Parallel configuration composite material fabricator

• US 7,137,182 B2
• Filed: 11/22/2002
• Issued: 11/21/2006
• Est. Priority Date: 11/22/2002
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Nelson, Paul E.
• Primary Examiner(s): Bryant, David P.
• Application Number:
  US10/301,949
• Publication Number:
  US 20040098852A1
• Time in Patent Office: 1,460 Days
• Field of Search: 156/361, 156/433, 156/441, 156/523, 156/574, 156/169, 156/175, 156/486, 156/577, 425/163, 425/375, 428/411.1, 298/09, 298/19
• US Class Current: 29/428
• CPC Class Codes: B29C 2793/0081 before shaping
• CPC Class Codes: B29C 70/088 and with one or more layers of non-plastics material or non-specified material, e.g. supports
• CPC Class Codes: B29C 70/202 arranged in parallel planes or structures of fibres crossing at substantial angles, e.g. cross-moulding compound [XMC] B29C70/207 takes precedence
• CPC Class Codes: B29C 70/207 arranged in parallel planes of fibres crossing at substantial angles
• CPC Class Codes: B29C 70/222 the structure being shaped to form a three dimensional configuration
• CPC Class Codes: B29C 70/32 on a rotating mould, former or core
• CPC Class Codes: B29C 70/34 and shaping or impregnating by compression , i.e. combined with compressing after the lay-up operation
• CPC Class Codes: B29C 70/386 Automated tape laying [ATL]
• CPC Class Codes: B29C 70/545 Perforating, cutting or machining during or after moulding
• CPC Class Codes: B29K 2105/08 of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
• CPC Class Codes: B29K 2105/0809 Fabrics
• CPC Class Codes: B29K 2105/108 arranged in parallel planes and crossing at substantial angles B29K2105/206 takes precedence
• CPC Class Codes: B29K 2705/00 Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
• CPC Class Codes: B29K 2707/04 Carbon
• CPC Class Codes: B29K 2709/08 Glass
• CPC Class Codes: B29K 2711/12 Paper, e.g. cardboard
• CPC Class Codes: Y10T 156/1057 Subsequent to assembly of laminae
• CPC Class Codes: Y10T 156/1077 Applying plural cut laminae to single face of additional lamina
• CPC Class Codes: Y10T 156/1084 of continuous or running length bonded web
• CPC Class Codes: Y10T 156/1097 Lamina is running length web
• CPC Class Codes: Y10T 156/1348 : Work traversing type
• CPC Class Codes: Y10T 156/1788 : Work traversing type and/or means applying work to wall or static structure
• CPC Class Codes: Y10T 29/49826 : Assembling or joining
• CPC Class Codes: Y10T 29/49885 : with coating before or during assembling
• CPC Class Codes: Y10T 29/53526 : Running-length work

Abstract

A device for fabricating a composite article having a plurality of material dispensers to increase productivity. The device includes a structure defining a work surface datum, the plurality of material dispensers which are movable relative to the structure, where each of the material dispensers applies a strip material to the work surface datum along a predetermined axis, and wherein each of said predetermined axes are parallel to one another and where the strip material as applied to the work surface datum forms a layer. A method for fabricating a composite in accordance with the present invention is also provided.

Claims

1. A device for fabricating a composite article comprising:

a structure defining a work surface datum;

a plurality of material dispensers movable relative to said structure, wherein each of said material dispensers applies a strip material to said work surface datum along a predetermined axis; and

wherein each of said predetermined axes are parallel to one another and wherein said strip material when applied to the work surface datum forms an integral flat layer of a single composite article;

wherein said plurality of material dispensers includes at least a first material dispenser and at least a second material dispenser separate from the first material dispenser that applies strip material to the same work surface datum as the first material dispenser, wherein the second material dispenser only applies strip material to said work surface datum in a direction opposite that which the first material dispenser applies strip material to said work surface datum, wherein the first material dispenser applies strip material to said work surface datum in a first direction while the second material dispenser is inactive, and the second material dispenser applies strip material to said work surface datum in a second direction while the first material dispenser is inactive.

2. The device according to claim 1, further comprising a support base, wherein said structure rests on said support base.

3. The device according to claim 1, wherein at least two structures are placed under said plurality of material dispensers.

4. The device according to claim 1, wherein said structure is a lay-up mandrel.

5. The device according to claim 1, wherein said structure is a transfer sheet.

6. The device according to claim 1, further comprising a gantry, wherein said plurality of material dispensers are attached thereto.

7. The device according to claim 6, wherein said gantry includes a rotary mechanism for rotating said plurality of material dispensers.

8. The device according to claim 1, further comprising a gantry, wherein said plurality of material dispensers are attached thereto, and wherein said first material dispenser is attached to a first side of said gantry, and said second material dispenser is attached to a second side of said gantry.

9. The device according to claim 8, wherein said plurality of material dispensers is attached to said gantry by a quick release connection.

10. The device according to claim 6, wherein one of said gantry and said structure is rotatable relative to the other one of said gantry and said structure.

11. The device according to claim 2, wherein said support base includes a rotary turntable.

12. The device according to claim 1, wherein said strip material comprises a material selected from the group consisting of:

fiber reinforced composites, polymers, adhesives, metals, and mixtures thereof.

13. The device according to claim 12, wherein said fiber reinforced composite material is selected from the group consisting of pre-impregnated resin composite material and non-impregnated composite material.

14. The device according to claim 12, wherein said fiber reinforced material comprises fibers selected from the group consisting of:

carbon containing fibers, Kevlar®

fibers, glass, and mixtures thereof.

15. The device according to claim 1, wherein said strip material comprises a fiber reinforced composite material selected from the group consisting of:

tape, woven cloth, non-woven cloth, paper, and mixtures thereof.

16. The device according to claim 1, further comprising an automated strip material replacement system for replacing strip material for said plurality of material dispensers.

17. The device according to claim 16, wherein said strip material replacement system includes a mobile modular strip material changer.

18. The device according to claim 1, wherein said each of said plurality of material dispensers includes a retractable compactor operable for smoothing said strip material along said work surface datum.

19. The device according to claim 18, wherein said retractable compactor has a rotational degree of freedom with respect to a contoured surface on said work surface datum, wherein said retractable compactor smoothes strip material over said contoured surface along said work surface datum.

34. The device according to claim 1, wherein each said material dispenser includes an onboard supply of strip material.

35. The device according to claim 34, wherein each said material dispenser includes a housing, a spool within the housing, and strip material rolled onto the spool.

36. The device according to claim 34, wherein each said material dispenser includes a housing, a cartridge within the housing, and strip material within the cartridge.

37. The device according to claim 36, further comprising at least one automated material changer operable for changing out the cartridges carried onboard the material dispensers.

38. The device according to claim 34, further comprising at least one automated material changer operable for changing out the material dispensers.

39. The device according to claim 34, wherein each said onboard supply of strip material is the only source of strip material for the corresponding material dispenser.

40. The device according to claim 34, wherein said material dispensers are operable for simultaneously applying parallel strips of material to said work surface datum to thereby form a layer of the composite article.

41. The device according to claim 34, wherein said plurality of material dispensers are attached to a movable gantry for common translation therewith, wherein said plurality of material dispensers includes a first material dispenser that applies strip material to said work surface datum in a first direction during an out stroke of said gantry, and a second material dispenser that applies strip material to said work surface datum in a second direction during a return stroke of said gantry, and wherein said first direction and said second direction are opposite to one another.

42. The device according to claim 34, wherein the onboard supply of strip material includes strip material having a width of about six inches or more.

43. The device according to claim 1, wherein said material dispensers are operable for collectively applying parallel strips of material to said work surface datum to thereby form a generally flat layer of a generally flat composite article.

44. The device according to claim 1, wherein the first material dispenser applies a first layer of strip material in the first direction and the separate second material dispenser applies a second layer of strip material in the second direction over the first layer of strip material, in a single roundtrip stroke of travel in the first direction followed by travel in the second direction.

20. A device for fabricating a composite article comprising:

a plurality of material dispensers operable for applying strip material to a plurality of structures within a work area, wherein said plurality of material dispensers are movable relative to said plurality of structures;

wherein at least one of said structures is in an active region of said work area and said plurality of material dispensers applies strip material thereto to form an integral flat layer of a single composite article, and at least one of said structures is in an inactive region of said work area in which said plurality of material dispensers are not applying strip material thereto;

wherein said plurality of material dispensers includes at least a first material dispenser and at least a second material dispenser separate from the first material dispenser that applies strip material to the same work surface datum as the first material dispenser, wherein the second material dispenser only applies strip material to said work surface datum in a direction opposite that which the first material dispenser applies strip material to said work surface datum, wherein the first material dispenser applies strip material to said work surface datum in a first direction while the second material dispenser is inactive, and the second material dispenser applies strip material to said work surface datum in a second direction while the first material dispenser is inactive.

21. The device according to claim 20, wherein said structure is a lay-up mandrel.

22. The device according to claim 20, wherein said structure is a transfer sheet.

23. The device according to claim 20, wherein said plurality of material dispensers are attached to a gantry.

24. The device according to claim 23, wherein said gantry is rotatable relative to said plurality of structures.

25. The device according to claim 20, wherein said plurality of structures are on a plurality of support bases.

26. The device according to claim 25, wherein said plurality of support bases are movable relative to said plurality of said material dispensers.

27. The device according to claim 25, wherein said plurality of support bases comprise a rotary turntable.

28. The device according to claim 20, wherein said strip material in said plurality of material dispensers is replaced by an automated replacement system.

29. The device according to claim 28, wherein said automated replacement system includes a mobile modular strip material changer.

30. The device according to claim 20, wherein said strip material comprises a material selected from the group consisting of:

a fiber reinforced composite, a polymer, an adhesive, a metal, and mixtures thereof.

31. The device according to claim 20, wherein said strip material comprises a fiber reinforced composite material selected from the group consisting of:

tape, woven cloth, non-woven cloth, paper, and mixtures thereof.

32. The device according to claim 31, wherein said fiber reinforced composite material is selected from the group consisting of pre-impregnated resin composite material and non-pre-impregnated resin composite material.

33. The device according to claim 31, wherein said fiber reinforced material comprises fibers selected from the group consisting of:

carbon containing fibers, Kevlar®

fibers, glass, and mixtures thereof.

45. The device according to claim 20, wherein the first material dispenser applies a first layer of strip material in the first direction and the separate second material dispenser applies a second layer of strip material in the second direction over the first layer of strip material, in a single roundtrip stroke of travel in the first direction followed by travel in the second direction.