Apparatus for controllably cutting fibers and related methods

Abstract

The present disclosure provides an apparatus that includes a fiber gun. In an embodiment, the apparatus may controllably cut one or more fibers into one or more fiber segments. In an embodiment, the apparatus may controllably shape one or more fibers into different shapes (e.g., from loops into substantially straight fibers). In an embodiment, the apparatus may controllably position the one or more fiber segments onto a supporting member (e.g., a composite component). For example, the apparatus may include a robot that may controllably move the fiber gun relative to a supporting member and align the fiber gun such that the one or more fiber segments are controllably positioned on the supporting member. The apparatus may further include a controller that at least partially controls operation of the apparatus.

1 . A method of cutting one or more fibers, the method comprising:
 providing a fiber gun including:
 a mandrel including a longitudinal axis, the mandrel including an uppermost portion, a first portion at an/or near the uppermost portion, a lowermost portion spaced from the uppermost portion, and a second portion at and/or near the lowermost portion, the mandrel exhibiting a length extending between the uppermost portion and the lowermost portion, the mandrel exhibits a cross-sectional area that varies along at least a portion of a length of the mandrel, a cross-sectional perimeter that does not remain constant and varies by at most about 5% along substantially at least a portion of the length of the mandrel; 
 a transport mechanism; and 
 at least one cutting element disposed at least proximate to at least one cutting surface of the mandrel; 
   activating a transport mechanism to move one or more fibers from the first portion of a mandrel to the second portion of the mandrel;   cutting the one or more fibers using the at least one cutting element to form one or more fiber segments, the at least one cutting surface being at least one of at or near the lowermost portion of the mandrel; and   controllably positioning each of the one or more fiber segments on a supporting member that is disposed below the fiber gun.   
     
     
         2 . The method of  claim 1 , further comprising disposing the supporting member below the fiber gun, wherein the supporting member includes a composite component having one or more transition regions. 
     
     
         3 . The method of  claim 2 , where controllably positioning each of the one or more fiber segments on the supporting member includes controllably positioning each of the one or more fiber segments on or about at least one of the one or more transition regions. 
     
     
         4 . The method of  claim 1 , further comprising controllably moving the fiber gun relative to the supporting member. 
     
     
         5 . The method of  claim 1 , wherein activating a transport mechanism includes rotating at least one belt that is disposed at least proximate to the mandrel. 
     
     
         6 . The method of  claim 5 , wherein rotating the at least one belt includes rotating a first belt and a second belt, and wherein the mandrel includes a first surface and a second surface opposite the first surface, the first belt disposed at least proximate to the first surface and the second belt disposed at least proximate to the second surface. 
     
     
         7 . The method of  claim 1 , wherein cutting the one or more fibers using the at least one cutting element includes rotating the at least one cutting element relative to the mandrel, wherein the at least one cutting element includes at least one grinding wheel. 
     
     
         8 . The method of  claim 1 , wherein cutting the one or more fibers using the at least one cutting element includes cutting the one or more fibers with at least one ultrasonic scissor. 
     
     
         9 . The method of  claim 1 , wherein controllably positioning each of the one or more fibers segments on a supporting member includes controllably moving the supporting member. 
     
     
         10 . The method of  claim 1 , wherein the cross-sectional perimeter of the mandrel remains constant from the first portion of the mandrel to a portion of the mandrel near the lowermost portion or near at least one cutting surface or the mandrel, and wherein the cross-sectional perimeter increases by at most 5% from the portion of the mandrel near the lowermost portion or near the at least one cutting surface to the lowermost portion of near the at least one cutting surface. 
     
     
         11 . The method of  claim 1 , wherein the cross-sectional area of the mandrel generally decreases from the uppermost portion to the lowermost portion. 
     
     
         12 . The method of  claim 1 , wherein the cross-sectional area of the mandrel varies along substantially all of the length of the mandrel. 
     
     
         13 . The method of  claim 1 , wherein the cross-sectional perimeter of the mandrel increases by at most 3% from the portion of the mandrel near the lowermost portion or near the at least one cutting surface to the lowermost portion of the at least one cutting surface. 
     
     
         14 . The method of  claim 1 , wherein a cross-sectional shape of the mandrel at least one of at or near the uppermost portion is generally circular. 
     
     
         15 . The method of  claim 1 , wherein a cross-sectional shape of the mandrel at and/or near the lowermost portion is more elongated than a cross-sectional shape of the mandrel at least one of at or near the uppermost portion. 
     
     
         16 . The method of  claim 1 , wherein a cross-sectional shape of the mandrel at and/or near the lowermost portion includes at least one elongated side and at least one narrow side, wherein the at least one elongated side is substantially straight. 
     
     
         17 . The method of  claim 1 , further comprising applying a layer of polymer resin or adhesive to the supporting member. 
     
     
         18 . A method of cutting one or more fibers, the method comprising:
 positioning one or more fibers on a mandrel from a source of the one or more fibers, the mandrel including:
 an uppermost portion; 
 a first portion at an/or near the uppermost portion; 
 a lowermost portion spaced from the uppermost portion; 
 a second portion at and/or near the lowermost portion; 
 a length extending between the uppermost portion and the lowermost portion; and 
 a cross-sectional perimeter of the mandrel that does not remain constant and varies by at most about 5% along substantially at least a portion of the length of the mandrel; 
   activating a transport mechanism to move the one or more fibers from the first portion of the mandrel to the second portion of the mandrel; and   cutting the one or more fibers using at least one cutting element disposed at least proximate to the at least one cutting surface of the mandrel to form one or more fiber segments, the at least one cutting surface being at least one of at or near the lowermost portion of the mandrel.   
     
     
         19 . A method of cutting one or more fibers, the method comprising:
 wrap one or more fibers around a mandrel, the one or more fibers provided from a source of the one or more fibers that is coupled to the mandrel, the mandrel including:
 an uppermost portion; 
 a first portion at an/or near the uppermost portion; 
 a lowermost portion spaced from the uppermost portion; 
 a second portion at and/or near the lowermost portion; 
 a length extending between the uppermost portion and the lowermost portion; and 
 a cross-sectional perimeter that does not remain constant and varies by at most about 5% along substantially at least a portion of the length of the mandrel; 
   activating a transport mechanism to move the one or more fibers from the first portion of the mandrel to the second portion of the mandrel;   cutting the one or more fibers using at least one cutting element disposed at least proximate to the at least one cutting surface of the mandrel to form one or more fiber segments, the at least one cutting surface being at least one of at or near the lowermost portion of the mandrel;   controllably moving the mandrel relative to the supporting member; and   responsive to controllably moving the mandrel, positioning each of the one or more fiber segments on a supporting member that is disposed below the fiber gun.   
     
     
         20 . The method of  claim 19 , wherein controllably moving the mandrel includes moving the mandrel with a robot that includes a stationary portion and one or more active portions connected to the stationary portion.