Methods and systems for automated ply layup for composites

• US 9,421,744 B2
• Filed: 09/08/2014
• Issued: 08/23/2016
• Est. Priority Date: 08/31/2012
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Shair, Sultan, O'Flynn, Julian Thomas, Messmer, Mathias Ernst, Worthoff, Frank, Ostojic, Mile, Vermilyea, Mark Ernest
• Primary Examiner(s): Chan, Sing P
• Application Number:
  US14/479,871
• Publication Number:
  US 20140374003A1
• Time in Patent Office: 715 Days
• Field of Search: 156/73.6, 156/289, 156/297, 156/307.1, 156/307.3, 156/307.7, 156/705, 156/708, 156/711, 156/719, 156/362, 156/379.8, 156/499, 156/537, 156/538, 156/580, 156/582, 156/752, 156/754, 156/757, 156/767
• US Class Current: 1/1
• CPC Class Codes: B29C 33/68 Release sheets
• CPC Class Codes: B29C 65/18 using heated tools
• CPC Class Codes: B29C 65/20 with direct contact, e.g. using "mirror"
• CPC Class Codes: B29C 65/78 Means for handling the parts to be joined, e.g. for making containers or hollow articles , e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
• CPC Class Codes: B29C 66/004 Preventing sticking together, e.g. of some areas of the parts to be joined
• CPC Class Codes: B29C 66/80 General aspects of machine operations or constructions and parts thereof
• CPC Class Codes: B29C 66/83413 cooperating rollers, cylinders or drums
• CPC Class Codes: B29C 70/38 Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns application heads for tyres B29D30/28
• CPC Class Codes: B29C 70/541 Positioning reinforcements in a mould, e.g. using clamping means for the reinforcement positioning inserts in moulds B29C33/12; lay-up on a mould B29C70/30
• CPC Class Codes: B32B 2037/262 Partition plates or sheets for separating several laminates pressed simultaneously
• CPC Class Codes: B32B 2305/022 Foam
• CPC Class Codes: B32B 2305/024 Honeycomb
• CPC Class Codes: B32B 2305/77 Uncured, e.g. green
• CPC Class Codes: B32B 2309/12 Pressure
• CPC Class Codes: B32B 37/0007 involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality
• CPC Class Codes: B32B 37/0053 Constructional details of laminating machines comprising rollers; Constructional features of the rollers
• CPC Class Codes: B32B 37/02 characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
• CPC Class Codes: B32B 37/144 using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding constructional features for tensioning B32B38/1825
• CPC Class Codes: B32B 37/146 whereby one or more of the layers is a honeycomb structure
• CPC Class Codes: B32B 37/26 with at least one layer which influences the bonding during the lamination process, e.g. release layers or pressure equalising layers
• CPC Class Codes: B32B 38/0036 : Heat treatment for heating or cooling of layers during lamination B32B37/06, B32B37/08
• CPC Class Codes: B32B 38/1858 : using vacuum
• CPC Class Codes: B65H 41/00 : Machines for separating superposed webs
• CPC Class Codes: Y10T 156/16 : Surface bonding means and/or assembly means with bond interfering means [slip sheet, etc. ]
• CPC Class Codes: Y10T 156/17 : Surface bonding means and/or assemblymeans with work feeding or handling means
• CPC Class Codes: Y10T 156/1994 : Means for delaminating from release surface

Abstract

A method for applying at least one ply onto a tool or an uncured composite layup disposed on the tool includes automatically controlling slidably removing at least one nonstick separator relative to the at least one ply positioned on the at least one nonstick separator to inhibit at least a portion of the at least one ply from adhering to the tool or uncured composite layup while applying a moving compressive force to an outer surface of the at least one ply relative to a moving trailing edge of the at least one nonstick separator to adhere at least a portion of the at least one ply to the tool or to the uncured composite layup.

Claims

1. A method for applying at least one ply onto a tool or onto an uncured composite layup disposed on the tool, the method comprising:

automatically controlling slidably removing at least one nonstick separator relative to the at least one ply positioned on the at least one nonstick separator to inhibit at least a portion of the at least one ply from adhering to the tool or to the uncured composite layup while applying a moving compressive force to an outer surface of the at least one ply relative to a moving trailing edge of the at least one nonstick separator to adhere at least a portion of the at least one ply to the tool or to the uncured composite layup.

2. The method of claim 1, further comprising at least one of:

positioning the at least one nonstick separator on at least a portion of the tool or the uncured composite layup disposed on the tool; and

positioning the at least one ply on the at least one nonstick separator to inhibit at least a portion of the at least one ply from adhering to the tool or to the uncured composite layup.

3. The method of claim 1, further comprising:

positioning the at least one nonstick separator on at least a portion of the tool or the uncured composite layup disposed on the tool, and positioning the at least one ply on the at least one nonstick separator to inhibit at least a portion of the at least one ply from adhering to the tool or to the uncured composite layup.

4. The method of claim 1, further comprising at least one of:

automatically positioning the at least one nonstick separator on at least a portion of the tool or the uncured composite layup disposed on the tool; and

automatically positioning the at least one ply on the at least one nonstick separator to inhibit at least a portion of the at least one ply from adhering to the tool or to the uncured composite layup.

5. The method of claim 1, further comprising:

automatically positioning the at least one nonstick separator on at least a portion of the tool or the uncured composite layup disposed on the tool, and automatically positioning the at least one ply on the at least one nonstick separator to inhibit at least a portion of the at least one ply from adhering to the tool or to the uncured composite layup.

6. The method of claim 1, wherein the automatically controlling comprises:

automatically controlling slidably removing at least one nonstick separator at the same rate as applying the moving compressive force to an outer surface of the at least one ply.

7. The method of claim 1, further comprising:

automatically positioning a plurality of nonstick separators on at least a portion of the tool or the uncured composite layup disposed on the tool.

8. The method of claim 1, wherein the automatically controlling comprises:

automatically controlling slidably removing a first one of the at least one nonstick separator in a first direction relative to the positioned at least one ply while applying the moving compressive force to the outer surface of the at least one ply adjacent to the moving trailing edge of the first one of the at least one nonstick separator to adhere at least a first portion of the at least one ply to the tool or to the uncured composite layup; and

automatically controlling slidably removing a second one of the at least one nonstick separator in a second direction relative to the positioned at least one ply while applying the moving compressive force to the outer surface of the at least one ply adjacent to the moving trailing edge of the second one of the at least one nonstick separator to adhere at least a second portion of the at least one ply to the tool or to the uncured composite layup.

9. The method of claim 1, further comprising:

automatically positioning a plurality of nonstick separators on at least a portion of the tool or the uncured composite layup disposed on the tool with edges of the plurality of nonstick separators defining at least one gap therebetween.

10. The method of claim 1, wherein the automatically controlling comprises:

automatically controlling applying a moving compressive force to an outer surface of the at least one ply over a gap disposed between the at least one nonstick separator comprising a plurality of nonstick separators to adhere at least a portion of the at least one ply to the uncured composite layup.

11. The method of claim 1, wherein the tool comprises a non-flat planar molding surface, and the automatically controlling comprises:

automatically controlling slidably removing the at least one nonstick separator relative to the positioned at least one ply while applying the moving compressive force to the outer surface of the at least one ply adjacent to the moving trailing edge of the at least one nonstick separator to adhere at least a portion of the at least one ply to the non-flat planar molding surface of the tool or to the uncured composite layup disposed on the non-flat planar molding surface.

12. The method of claim 1, wherein the tool comprises intersecting surfaces, and the automatically controlling comprises:

automatically controlling slidably removing the at least one nonstick separator relative to the positioned at least one ply while applying a moving compressive force to the outer surface of the at least one ply adjacent to the moving trailing edge of the at least one nonstick separator to adhere at least a portion of the at least one ply to the intersecting surfaces of the tool or to the uncured composite layup disposed on the intersecting surfaces.

13. The method of claim 1, further comprising:

automatically controlling applying a moving compressive force to an outer surface of the at least one ply with the at least one nonstick separator disposed between the at least one ply and the tool or the uncured composite layup.

14. The method of claim 1, further comprising:

applying heat to the ply.

15. The method of claim 1, wherein the at least one nonstick separator comprises a nonstick sheet.

16. The method of claim 1, wherein the at least one nonstick separator comprises at least one of an air cushion having a plurality of apertures through which air is emitted, a vibrating sheet, and separator having passages for receiving a cooled fluid therein.

17. The method of claim 1, further comprising at least one roller for applying the moving compressive force to the outer surface of the at least one ply.

18. The method of claim 1, wherein the at least one roller comprises at least one conical roller.

19. The method of claim 1, wherein the at least one ply comprises at least one of a composite, adhesive, foam, wood, honeycomb, bagging material, peel ply, release film, bleeder, breather, and bagging film.

20. The method of claim 1, wherein the at least one ply comprises a stack of plies.