Abstract:
Film material is applied to a surface of an elongate structural member. A carriage moved along the structural member dispenses, compacts and cuts the film material in a single pass along the structural member.

Description:
BACKGROUND INFORMATION 
       [0001]    1. Field: 
         [0002]    The Present Disclosure Generally Relates to the application of film over a substrate, and deals more particularly with a method and apparatus for applying and trimming a film material along a surface of an elongate structural member, such as a composite stringer. 
         [0003]    2. Background: 
         [0004]    Composite and other structures may be bonded together using a structural film adhesive material which may include a carrier such as a scrim for controlling bondline thickness. For example, in the aircraft industry, a composite stringer may be joined to another composite part such as a skin by co-bonding, or in a secondary bonding operation using a structural film adhesive material that is applied over the surface of a flange on the stringer. The stringer flange with the applied film adhesive is placed against the skin and the film adhesive is cured using thermal or other techniques. 
         [0005]    Preparing long composite structural members such as aircraft stringers for an adhesive bonding operation is a multi-stage process that is currently time consuming and labor intensive. A film adhesive material is manually rolled out to the length of the stringer, which may be 90 feet or more in the case of aircraft applications, and a protective poly backer must then be removed from the film. The entire length of the film material is then flipped over by a team of workers in order to place the backside of the film adhesive on a base flange of the stringer. Workers then manually trim excess film material away from the edges of the base flange. This hand trimming technique may be tedious, time-consuming and presents the risk of damage to edges of the base flange, particularly where the flange is beveled. During hand trimming, foreign object debris may be produced which, if adhered to the stringer, may affect the desirability of the bond. After trimming, the film material is smoothed by hand following which the stringer is flipped over and vacuum bag processed in order to compact the film material against the stringer base flange. 
         [0006]    Accordingly, there is a need for a method and apparatus for applying film material to long structural members that reduce dependence on manual labor, and which improve process flow time. There is also a need for a method and apparatus for applying film material that provide rapid trimming of excess material to match structural details, and which eliminate the need for vacuum bag compaction. 
       SUMMARY 
       [0007]    The disclosed embodiments provide a method and apparatus for applying film material in roll form over surfaces of long structural members such as composite stringers, spars, beams and doublers, to name only a few. A film material applicator is used to place, trim, remove a backing and compact film material in a single pass along the length of the structural member. The film material applicator and related application method may reduce process flow time, as well as recurring costs including labor and materials. Improved material utilization may be achieved, along with improved film material uniformity and fit-up. Potential damage to edges of the structural member during trimming of the film material is reduced or eliminated. The film applicator avoids the use of on-board motors and automated controls, and is therefore relatively simple, reliable and easy-to-use. The film applicator can be easily set up and manually operated by production workers. 
         [0008]    According to one disclosed embodiment, apparatus is provided for applying film to a surface of an elongate member. The apparatus comprises a carriage, rollers adapted to mount the carriage for movement along the elongate member, and a supply of film material on the carriage for dispensing film. The apparatus further comprises a compaction roller on the carriage for compacting the film against the surface of the elongate member, and a film cutter assembly for trimming both edges of the film material as the carriage moves along the elongate member. 
         [0000]    The elongate member may include a top, a bottom and sides, and the rollers engage the top, bottom and sides of the elongate member. The rollers may include fore and aft rollers mounted on the carriage for gripping the sides of the elongate member, and fore and aft traction tires mounted on the carriage for engaging the top of the elongate member. The film includes a backer and the apparatus further comprises a backer take-up reel mounted on the carriage for taking up and accumulating the backer as the film is being dispensed from the supply of film, and a backer take-up drive assembly for driving the backer take-up reel to rotate as the carriage moves along the elongate member. The supply of film includes a film material feed roll mounted for rotation on the carriage, and the backer take-up drive assembly is driven by rotation of the film feed roll. The film cutter assembly may include a pair of laterally spaced arms pivotally attached to the carriage, and a pair of cutter knives respectively attached to the arms for cutting edges of the film material as the carriage moves along the elongate member. The film cutter assembly further includes a guide slot for guiding the film material, and follower surfaces adapted to slidably engage edges of the elongated member. The follower surfaces are coupled with the cutter knives and guide the cutter knives to cut the film material along edges of the elongated member. 
         [0009]    According to another embodiment, apparatus is provided for applying film material to a flange surface of an elongate composite stringer. The apparatus comprises a carriage adapted to be mounted on and movable along the elongate composite stringer, a compaction roller mounted on the carriage for compacting film material against the flange surface as the carriage moves along the stringer and a material feed roll assembly on the carriage adapted to hold a quantity of film material and to dispense the film material to the compaction roller. The apparatus may further comprise a take-up reel on the carriage adapted for taking up a backing on the film material as the film material is being dispensed to the compaction roller, a heater on the carriage for heating the flange surface as the carriage moves along the composite stringer, and a film trimmer for trimming edges of the film material to match the contour of the composite stringer after the film material has been compacted against the flange surface. The carriage includes an upper frame adapted to be positioned above the flange surface and on which the compaction roller, film material feed roll assembly, take-up reel, heater, and film trimmer are mounted, and a lower frame adapted to be disposed beneath the flange surface. The apparatus may further comprise rollers on the lower frame for gripping the carriage against the elongate composite stringer, a backer take-up reel mounted on the upper frame adapted for taking up a backer on the film material, and a drive coupled between the film feed roll assembly and the backer take-up reel for driving rotation of the backer take-up reel. The film trimmer comprises a pair of followers adapted to engage and follow opposite edges of the flange surface, and a pair of cutter knives respectively pivotally mounted on the followers for cutting the film material along the opposite edges of the flange surface. 
         [0010]    According to a further embodiment, a method is provided of applying film material to a surface of an elongate member. The method comprises moving a carriage along the surface of the elongate member, dispensing film from a material supply on the carriage, compacting the film against the surface of the elongate member using a compaction roller on the carriage as the carriage moves along the surface of the elongate member, and trimming edges of the film that have been compacted against the surface of the elongate member, including using the carriage to move at least one cutter through the film as the carriage moves along the surface of elongate member. The dispensing, compacting and trimming are performed in a single pass as the carriage moves along a surface of the elongate member. The method may further comprise 
         [0011]    removing a backer from the film being dispensed, and accumulating the backer on a backer take-up reel on the carriage. Trimming the edges of the film includes drawing a pair of cutting knives through the film as the carriage moves along a surface of the elongate member, following the edges of the elongate member, and moving the cutting knives to follow the edges of the surface of the elongate member. 
         [0012]    According to still another embodiment, a method is provided of applying film material over the length of a flange surface on a composite stringer. The method comprises placing a film material applicator on the flange surface, moving the film material applicator along the length of the composite stringer, using the film material applicator to dispense and apply film material to the flange surface as the film material applicator moves along the length of the composite stringer, and using the film material applicator to trim edges of the film material to substantially match edges of the flange surface as the film material applicator moves along the length of the composite stringer. Placing the film material applicator on the flange surface includes gripping the film material applicator against a top, bottom and sides of the composite stringer. Using the film material applicator to trim edges of the film material includes following edges of the flange surface, moving cutting knives to follow the edges of the flange surface, and using the cutting knives to cut edges of the film material along the edges of the flange surface. The method may further comprise taking up scrap film on a reel on the carriage produced by cutting the edges of the film material. The method may also include taking up a film material backing on a reel on the carriage. The reels may be allowed to slip during take up of the scrap film and the film material backing using slip clutches. 
         [0013]    The features, functions, and advantages can be achieved independently in various embodiments of the present disclosure or may be combined in yet other embodiments in which further details can be seen with reference to the following description and drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims. The illustrative embodiments, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment of the present disclosure when read in conjunction with the accompanying drawings, wherein: 
           [0015]      FIG. 1  is an illustration of a functional block diagram of a film material applicator according to the disclosed embodiments. 
           [0016]      FIG. 2  is an illustration of a perspective view of a stringer having a base flange surface to which film material is applied using the film material applicator shown in  FIG. 1 . 
           [0017]      FIG. 3  is an illustration of an end view of the stringer shown in  FIG. 2 . 
           [0018]      FIG. 4  is an illustration of an upper perspective view showing one side of the film material applicator in the process of placing film on a stringer flange. 
           [0019]      FIG. 5  is an illustration similar to  FIG. 4  but showing the opposite side of the film material applicator. 
           [0020]      FIG. 6  is an illustration of a lower perspective view showing one side of the film material applicator. 
           [0021]      FIG. 7  is an illustration similar to  FIG. 6  but showing the opposite side of the film material applicator. 
           [0022]      FIGS. 8-11  are illustrations respectively similar to  FIGS. 4-7 , but enlarged to show additional details of the film material applicator. 
           [0023]      FIG. 12  is an illustration of a perspective view of the rear half of the film material applicator, showing details of the film cutter assembly and film scrap take-up assembly. 
           [0024]      FIG. 13  is an illustration of an elevational view of one side of the film material applicator. 
           [0025]      FIG. 14  is an illustration of an elevational view of the other side of the film material applicator. 
           [0026]      FIG. 15  is an illustration of a top plan view of the film material applicator. 
           [0027]      FIG. 16  is an illustration of a perspective view of one side of the film feed roll assembly. 
           [0028]      FIG. 17  is an illustration of a perspective view of the other side of the film feed roll assembly. 
           [0029]      FIG. 18  is an illustration of a perspective view of the film scrap take-up assembly. 
           [0030]      FIG. 19  is an illustration of a perspective view of the film material, diagrammatically showing the portions that are dispensed, placed, trimmed and taken up. 
           [0031]      FIG. 20  is an illustration of a front perspective view of the film cutter assembly. 
           [0032]      FIG. 21  is an illustration of a rear perspective view of the film cutter assembly. 
           [0033]      FIG. 22  is an illustration of a perspective view of the film cutter assembly shown in  FIGS. 20 and 21 , illustrating edges of a film being cut. 
           [0034]      FIG. 23  is an illustration of a flow diagram of an embodiment of a method of applying a film material along a surface of elongate member. 
           [0035]      FIG. 24  is an illustration of a flow diagram of a method of using the film applicator to apply film material on the flange of a stringer. 
           [0036]      FIG. 25  is an illustration of a flow diagram of aircraft production and service methodology. 
           [0037]      FIG. 26  is illustration of a block diagram of an aircraft. 
       
    
    
     DETAILED DESCRIPTION 
       [0038]    Referring first to  FIG. 1 , the disclosed embodiments relate to an apparatus  30  for dispensing, placing, compacting and trimming film material  32  on the surface  60   a  of elongate structural member  34 . For simplicity of description the apparatus  30  will be hereinafter referred to as a film applicator  30 , and the film material  32  may be referred to as film  32 , material or film material  32 . In the illustrated example discussed below in more detail, the structural member  34  is a composite stringer, however it is to be understood that the film applicator  30  may be employed to apply film material  32  to the surface of any long, relatively narrow members such as, without limitation, spars, beams, doublers, etc. The film material  32  may comprise any relatively thin, flexible material that is required to be applied to the elongate structural member  34 , such as without limitation, an adhesive. 
         [0039]    The film applicator  30  comprises several functional components discussed below that are mounted on a carriage  36  for rolling movement along the structural member  34  by means of pinch rollers  38 . The pinch rollers engage and grip the top, bottom and sides of the structural member  34  in order to both guide and index the film applicator  30  as the film applicator  30  is moved along the length of the structural member  34  in the direction of travel or placement  54 . 
         [0040]    The film applicator  30  includes a film feed roll assembly  40  containing a supply of the film material  32  which is dispensed and fed to a film compaction roller  46 . The film compaction roller  46  compacts the film material  32  against the surface  60   a  as the carriage  36  moves along the length of the structural member  34 . Optionally, a suitable heater  52  such as an infrared heater mounted on the carriage  36  may be used to heat  52   a  the surface  60   a  immediately before the film  32  is placed and compacted in order to improve adhesion of the film material  32  to the surface  60   a . As the film  32  is being dispensed, a backer  56 , typically a poly film material protectively covering the film material  32 , is drawn away from the film material  32  and is fed to a backer take-up reel  42 . A film cutter assembly  48  mounted on the carriage  36  aft of the film compaction roller  46  trims the outer edges of the film material  32  to substantially match the edges of the structural member  34 . The film scrap  58  resulting from this trimming operation is accumulated on a film scrap take-up assembly  50  which is also mounted on the carriage  36 . 
         [0041]    Referring now to  FIGS. 2 and 3 , the structural member  34  may comprise a composite laminate stringer  34 , which is shown in an inverted position in Figures. The stringer  34  includes a base flange  60  and a top flange  62  connected by a central web  64 , forming a generally “T”-shaped cross-section (in the inverted position). The base flange  60  includes a flange surface  60   a  extending the entire length of the stringer  34  and has a width “W”. In the example shown in  FIGS. 2 and 3 , the width “W” is substantially constant along the entire length of the stringer  34 , however in other examples the width “W” of the flange surface  60   a  may vary. Also, although the illustrated flange surface  60   a  is substantially flat, in other examples, the flange surface  60   a  may be curved, and/or twisted along its length. Opposite longitudinal edges  66  of the base flange  60  may be beveled. In order to bond the base flange  60  to another structure such as, for example and without limitation, a skin (not shown), a film adhesive is applied over the base flange surface  60   a  using the film applicator  30  shown in  FIG. 1  and described in more detail below. 
         [0042]    Attention is now directed to  FIGS. 4-15  which illustrate one embodiment of the film applicator  30  which may be employed to place film material  32  on the flange surface  60   a  of a stringer  34 . In this example, the flange surface  60   a  includes an inward taper  68  (see  FIGS. 4 and 5 ) along its opposite beveled edges  66 . As shown in  FIGS. 9 ,  10 ,  13  and  14 , the film applicator  30  includes a carriage  36  comprising a lower frame  84  and an upper frame  100  which are fixedly attached to each other by brackets  86 . Handlebars  98  on opposite sides of the upper frame  100  are adapted to be grasped by a worker for handling and transporting the film applicator  30 , and for manually moving it along the stringer  34  during the film application process. Outrigger wheels  92  attached to the outer ends of brackets  86  may be used to support and guide the film applicator  30  along a fixture (not shown) that may be used to hold the stringer  34  in a fixed, inverted position during the film placement process. 
         [0043]    A first set of longitudinally spaced pinch rollers  38   a  ( FIGS. 6 and 7 ) mounted on the lower frame  84  engage opposite sides  64   a  of the web  64  (see  FIG. 3 ), thereby laterally indexing the carriage  36  on the stringer  34 . The pinch rollers  38   a  may be formed of any suitable material such as, without limitation, a synthetic rubber, and may include be spring-loaded inwardly against the sides  64   a  of the web  64 . A second set of longitudinally spaced pinch rollers  38   b  (see  FIGS. 10 and 13 ) similar in construction to pinch rollers  38   a , are also mounted on the lower frame  84 , and bear upwardly against lower base flange surfaces  60   b  (see  FIG. 3 ) of the base flange  60 . Pinch rollers  38   b  may be spring-loaded upwardly against the lower base flange surfaces  60   b . Pinch rollers  38   b , in combination with other components discussed below, vertically index the carriage  36  and grip the film applicator  30  onto the stringer  34 . The pinch rollers  38   a ,  38   b  effectively guide and allow the carriage  36  to roll along surfaces  64   a ,  64   b  ( FIG. 3 ) of the stringer  34 . 
         [0044]    The film feed roll assembly  40  broadly comprises a removable feed roll  96  on which a quantity of the film material  32  may be stored. A backer take-up reel  42  takes up and accumulates a protective backer  56  on the film material  32  as the film material  32  is drawn from the film feed roll  40  assembly. The film material  32  is fed into a nip  70  ( FIGS. 13 and 14 ) between the compaction roller  46  and the flange surface  60   a  as the carriage  36  moves along the stringer  34 . Although not shown in the drawings, the film material  32  may include a second backer that is remains adhered to the film material  32  as it is compacted against the flange surface  60   a.    
         [0045]    Referring now particularly to  FIGS. 13-17 , the backer take-up reel  42  is mounted on a shaft  80  by a spring loaded slip clutch  76  which allows the take-up reel  42  to slip relative to the shaft  80  under certain conditions, discussed later. As best seen in  FIGS. 14 and 17 , the shaft  80  along with the feed roll  96  are journaled for rotation on a support bracket  106  mounted on the upper frame  100 . The shaft  80  is driven by a take-up reel drive belt  108  coupled with a toothed pulley  110  attached to and driven by rotation of the feed roll  96 , so that normally, the backer take-up reel  42  rotates in synchronization with rotation of the feed roll  96  as the film  32  is drawn from the feed roll  96 . 
         [0046]    Referring now again to  FIGS. 4-14 , the compaction roller  46  is journaled for rotation on the upper frame  100  and is adapted to bear against the flange surface  60   a . Film  32  drawn from the feed roll  96  is fed to the nip  70  and then compacted against flange surface  60   a  by the compaction roller  46  so that the film  32  adheres substantially uniformly to flange surface  60   a . Optionally, depending upon the application, suitable a heater  52 , which may comprise, without limitation, an infrared heater, is mounted on the upper frame  100 , forward of the compaction roller  46  and extends across substantially the entire width of the base flange surface  60   a . The heater  52  functions to heat the flange surface  60   a  in advance of placement of the film material  32  in order to promote adhesion of the film to the surface  60   a . Other means of heating the base flange surface  60   a  immediately in advance of film placement may be possible. 
         [0047]    A centrally located front traction tire  104  ( FIGS. 5 ,  9 ,  13 ,  14 ) is journaled for rotation on the upper frame  100 , and is positioned above the forward set of the pinch rollers  38   b . Spring-loading of the forward set of pinch rollers  38   b  cause the front traction tire  104  to be drawn down against the base flange surface  60   a , effectively “pinching” the base flange  60  between the front traction tire  104  and the forward set of pinch rollers  38   b . Similarly the base flange  60  is pinched between the compaction roller  46  and the pinch rollers  38   a ,  38   b . 
         [0048]    Referring now to  FIGS. 12-15 , and  20 - 22 , the film cutter assembly  48  comprises a pair of laterally spaced link arms  118  that are pivotally attached to a mounting bracket  114  by pivot pins  116 . The mounting bracket  114  is fixed to the upper frame  100 , as best seen in  FIGS. 8 , and  13 - 15 . Cutter follower arms  94  are pivotally attached to the outer ends of link arms  118  by followers  126  which are attached to link arms  118  by pivot shafts  129 . Each of the followers  126  includes a lower guide surface  126   a  ( FIGS. 21 and 22 ) which bears against, and guides the film  32  as the film  32  passes through the film cutter assembly  48 . The lower guide surface  126   a  may be formed of a low friction material that is resistant to wear, such as, without limitation, a UHMW (ultrahigh molecular weight) polyethylene. Spring plates  128  are fixed to the followers  126 , and although not shown in the drawings, a spring may be connected between the spring plates  128  in order to bias the link arms  118  to swing inwardly toward each other. 
         [0049]    Each of the cutter follower arms  94  comprises an upper follower arm  122 , and a lower follower arm  124  which are spaced apart from each other to form film guide slots  102  into which the outer edges of the film  32  is fed. Each of the upper follower arms  122  is provided with a bearing pad  138  which may be formed of a low friction material that is resistant to wear, such as UHMW polyethylene which is adapted to bear against the outer edges of the film  32  as it passes through the guide slots  102  in the cutter follower arms  94 . Guide blocks  132  are attached to the ends of the lower follower arms  124 . Pivot blocks  130  are secured to the guide blocks  132  and include upper follower surfaces  130   a  that are respectively matched in geometry to the contour of the edges  66  of the stringer  34 . 
         [0050]    In the illustrated example, the upper follower surfaces  130   a  are beveled to match and engage the beveled edges  66  ( FIG. 3 ) of the stringer  34 , beneath the film  32 . The upper beveled follower surfaces  130   a  of the pivot blocks  130  may also include a layer of low friction material that is resistant to wear such as UHMW polyethylene. Cutter knives  134 , made of suitable wear resistant material such as carbide, are releasably attached to the cutter follower arms  94  by thumbscrews  136  which hold the knives  134  against the followers  126 , pivot blocks  130  and guide blocks  132 . Moving the film material applicator  30  along the stringer  34  forces the cutter knives  134  through the film material  32  (including any backer that may be present on the film material  32 ), thereby trimming the film material  32  to match the width of the base flange surface  60   a  along the length of the stringer  34 . The cutter knives  134  are guided by the beveled follower surfaces  130   a  on the pivot blocks  130  which are biased into sliding engagement with the beveled edges  66  ( FIG. 3 ) of the stringer  34 . Pivotal mounting of the beveled follower surfaces  130   a  together with the cutter knives  134  allows the cutter knives  134  to individually follow and cut the film material  32  along the opposite beveled edges  66  of the stringer  34 , thereby matching the cut width of the film material  32  to the geometry of the top flange  60 . 
         [0051]    Attention is now directed to  FIGS. 12 ,  13 ,  15 , and  18  which illustrate additional details of the film scrap take-up assembly  50 . A pair of scrap take-up rollers  44  are mounted on a shaft by means of a slip clutch  72  that allows the rollers  44  to slip relative to the shaft  74  under certain conditions described later in more detail. The shaft  74  is journaled for rotation on an upright take-up support bracket  82  that is attached to an adjacent pair of the mounting brackets  86 . A rear traction tire  88  may be made of any suitable material that achieve traction against the film  32 . The rear traction tire  88  is mounted for rotation on a pair of laterally spaced arms  85  (see  FIG. 18 ) attached to brackets  86 . A gear wheel  112  attached to the end of the traction tire  88  is connected by a take-up reel drive belt  108  to a gear wheel (not shown) on the shaft  74 . Rotation of the traction tire  88  as a result of rolling over the film  32  during the film placement process drives rotation of the take-up rollers  44  through drive belt  108 . 
         [0052]    In operation, a supply of the film material  32  is loaded onto the feed roll  96  in preparation for covering the flange surface  60  of the stringer  34  with material. As previously discussed, the stringer  34  may be placed in a fixture (not shown) that is designed to hold the stringer  34  in a fixed, inverted position during the film placement process. The film applicator  30  is loaded onto one end of the stringer  34  and the film  32  is drawn down and into the nip  70  ( FIG. 13 ) between the compaction roller  46  and the flange surface  60   a , while the backer  56  is separated and partially wrapped around the backer take-up reel  42 . In cases where a fixture is used to hold the stringer  34 , the outrigger rollers  92  may be placed on the fixture in preparation for rolling the film applicator  30  down the length of the stringer  34 . 
         [0053]    Workers grasp the handle bars  98  to move the film applicator  30  along the length of the stringer  34 . In some embodiments, however, it may be possible to move the film applicator  30  along the stringer  34  using a computer controlled equipment, modifications to incorporate self-powering operation, or other automated equipment (not shown). The heater  52  heats the flange surface  60   a  immediately ahead of the compaction roller  46 . Linear movement of the film applicator  30  draws film material  32  from the film feed roll  96 . As the film material  32  is fed to the compaction roller  46 , the backer  56  is taken up on the backer take-up reel  42  which is belt driven by the rotation of the feed roll  96 . In the event that the feed roll  96  rotates more quickly than the backer take-up reel  42 , the slip clutch  76  allows dynamic slipping of the backer take-up reel  42 . 
         [0054]    After the film  32  has been compacted beneath the compaction roller  46 , the film cutter assembly  48  trims away edges of the film  32  to match the width of the flange surface  60   a , even in cases where the width of the base flange surface  60   a  may vary along the length of the stringer  34 . As best seen in  FIG. 22 , inward biasing of the link arms  118  results in the cutter knives  134  cutting the film  32  at the edges of the base flange surface  60   a . The film scrap  58  passes through the guide slots  102  in the cutter follower arms  94  and is taken up on the scrap take-up rollers  44 . The scrap take-up rollers  44  are belt driven by the rear traction tire  88 . In the event that the scrap take-up rollers  44  rotate more slowly than the rear traction tire  88 , the slip clutch  72  allows dynamic slipping of the rollers  44 .  FIG. 19  diagrammatically illustrates processing of the film  32  during the film material placement process. The film material  32  is drawn from the feed roll  96  and the backer  56  is rolled up on the backer take-up reel  42 . The film  32  is compacted and then cut at  61 . Film scrap  58  is rolled up onto the film scrap take-up reels  44  as the film  32  is cut to match the width of the flange surface  60   a , including along the flange taper  68 . 
         [0055]      FIG. 23  illustrates the overall steps of a method of applying film  32  to the surface  60   a  of an elongate member  34 . At  140 , a carriage  36  moved along the surface  60   a  of the elongate member  32 , and at  142  the film  32  is dispensed from a film supply  40  on the carriage  36 . At  144  the film  32  is compacted against the surface  60   a  using a compaction roller  46  as the carriage  36  moves along the surface  60   a . At step  146 , the edges of the film  32  are trimmed, using the carriage  36  to move cutter knives  134  through the film  32 . 
         [0056]      FIG. 24  illustrates the overall steps of a method of applying film material  32  over the length of a base flange surface  60   a  on a composite stringer  34 . Beginning at  148 , an film material applicator  30  is placed on the flange surface  68   a . At  150 , the film applicator  30  is moved along the length of the stringer  34 . At  152  the film applicator  30  is used to dispense and apply film material  32  to the flange surface  60   a  as the film applicator  30  moves along the length of the stringer  34 . At  154 , the film applicator  30  is used to trim edges of the film material  32  to substantially match edges of the flange surface  60   a  as the film applicator  30  moves along the length of the stringer  34 . 
         [0057]    Embodiments of the disclosure may find use in a variety of potential applications, particularly in the transportation industry, including for example, aerospace, marine, automotive applications and other application where automated layup equipment may be used. Thus, referring now to  FIGS. 25 and 26 , embodiments of the disclosure may be used in the context of an aircraft manufacturing and service method  160  as shown in  FIG. 25  and an aircraft  162  as shown in  FIG. 26 . Aircraft applications of the disclosed embodiments may include, for example, without limitation, stringers, spars, doublers, and beams, to name only a few. During pre-production, exemplary method  160  may include specification and design  164  of the aircraft  162  and material procurement  166 . During production, component and subassembly manufacturing  168  and system integration  170  of the aircraft  162  takes place. Thereafter, the aircraft  162  may go through certification and delivery  172  in order to be placed in service  174 . While in service by a customer, the aircraft  162  is scheduled for routine maintenance and service  176 , which may also include modification, reconfiguration, refurbishment, and so on. 
         [0058]    Each of the processes of method  160  may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include without limitation any number of aircraft manufacturers and major-system subcontractors; a third party may include without limitation any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on. 
         [0059]    As shown in  FIG. 26 , the aircraft  162  produced by exemplary method  160  may include an airframe  178  with a plurality of systems  180  and an interior  182 . Examples of high-level systems  180  include one or more of a propulsion system  184 , an electrical system  186 , a hydraulic system  188 , and an environmental system  190 . Any number of other systems may be included. The disclosed method and apparatus may be employed to place and trim film material on one or more elongate components forming part of the airframe  178  or the interior  182  such as, without limitation, stringers and spars. Although an aerospace example is shown, the principles of the disclosure may be applied to other industries, such as the marine and automotive industries. 
         [0060]    Systems and methods embodied herein may be employed during any one or more of the stages of the production and service method  160 . For example, components or subassemblies corresponding to production process  168  may be fabricated or manufactured in a manner similar to components or subassemblies produced while the aircraft  162  is in service. Also, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during the production stages  168  and  170 , for example, by substantially expediting assembly of or reducing the cost of an aircraft  162 . Similarly, one or more of apparatus embodiments, method embodiments, or a combination thereof may be utilized while the aircraft  162  is in service, for example and without limitation, to maintenance and service  176 . 
         [0061]    The description of the different illustrative embodiments has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the embodiments in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. Further, different illustrative embodiments may provide different advantages as compared to other illustrative embodiments. The embodiment or embodiments selected are chosen and described in order to best explain the principles of the embodiments, the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.