the composite material, and a fiber-teasing mechanism located inside the body and upstream of the discharge end and the wetting location. The body and fiber-teasing mechanism may be configured to move together during movement of the support.
    Type: Application
    Filed: December 5, 2019
    Publication date: April 9, 2020
    Applicant: Continuous Composites Inc.
    Inventors: Kenneth Lyle Tyler, Ryan C. Stockett, Kaleb Forrest Beebout
  • ADDITIVE MANUFACTURING SYSTEM HAVING IN-HEAD FIBER-TEASING
    Publication number: 20200108556
    Abstract: A method is disclosed for additively manufacturing a composite structure. The method may include directing a continuous reinforcement into a print head, spreading the continuous reinforcement while inside of the print head, and wetting the continuous reinforcement inside of the print head. The method may also include discharging the wetted continuous reinforcement, and moving the print head during discharging.
    Type: Application
    Filed: December 5, 2019
    Publication date: April 9, 2020
    Applicant: Continous Composites Inc.
    Inventors: Kenneth Lyle Tyler, Ryan C. Stockett, Kaleb Forrest Beebout
  • Method and apparatus for continuous composite three-dimensional printing
    Patent number: 10603836
    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: November 4, 2016
    Date of Patent: March 31, 2020
    Assignee: Continuous Composites Inc.
    Inventor: Kenneth Lyle Tyler
  • Additive manufacturing system having adjustable energy shroud
    Patent number: 10603840
    Abstract: A system is disclosed for use in additively manufacturing a composite structure. The system may include a head configured to discharge a composite material including a matrix and a plurality of continuous reinforcements. The system may also include a cure enhancer configured to direct energy to the composite material to enhance curing of the matrix, and a shroud adjustably mounted to the head and configured to selectively block at least some of the energy from reaching the matrix.
    Type: Grant
    Filed: June 8, 2017
    Date of Patent: March 31, 2020
    Assignee: Continuous Composites Inc.
    Inventors: Kenneth Lyle Tyler, Martin S. Mueller
  • Print head for additive manufacturing system
    Patent number: 10589463
    Abstract: A print head is disclosed for use with an additive manufacturing system. The print head may include a nozzle, and a traveling anchor point mounted at a trailing side of the nozzle. The traveling anchor point may include an arm extending radially outward from the nozzle, and a plunger slidingly disposed in the arm. The traveling anchor point may also include an actuator configured to selectively move the plunger from a stowed position to an engaged position against material discharging from the nozzle.
    Type: Grant
    Filed: April 24, 2018
    Date of Patent: March 17, 2020
    Assignee: Continuous Composites Inc.
    Inventors: Ryan C. Stockett, Kenneth Lyle Tyler
  • Additive manufacturing system having in-head fiber teasing
    Patent number: 10543640
    Abstract: A head is disclosed for an additive manufacturing system. The head may include a body, and a nozzle connected to a discharge end of the body. The nozzle may be configured to discharge a composite material including a matrix and a continuous reinforcement that is at least partially coated in the matrix. The head may also include a fiber-teasing mechanism located inside the body and upstream of the nozzle.
    Type: Grant
    Filed: August 22, 2017
    Date of Patent: January 28, 2020
    Assignee: Continuous Composites Inc.
    Inventors: Kenneth Lyle Tyler, Ryan C. Stockett, Kaleb Forrest Beebout
  • ADDITIVE MANUFACTURING SYSTEM
    Publication number: 20200001528
    Abstract: A system for additively manufacturing a composite part is disclosed. The system may include a vat configured to hold a supply of resin, and a build surface disposed inside the vat. The system may also include a print head configured to discharge a matrix-coated continuous reinforcement onto the build surface, and an energy source configured to expose resin on a surface of the matrix-coated continuous reinforcement to a cure energy.
    Type: Application
    Filed: August 12, 2019
    Publication date: January 2, 2020
    Applicant: Continuous Composites Inc.
    Inventors: Kenneth Lyle Tyler, Ryan C. Stockett
  • METHOD AND APPARATUS FOR CONTINUOUS COMPOSITE THREE-DIMENSIONAL PRINTING
    Publication number: 20190322034
    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: Application
    Filed: July 2, 2019
    Publication date: October 24, 2019
    Applicant: Continuous Composites Inc.
    Inventor: Kenneth Lyle Tyler
  • METHOD AND APPARATUS FOR CONTINUOUS COMPOSITE THREE-DIMENSIONAL PRINTING
    Publication number: 20190322035
    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: Application
    Filed: July 2, 2019
    Publication date: October 24, 2019
    Applicant: Continuous Composites Inc.
    Inventor: KENNETH LYLE TYLER