Apparatus and method for composite material trim-on-the-fly
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Abstract
Disclosed is a method and apparatus for manufacturing multiple layer composite structures and structures containing components made of multiple layer composite structures, comprising dispensing layers of composite material, trimming each layer to its final shape as it is being dispensed, and positioning it properly with respect to prior layers in the part lay-up.
59 Citations
20 Claims
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1-11. -11. (canceled)
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12. A method of manufacturing a composite structure comprising:
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a. Dispensing a first layer of composite material; b. Trimming an outer contour of the first layer of composite material in two dimensions while the first layer of composite material is in continuous linear motion across a trim table; c. Positioning the first layer of composite material on a surface; d. Dispensing a second layer of composite material; e. Trimming an outer contour of the second layer of composite material in two dimensions while the second layer of composite material is in continuous linear motion across a trim table; f. Positioning the second layer of composite material on the first layer of composite material in the proper position relative to the first layer; g. Repeating steps d through f for subsequent layers of composite material to form a stack, until all the required layers of composite material are present and correctly aligned with one another to form a composite preform. - View Dependent Claims (13, 14, 15, 16, 17)
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18. A method of manufacturing a composite structure comprising:
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h. Positioning one of a plurality of supply rolls as a feed roll for a first layer of composite material; i. Feeding the first layer of composite material from the feed roll; j. Trimming the composite material to the final shape for a first part layer using two cutters, each controllable in three axes, while the composite material is in continuous linear motion across a trim table, to form a first trimmed composite layer; k. Peeling a backing layer from the first trimmed composite layer to form a first part layer; l. Positioning the first part layer on a platform moving at the same speed as the composite material; m. Positioning one of the plurality of supply rolls as the feed roll for a second layer of composite material; n. Feeding the second layer of composite material from the feed roll; o. Trimming the composite material to a final shape for a second part layer using two cutters, each controllable in three axes, while the composite material is in continuous linear motion across the trim table, to form a second trimmed composite layer; p. Peeling the backing layer from the second trimmed composite layer to form a second part layer; q. Positioning the second part layer in the correct position on the first part layer on a platform moving at the same speed as the composite material; r. Repeating steps f through j for successive layers of composite materials until all part layers for the structure are in place.
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19. A method of manufacturing an airplane comprising:
manufacturing a composite structure comprising; i. Positioning one of a plurality of supply rolls as a feed roll for a first layer of composite material; ii. Feeding the first layer of composite material from the feed roll; iii. Trimming the composite material to the final shape for a first part layer using two cutters, each controllable in three axes, while the composite material is in continuous linear motion across a trim table, to form a first trimmed composite layer; iv. Peeling a backing layer from the first trimmed composite layer to form the first part layer; v. Positioning the trimmed composite layer on a platform moving at the same speed as the composite material; vi. Positioning one of the plurality of supply rolls as the feed roll for a second layer of composite material; vii. Feeding the second layer of composite material from the feed roll; viii. Trimming the composite material to a final shape for a second part layer using two cutters, each controllable in three axes, while the composite material is in continuous linear motion across the trim table, to form a second trimmed composite layer; ix. Peeling a backing layer from the second trimmed composite layer to form the second part layer; x. Positioning the second part layer in the correct position on the first part layer on a platform moving at the same speed as the composite material; xi. Repeating steps f through j for successive layers of composite materials until all part layers for the structure are in place to form a composite preform; xii. Further processing the composite preform into a finished part; and xiii. Installing the part in an aircraft structure.
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20. (canceled)
Specification