APPARATUS AND METHOD FOR MANUFACTURE OF BRAIDED PREFORMS

Abstract

A braiding apparatus may comprise a braiding machine, a lower guide mechanism, and an upper guide mechanism. The lower guide mechanism may comprise a multiple-axis robot or a multiple axis-mechanism. The upper guide mechanism may comprise a multiple-axis robot or a multiple axis-mechanism.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to, and the benefit of, U.S. Provisional Patent Application No. 61/970,643 filed Mar. 26, 2014, and U.S. Provisional Patent Application No. 61/970,671 filed Mar. 26, 2014, and U.S. Provisional Patent Application No. 61/970,677 filed Mar. 26, 2014, and U.S. Provisional Patent Application No. 61/970,668 filed Mar. 26, 2014, and U.S. Provisional Patent Application No. 61/970,623 filed Mar. 26, 2014, and U.S. Provisional Patent Application No. 61/970,952 filed Mar. 27, 2014, all of which were filed with the United States Patent and Trademark Office, and each of which is hereby incorporated herein by reference.

TECHNICAL FIELD

The present subject matter relates generally to a braiding apparatus. More specifically, the present subject matter relates to an apparatus and method for manufacturing braided articles. In some embodiments the braided articles may be preforms.

SUMMARY AND BACKGROUND

The manufacture of braided articles is of substantial interest. Development of new methods and apparatus to conduct the braiding of article including, preforms, remains of interest.

Provided is a braiding apparatus that may comprise a braiding machine, a lower guide mechanism, and an upper guide mechanism. The lower guide mechanism may comprise a multiple-axis robot or a multiple axis-mechanism. The upper guide mechanism may comprise a multiple-axis robot or a multiple axis-mechanism.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is an elevation view of a braiding apparatus.

FIG. 2 is elevation view of a braiding apparatus braiding a start assembly.

FIG. 3 is an elevation view of a braiding apparatus cutting an overbraid on an overbraid form assembly.

FIG. 4 is a view of an overbraid form assembly.

FIG. 5 is a view of a start assembly.

FIG. 6 is an elevation view of a braiding apparatus operating on an interconnected overbraid form assembly.

FIG. 7 shows multiple views of the various orientations of an interconnected overbraid form assembly as it moves though a braiding operation.

Also attached is an Appendix with drawings showing related subject matter.

DETAILED DESCRIPTION

With reference to FIGS. 1-N, an apparatus usable in a method to manufacture braided articles may be referred to herein as a braiding apparatus 100. A braiding apparatus 100 may comprise a braiding machine 120, a lower guide mechanism 140, and an upper guide mechanism 160. The lower guide mechanism 140 may comprise either a multiple-axis robot 142 or another multiple axis mechanism. The upper guide mechanism 160 may comprise either a multiple-axis robot 162 or another multiple axis mechanism. The lower guide mechanism 140 and the upper guide mechanism 160 may have coordinated control by a controller 104. In certain embodiments, and without limitation, the braiding machine 120 may be a maypole braider.

The braiding apparatus 100 may further comprise a cutting mechanism 172. The cutting mechanism 172 may be affixed to the upper guide mechanism 160 or may be part of a separate mechanism 170. Mechanism 170 may be a multiple-axis robot 174 or another multiple axis mechanism.

The braiding apparatus 100 may be adapted for operational engagement with an overbraid form assembly 180. An overbraid form assembly 180 may comprise an overbraid form 182 having a leading form edge 181, a lead guide tool 184 affixed to the leading form edge 181, and a trailing guide tool 186. The overbraid form 182 comprises an overbraid form surface 182a which is adapted for forming a braid 118 thereon. Operational engagement of the braiding apparatus 100 with the overbraid form assembly 180 may comprise forming of a braid 118 over the overbraid form 182 by the braiding machine 100 and either 1) engagement of the trailing guide tool 186 by the lower guide mechanism 140, or 2) engagement of the lead guide tool 184 by the upper guide mechanism 160.

The lead guide tool 184 may comprise a lead grasp feature 185 adapted for being grasped by a grasping component 164 of the upper guide mechanism 160. By grasping the lead grasp feature 185, the upper guide mechanism 160 may guide the lead guide tool 184 through a braid formation region 124. The braid formation region 124 is the general area of the braiding machine 120 where the braided structure 110 begins to form. As the braided structure 110 is laid down on the overbraid form 182 the upper guide mechanism 160 is engaged to the lead guide tool 184 by lead grasp feature 185 through the braid 118. That is, the braid 118 is trapped between the grasping component 164 of the upper guide mechanism 160 and the lead guide tool 184.

The lead guide tool 184 may comprise a lead interlocking feature 188. A lead interlocking feature 188 may be adapted for selectable engagement with a counterpart feature such as the trailing interlocking feature 189 or the start interlocking tool 136 described herebelow. A lead interlocking feature 188 may be male or female or of other form chosen with good engineering judgment. A lead guide tool 184 may comprise a cutting facilitation feature 183. A cutting facilitation feature 183 may facilitate the cutting of the braid 118 and may be, without limitation a cutting groove.

The trailing guide tool 186 may comprise a trailing grasp feature 187 adapted for being grasped by a grasping component 144 of the lower guide mechanism 140. The trailing guide tool 186 may comprise a trailing interlocking feature 189. A trailing interlocking feature 189 may be adapted for selectable engagement with a counterpart feature such as a lead interlocking feature 188. A trailing interlocking feature 189 may be male or female or of other form chosen with good engineering judgment. A trailing guide tool 186 may comprise a cutting facilitation feature 183. A cutting facilitation feature 183 may facilitate the cutting of the braid 118 and may be, without limitation a cutting groove.

The braiding apparatus 100 may be adapted for operational engagement with a start assembly 130. A start assembly 130 may comprise an elongated mandrel 132, a start guide tool 134 having a leading start edge 131, and a start interlocking tool 136.

The elongated mandrel 132 comprises an elongated mandrel surface 132a which is adapted for forming a braid 118 thereon. In some embodiments the elongated mandrel 132 is substantially cylindrical. Operational engagement of the braiding apparatus 100 with the start assembly 130 may comprise forming of a braid 118 over the elongated mandrel 132 by the braiding machine 100 and either 1) engagement of the start interlocking tool 136 by the lower guide mechanism 140, or 2) engagement of the start guide tool 134 by the upper guide mechanism 160.

The start guide tool 134 may comprise a start grasp feature 135 adapted for being grasped by a grasping component 164 of the upper guide mechanism 160. By grasping the start grasp feature 135, the upper guide mechanism 160 may guide the start assembly 130 through the braid formation region 124. As the braided structure 110 is laid down on the elongated mandrel 132 the upper guide mechanism 160 is engaged to the start guide tool 134 by start grasp feature 135 through the braid 118. That is, the braid 118 is trapped between the grasping component 164 of the upper guide mechanism 160 and the start guide tool 134. The start guide tool 134 may comprise a cutting facilitation feature 133. A cutting facilitation feature 133 may facilitate the cutting of the braid 118 and may be, without limitation a cutting groove. The start guide tool 134 may optionally comprise conventional features for ting or gripping fibers 112, axial bias or otherwise, at the beginning of the braiding operation.

The start interlocking tool 136 may be graspable by the grasping component 144 of the lower guide mechanism 140. By grasping the start interlocking tool 136, the lower guide mechanism 140 may guide the start assembly 130 into or through the braid formation region 124. The start interlocking tool 136 may be adapted for selectable engagement with a counterpart feature such as a lead interlocking feature 188. A start interlocking tool 136 may be male or female or of other form chosen with good engineering judgment.

The leading form edge 181 may be the first portion of the overbraid form 182 to enter the shed 122 during a braiding operation.

Without limitation, one method for using the braiding apparatus 100 to manufacture braided articles is as follows.

Lower guide mechanism 140 engages start assembly 130 by grasping the start interlocking tool 136 with the grasping component 144 and guides the start assembly 130 so that the leading edge 131 of the start guide tool 134 is located at a predetermined position in the braid formation region 124. Fibers 112 are pulled off of bias carriers 114 and/or axial spools 116 and brought to the axis 126 of the braiding machine 120 and up along the start assembly 130. Braiding machine 120 is operated at some operating speed to generate braid 118 over start guide tool 134 and start assembly 130 is moved along axis 126 by the lower guide mechanism 140 at some predetermined ratio with respect to the operating speed of braiding machine 120. Once the braid 118 has formed over the start guide tool 134, the upper guide mechanism 160 may engage the start grasp feature 135, trapping the braid 118 between the grasping component 164 of the upper guide mechanism 160 and the start guide tool 134, to guide the start assembly 130. The lower guide mechanism 140 disengages from the start assembly 130. The lower guide mechanism 140 picks up an overbraid form assembly 180 by engaging with its trailing guide tool 186 and engages the lead guide tool 184 of the overbraid form assembly 180 with the start interlocking tool 136 on the start assembly 130. Operation of the braiding machine 120 to continue braiding resumes until lead guide tool 184 of overbraid form assembly 180 is in position to be engaged by the upper guide mechanism 160. At this point a repetitive operational loop may be initiated. The upper guide mechanism 160 engages the lead guide tool 184 of the overbraid form assembly 180 to guide the overbraid form assembly 180. The cutting mechanism 172 is activated to trim the braid 118 at some desired location above the region at which the upper guide mechanism 160 engages the lead guide tool 184. Operation of the braiding machine 120 to continue braiding resumes with the upper guide mechanism 160 and the lower guide mechanism 140 coordinating motion through controller 104 so that the axial fibers follow desired predetermined paths along the overbraid form assembly 180. When the overbraid form 182 and a desired portion of the trailing guide tool 186 have been braided, braiding stops. The lower guide mechanism 140 disengages from the trailing guide tool 186. At this point braiding may stop entirely or if further braiding is desired, continued. If continuation is desired, the lower guide mechanism 140 picks up a new overbraid form assembly 180 and engages the lead guide tool 184 of this new overbraid form assembly 180 with the trailing guide tool 186 of the old overbraid form assembly 180. Operation of the braiding machine 120 to continue braiding resumes until the lead guide tool 184 of the new overbraid form assembly 180 in in position to be engaged by the upper guide mechanism 160. At this point the repetitive operational loop terminates and operation continues by repeating the steps beginning at the point of initiation of the repetitive operational loop.

It should be understood that the braided articles to be formed may comprise any of a variety of desired shapes. In some non-limiting embodiments, the braided articles to be formed may be preforms for use in braided shoes or components of braided shoes, braided preforms for aircraft seat frames, braided preforms for vehicle fuselage frames and families of braided structures of similar geometry but varying dimensions.

For families of braided structures of similar geometry but varying overall or other dimensions, the lead guide tool 184 and the trailing guide tool 186 of the overbraid form assemblies 180 may have varying extents such that the grasp features, lead grasp feature 185 and trailing grasp feature 187, are located at a fixed position relative to a common point within the family of braided structures, thereby enabling the upper guide mechanism 160 and the lower guide mechanism 140 to grip the lead guide tool 184 and the trailing guide tool 186 at the same fixed position in the braiding space as each overbraid form assembly 180 is braided. This eliminates the need for a hunting mechanism to locate the grasp features.

For braided structures comprised of more than one overbraid layer, the above-described method and apparatus may be employed to overbraid a first layer on the overbraid form assembly 180, and subsequent overbraid layers may be laid over the first layer by feeding the same overbraid form assembly 180, with the first layer thereon, back through the braiding apparatus 100 and using the apparatus and method as described to overbraid a second layer on the braided overbraid form assembly 180. In this manner two or more layers of braid may be layered as required.

In some embodiments, multiple apparatus may be used for layers of varying fiber content, fiber density, etc.

To facilitate tracking an quality control of preforms some of the overbraid forms, such as overbraid form assembly 180, may employ an identification means 192 such as, without limitation, non-contact, non-line-of-sight means like an embedded RFID tag. By using such identification means ID and other designation data can be sensed through any braid layers thereon. Such identification means 192 may be detectable by detectors 194 in other components in the apparatus.

The overbraid forms, such as overbraid form assembly 180, may be constant geometry forms selected as required for the production sequence or, may be comprised of customized or customizable geometric features to facilitate production of preforms within the range of parts comprising the family of parts to be produced.

The overbraid forms, such as overbraid form assembly 180, may be produced on demand by 3D printing, building up customized geometric features on a standards form by 3D printing, machining customized 3D forms on demand from a standard master with overall dimensions greater than or equal to the maximum dimensions encompassed by the family of parts, or may be comprised of flexible forms with internal mechanical, pneumatic, or other internal adjustment means to change the outer geometric form of the overbraid form, or the dimensions of a standard master form may be altered by selective dipping of the form into a hardenable or semi-hardenable medium chosen with good engineering judgment.

The braided structure 110 produced on said apparatus 100 and by said method may be comprised of conventional triaxial braided structures with dry fibers wherein the axial fibers 112 laid into the regular, or plain, braid lock the overall geometry of the braided structure 110 once the overbraid is fully formed over the entire overbraid form 182.

Alternatively, hot melt fibers may be co-wound with the axial fibers 112 with heat then applied to the fully-formed braid 118 continuously or periodically in the region below the lead grasp feature 185 through to the trailing grasp feature 187 or portions of said region thereby further assisting the retention of the fully-formed overbraid braided structure 110.

Alternatively, elastic axial fibers may be substituted for some or all generally inelastic fibers to facilitate making preforms of a braided structure 110 that can be stretched to remove them from the overbraid form 182 and then return to the original overbraid shape or, once remove, to permit the braided structure 110 to be stretched over other forms to facilitate subsequent processing.

It should be noted that the engagement of the above noted interlocking components, start interlocking tool 136, lead interlocking feature 188, and trailing interlocking feature 189 may be rotatable engagement whereby the engaged components are free to rotate with respect to one another about multiple dimensions simultaneously. Such engagement may be chosen with good engineering judgment. Such engagement may include various kinds of ball joints.

While the subject matter has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the subject matter. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the subject matter without departing from its scope. Therefore, it is intended that the subject matter not be limited to the particular embodiment disclosed, but that the subject matter will include all embodiments falling within the scope of the appended claims.

Claims

1. A braiding apparatus comprising,

a braiding machine

a lower guide mechanism comprising either a multiple-axis robot; or a multiple axis-mechanism; and

an upper guide mechanism comprising either a multiple-axis robot; or a multiple axis-mechanism.

2. The braiding apparatus of claim 1, wherein the braiding apparatus is adapted for operational engagement with an overbraid form assembly,

said overbraid form assembly comprising an overbraid form having a leading form edge, a lead guide tool affixed to the leading edge, and a trailing guide tool; and

said operational engagement with the overbraid form assembly comprising the forming of a braid over the overbraid form by the braiding machine, and either engagement of the trailing guide tool by the lower guide mechanism, or engagement of the lead guide tool by the upper guide mechanism.

3. The braiding apparatus of claim 2, wherein the braiding apparatus is adapted for operational engagement with a start assembly,

said start assembly comprising an elongated mandrel; a start guide tool having a leading start edge; and a start interlocking tool; and

said operational engagement with the start assembly comprising the forming of a braid over the elongated mandrel by the braiding machine, and either engagement of the start interlocking tool by the lower guide mechanism, or engagement of the start guide tool by the upper guide mechanism.

4. The braiding apparatus of claim 3, wherein said braiding machine is a maypole braider.

5. The braiding apparatus of claim 4, wherein said lead guide tool comprises

a lead grasp feature adapted for being grasped by the upper guide mechanism; and

a lead interlocking feature.

6. The braiding apparatus of claim 5, wherein said trailing guide tool comprises

a graspable feature adapted for being grasped by the lower guide mechanism; and

a trailing interlocking feature.

7. The braiding apparatus of claim 6, wherein said lead guide tool comprises a cutting facilitation feature.

8. The braiding apparatus of claim 7, wherein said trailing guide tool comprises a cutting facilitation feature.