System and head for continuously manufacturing composite structure

Abstract

A print head is disclosed for use with an additive manufacturing system. The head may have a matrix reservoir, and a nozzle base disposed downstream of the matrix reservoir. The nozzle base may include an opening configured to receive a plurality of continuous reinforcements coated in a liquid matrix. The print head may also have a cover configured to engage the nozzle base and close off a side of the opening, and a guide removably receivable within at least one of the nozzle base and the cover. The guide may include at least one divider configured to axially divide the opening into a plurality of adjacent channels that each receive at least one of the plurality of continuous reinforcements. The print head may further have a cure enhancer mounted at a trailing side of the nozzle base opposite the cover and configured to expose the matrix coating on the plurality of continuous reinforcements to a cure energy.

What is claimed is: 
     
         1 . A nozzle assembly for an additive manufacturing print head, comprising:
 a nozzle base having an opening configured to receive a plurality of continuous reinforcements;   a cover configured to engage the nozzle base and close off a side of the opening; and   a guide removably receivable within at least one of the nozzle base and the cover, the guide having at least one divider configured to axially divide the opening into a plurality of adjacent channels that each receive at least one of the plurality of continuous reinforcements.   
     
     
         2 . The nozzle assembly of  claim 1 , wherein:
 the guide is a first guide; and   the nozzle assembly further includes a second guide that is swappable with the first guide, the second guide having at least one divider configured to axially divide the opening into a plurality of adjacent channels.   
     
     
         3 . The nozzle assembly of  claim 2 , wherein the plurality of adjacent channels of the second guide are different from the plurality of adjacent channels of the first guide. 
     
     
         4 . The nozzle assembly of  claim 3 , wherein the plurality of adjacent channels of the second guide are different in at least one of a number, a cross-sectional shape, a width dimension, a depth dimension, and a taper. 
     
     
         5 . The nozzle assembly of  claim 1 , wherein at least one of the plurality of adjacent channels tapers in at least one of a width direction and a depth direction. 
     
     
         6 . The nozzle assembly of  claim 5 , wherein the at least one of the plurality of adjacent channels tapers in both the width direction and the depth direction. 
     
     
         7 . The nozzle assembly of  claim 1 , wherein the plurality of adjacent channels each have one of a square cross-sectional shape and a rectangular cross-sectional shape. 
     
     
         8 . The nozzle assembly of  claim 1 , wherein the cover includes an inner surface coated with a low-friction material. 
     
     
         9 . The nozzle assembly of  claim 8 , wherein the guide is fabricated from the low-friction material. 
     
     
         10 . The nozzle assembly of  claim 1 , wherein the cover is L-shaped. 
     
     
         11 . The nozzle assembly of  claim 1 , wherein an edge of the guide at an outlet over which the plurality of continuous reinforcements pass is rounded. 
     
     
         12 . The nozzle assembly of  claim 1 , wherein a cross-sectional area at an outlet of each of the plurality of adjacent channels is smaller than a cross-sectional area at an inlet of each of the plurality of adjacent channels. 
     
     
         13 . The nozzle assembly of  claim 1 , wherein a depth and a width of each of the plurality of adjacent channels at an outlet is about 0.01 inch to about 0.10 in. 
     
     
         14 . The nozzle assembly of  claim 1 , wherein the nozzle base includes a recess configured to receive the guide. 
     
     
         15 . The nozzle assembly of  claim 1 , wherein the guide is configured to cause the plurality of continuous reinforcements to converge into a ribbon. 
     
     
         16 . A print head for an additive manufacturing system, comprising:
 a matrix reservoir;   a nozzle base disposed downstream of the matrix reservoir and having an opening configured to receive a plurality of continuous reinforcements coated in a liquid matrix;   a cover configured to engage the nozzle base and close off a side of the opening;   a guide removably receivable within at least one of the nozzle base and the cover, the guide having at least one divider configured to axially divide the opening into a plurality of adjacent channels that each receive at least one of the plurality of continuous reinforcements; and   a cure enhancer mounted at a trailing side of the nozzle base opposite the cover and configured to expose the matrix coating the plurality of continuous reinforcements to a cure energy.   
     
     
         17 . The print head of  claim 16 , wherein:
 the guide is a first guide;   the print head further includes a second guide that is swappable with the first guide, the second guide having at least one divider configured to axially divide the opening into a plurality of adjacent channels; and   the plurality of adjacent channels of the second guide are different from the plurality of adjacent channels of the first guide in at least one of a number, a cross-sectional shape, a width dimension, a depth dimension, and a taper.   
     
     
         18 . The print head of  claim 16 , wherein at least one of the plurality of adjacent channels tapers in at least one of a width direction and a depth direction. 
     
     
         19 . The print head of  claim 16 , wherein:
 the cover includes an inner surface coated with a low-friction material; and   the guide is fabricated from the low-friction material.   
     
     
         20 . The print head of  claim 16 , wherein:
 the nozzle base includes a recess configured to receive the guide; and   the guide is configured to cause the plurality of continuous reinforcements to converge into a ribbon.