Edge delamination methods and systems

Methods and systems according to one or more examples are provided for laminating composite materials. In one example, a method comprises receiving a first layer material and a second layer material at a nip roller assembly and laminating, by the nip roller assembly, the first and second layer material to provide a laminated composite material comprising a main portion and at least one edge portion. The method further comprises delaminating the at least one edge portion of the laminated composite material to provide a partially laminated composite material for use in manufacturing a composite product.

TECHNICAL FIELD

The present disclosure relates generally to the manufacture of composite materials and more specifically to improved techniques for laminating composite materials.

BACKGROUND

Various lamination processes are commonly used in the manufacture of composite materials. In this regard, heat or pressure may be applied to two or more layers which cause them to adhere, bind, or otherwise become fixed together. For example, in some cases, bonding agents or other materials provided between the layers may be activated by the applied heat or pressure to laminate the layers together.

In some conventional lamination processes, the edges of the resulting composite material may exhibit undesirable non-uniformities after passing through a nip roller assembly. Such non-uniformities may include, for example, curling of the edges, wrinkles, waves, inconsistent surface textures at the edges, and/or other inconsistencies.

Unfortunately, such edge non-uniformities can be problematic for downstream manufacturing processes. For example, certain processes may be preferably performed on a laminated composite material that is disposed in a substantially flat orientation. Non-uniformities in the edges of the laminated composite material may reduce the efficacy of such processes.

One conventional approach to solving these problems involves the use of nip rollers having a reduced width to avoid laminating the edges of the composite material. In this case, the nip rollers may be applied to a main portion of the layers, while the edges of the layers pass through unaffected. Unfortunately, this approach can be of only limited use as the costs and practical implementation of nip rollers generally require them to be maintained at a fixed size.

In another approach, it may be possible to discard the non-uniform edge portions of the laminated composite material, for example, by severing them from the main body of the laminated composite material. However, such an approach is also costly and results in wasted material.

Accordingly, there is a need for improved systems, apparatus, and related methods to reduce non-uniformities in the edges of laminated composite materials.

SUMMARY

Methods and systems are disclosed herein that provide improved techniques for laminating materials. In some examples, a laminated composite material is formed from a thin film cap layer and a thin film substrate layer that are pressed together and subsequently delaminated at an edge to form a partially delaminated composite material. The cap layer and substrate layer are unwound from respective spools and fed through a nip roller assembly. The cap layer is heated during the feeding and the compliant substrate layer is pressed against the cap layer to form the laminated composite material by application of heat and pressure. The laminated composite material is selectively delaminated at one or more edges and taken up at a rewind roller.

In one example, a method includes receiving a first layer material and a second layer material at a nip roller assembly; laminating, by the nip roller assembly, the first and second layer material to provide a laminated composite material comprising a main portion and at least one edge portion; and delaminating the at least one edge portion of the laminated composite material to provide a partially laminated composite material for use in manufacturing a composite product.

In another example, a system includes a nip roller assembly configured to laminate a first layer material and a second layer material to provide a laminated composite material comprising a main portion and at least one edge portion; and a delaminator positioned to receive the laminated composite material from the nip roller assembly and configured to delaminate the at least one edge portion of the laminated composite material to provide a partially laminated composite material for use in manufacturing a composite product.

The scope of the disclosure is defined by the claims, which are incorporated into this section by reference. A more complete understanding of examples of the disclosure will be afforded to those skilled in the art, as well as a realization of additional advantages thereof, by a consideration of the following detailed description of one or more examples. Reference will be made to the appended sheets of drawings that will first be described briefly.

DETAILED DESCRIPTION

Various examples of the present disclosure provide for improved approaches to laminating materials. Materials that are commonly laminated include, but are not limited to, a thin film cap layer material laminated to a thin film substrate layer material to produce a laminated composite material. To prepare the laminated composite material for further processing, the present disclosure provides for delaminating one or more edges of the laminated composite material. Such delamination method eliminates waviness or wrinkles and allows for the composite material to lie flat, thus improving the effectiveness of downstream processing operations. In some examples, the cap layer material and/or the substrate layer material may be thin film materials that range in thickness from approximately one to two thousandths of an inch.

FIG. 1Aillustrates a block diagram of a lamination system100in accordance with an example of the disclosure. As illustrated, lamination system100includes a composite layer material supply105, a nip roller assembly110(e.g., a primary laminator), a delaminator assembly115, and a post-processing subsystem199. Lamination system100may be configured to perform lamination operations, delamination operations, and post-processing operations to manufacture a finished composite product.

Composite layer material supply105is configured to supply thin film material, such as a cap layer material120and a substrate layer material130, used for forming a laminated composite material150, as discussed herein. Composite layer material supply105includes a cap layer unwind spool122and a substrate layer unwind spool132. Cap layer unwind spool122contains cap layer material120. Substrate layer unwind spool132contains substrate layer material130.

Nip roller assembly110is configured to laminate thin film materials, such as cap layer material120and substrate layer material130, to form laminated composite material150, as discussed herein. Nip roller assembly110includes a heated roller112and a compliant roller114. In addition, an outtake roller140is configured to support laminated composite material150.

Delaminator assembly115is configured to delaminate one or more edges of laminated composite material150to form a partially laminated composite material151. Delaminator assembly115includes a position mechanism190and a delaminator160.

Post-processing subsystem199is configured to perform various manufacturing operations on partially laminated composite material151. Post-processing subsystem199includes a flat surface194and a post-processing laminator197.

FIG. 1Billustrates a block diagram of the lamination system100with further configuration details illustrated in accordance with an example of the disclosure. As shown inFIG. 1B, lamination system100includes cap layer unwind spool122and substrate layer unwind spool132(e.g., as part of composite layer material supply105), nip roller assembly110, position mechanism190and delaminator160(e.g., as part of delaminator assembly115), composite layer rewind spool170, and post-processing subsystem199. As further discussed below, lamination system100may be configured to laminate cap layer material120to substrate layer material130to form laminated composite material150. In some examples, cap layer material120and substrate layer material130are implemented as a thin film material. In addition, lamination system100may be further configured to delaminate cap layer material120from substrate layer material130at one or more edges to form partially laminated composite material151that is partially delaminted at one or more edges. Position mechanism190may be used to position and/or move delaminator160to selectively adjust a width of the edge portion to be delaminated.

In some examples, cap layer material120is wound or otherwise disposed on cap layer unwind spool122and fed into nip roller assembly110. Substrate layer material130is wound or otherwise disposed on substrate layer unwind spool132and fed into nip roller assembly110. Nip roller assembly110includes heated roller112and compliant roller114that receive cap layer material120and substrate layer material130, respectively. Heated roller112applies heat at the cap layer material120to thermally bond the cap layer material120to the substrate layer material130while compliant roller114in conjunction with heated roller112applies pressure to adhere the cap layer material120and the substrate layer material130together to form laminated composite material150. Laminated composite material150is supported by outtake roller140as it moves toward composite layer rewind spool170.

In some examples, before laminated composite material150is received at composite layer rewind spool170, an edge delamination is performed where one or more edges of laminated composite material150is delaminated. In this regard, laminated composite material150is fed to delaminator160at a position156. Delaminator160is interposed between cap layer material120and substrate layer material130at position157ofFIG. 1B. Delaminator160may be interposed between a leader portion of cap layer material120and substrate layer material130by position mechanism190before the start of the lamination process.

Position mechanism190may move delaminator160to selectively adjust a width of one or more edge portions to be delaminated. In some examples, position mechanism190may be manually operated to move delaminator160, as further discussed with regard toFIG. 2. In other examples, delaminator160is moved by an automated implementation of position mechanism190, as further discussed with regard toFIG. 3.

In some examples, delaminator160selectively separates cap layer material120and substrate layer material130of laminated composite material150to form partially laminated composite material151at a position158that is partially delaminted. Composite layer rewind spool170is used to collect the partially laminated composite material151. In this regard, the partially laminated composite material151, having been partially delaminated, lies flat on a working surface in preparation for additional manufacturing operations in the production of a final product, for example, a composite product used in an interior of an aircraft.

Post-processing subsystem199performs additional manufacturing operations such as adding additional layers, texturing the laminated composite material150, adding a backing material, and/or re-laminating the edge previously delaminted, as discussed herein. Post-processing subsystem199includes a flat surface194configured to receive partially laminated composite material151from composite layer rewind spool170.

Post-processing subsystem199also includes a post-processing laminator197configured to re-laminate one or more edges of partially laminated composite material151received from flat surface194. Post-processing laminator197may be implemented with one or more rollers, ovens, and/or other appropriate lamination devices.

FIG. 2illustrates delaminator160of the lamination system100ofFIG. 1Bin accordance with an example of the disclosure. As shown inFIG. 2, lamination system100includes various features previously identified inFIG. 1Bincluding delaminator160, outtake roller140, and composite layer rewind spool170. In the example shown inFIG. 2, the position mechanism is implemented by a manually operated position mechanism190A. As shown, position mechanism190A is implemented as a C-clamp fixed to a mount166and used to secure delaminator160in place relative to laminated composite material150. Although a C-clamp is illustrated, other types of holding devices are possible, such as an A-clamp, a twist clamp, and/or a fixed fastening device, for example.

In various examples, delaminator160is adjusted at edge154of laminated composite material150. Position mechanism190A may be adjusted to selectively control a delamination width and/or a height of delaminator160at edge154. In some examples, delaminator160ofFIG. 2may also be provided at an opposite side of laminated composite material150(as shown inFIG. 3), and selectively adjusted using position mechanism190A fixed to mount166at the opposite side. In this regard, lamination system100provides both modularity and adaptability for de-laminating one or more edges154at selective delamination widths and/or heights for various sizes of laminated composite material150.

In this particular example, delaminator160includes a bias member162and a base member164. Bias member162is secured by base member164in a fixed location at the edge of laminated composite material150. Bias member162is interposed between cap layer material120and substrate layer material130of laminated composite material150at the edge154. Bias member162may be selectively positioned (e.g., by positioning base member164) to select a delamination width of edge154of laminated composite material150along the directions identified by arrows202. In this regard, as illustrated inFIG. 2, position mechanism190A is implemented as a C-clamp that is loosened to move base member164to selectively adjust a delamination width and/or a height of bias member162along laminated composite material150. As laminated composite material150moves from heated roller112and compliant roller114(not shown) past outtake roller140, bias member162separates laminated composite material150at edge154. Main portion152of laminated composite material150remains laminated as partially laminated composite material151, having been partially delaminated, is taken up by composite layer rewind spool170.

FIG. 3illustrates a plan view of the lamination system100ofFIG. 1Bin accordance with an example of the disclosure. In the example shown inFIG. 3, lamination system100includes delaminator160A and delaminator160B, each of which may be implemented in the same or similar manner as delaminator160shown inFIG. 2. Also inFIG. 3, the position mechanism is implemented by a position mechanism190B which may be used to selectively adjust the position of delaminators160A and160B. As shown, position mechanism190B includes a controller180and actuators185A and185B. In this particular example, controller180provides control signals184A and184B to actuators185A and185B, respectively, to control movement of delaminators160A and160B, respectively.

Controller180includes a processor181, a memory182, and a communication interface183. Processor181may include, for example, a microprocessor, a single-core processor, a multi-core processor, a microcontroller, an application-specific integrated circuit (ASIC), a logic device (e.g., a programmable logic device configured to perform processing operations), a digital signal processing (DSP) device, one or more memories for storing executable instructions (e.g., software, firmware, or other instructions), and/or any other appropriate combination of processing device and/or memory to execute instructions to perform any of the various operations described herein.

In various examples, where the processing operation is automated, it should be appreciated that processing operations and/or instructions are integrated in software and/or hardware as part of processor181, or code (e.g., software or configuration data) which is stored in memory182. Examples of processing operations and/or instructions disclosed herein are stored by a machine readable medium in a non-transitory manner (e.g., a memory, a hard drive, a compact disk, a digital video disk, or a flash memory) to be executed by a computer (e.g., logic or processor-based system) to perform various methods disclosed herein.

Memory182includes one or more memory devices (e.g., one or more memories) to store data and information. The one or more memory devices include various types of memory including volatile and non-volatile memory devices, such as RAM (Random Access Memory), ROM (Read-Only Memory), EEPROM (Electrically-Erasable Read-Only Memory), flash memory, or other types of memory. In one example, processor181is adapted to execute software stored in memory182to perform various methods, processes, and operations in a manner as described herein.

Controller180is adapted to interface and communicate with actuator185A, actuator185B, and/or other devices (e.g., such as a display (not shown), for example) via a communication interface183to perform method and processing steps as described herein. Communication interface183includes wired or wireless communication buses within lamination system100. Communication interface183may be implemented as a wireless communication interface and may include, for example, Wi-Fi, Bluetooth, Zigbee, and/or other radio wave or optical interfaces.

In one example, controller180controls movement of delaminators160A and160B. In this regard, controller180communicates with actuators185A and185B via control signals184A and184B, respectively, to operate actuators185A and185B to move delaminators160A and160B in directions identified by arrows202to adjust a delamination width. Actuators185A and185B can be implemented as linear actuators, mechanical actuators, hydraulic actuators, electro-mechanical actuators, and/or other devices as appropriate.

In the above example, controller180may operate actuators185A and185B to move synchronously or independently to adjust delaminator160A and/or160B inward approximately two inches maximum from edge154of laminated composite material150, at position157. Other delaminator160adjustments are possible alone or in combination with adjustments described above.

As illustrated inFIG. 3, laminated composite material150, including cap layer material120and substrate layer material130, moves in a direction identified by arrow304along position156. As laminated composite material150reaches position157, cap layer material120and substrate layer material130are separated at an edge154by one or both delaminators160A and160B. A partially laminated composite material151including edge154portions that have been delaminated (e.g., as illustrated by dashed lines inFIG. 3), and main portion152(e.g., with lamination intact) proceeds to composite layer rewind spool170along position158. In this regard, lamination system100provides for a delaminator160that is selectively positionable and efficiently produces a partially laminated composite material151that is partially delaminated and advantageously lies flat on a working surface when performing secondary manufacturing operations.

In one example, delaminator160is positioned between the cap layer material120and substrate layer material130during an initial setup of lamination system100. In this regard, a leader material of cap layer material120is spooled from cap layer unwind spool122and fed through nip roller assembly110to position157. In addition, a leader material of substrate layer material130is spooled from substrate layer unwind spool132and fed through nip roller assembly110to position157. Cap layer material120and substrate layer material130are not laminated at this time to provide for delaminators160A and160B to be effectively interposed between cap layer material120and substrate layer material130. Inserting delaminator160between non-laminated leader materials prior to the start of the lamination process provides for efficient delamination of edge154without tearing or ripping of the laminated composite material150during the lamination/partial delamination operation.

FIG. 4illustrates a process for providing a composite product in accordance with an example of the disclosure. The process may begin in block402to initially set up lamination system100. Leader material of cap layer material120is unwound from cap layer unwind spool122and fed through nip roller assembly110between heated roller112(e.g., not heated at this time) and compliant roller114to position157. In addition, leader material of substrate layer material130is unwound from substrate layer unwind spool132and fed through nip roller assembly110to position157.

In block404, delaminator160is inserted between non-laminated leader material of cap layer material120and substrate layer material130at position157.

In block406, delaminator160is positioned at edge154and selectively adjusted to control a delamination width of laminated composite material150at edge154. Leader material of cap layer material120and leader material of substrate layer material130are fed to and wound at composite layer rewind spool170.

In block408, cap layer material120and substrate layer material130are unwrapped from cap layer unwind spool122and substrate layer unwind spool132, respectively.

In block410, cap layer material120and substrate layer material130are received at nip roller assembly110. In some examples, cap layer material120is received nearest heated roller112and substrate layer material130is received nearest compliant roller114. In some examples, such positioning may be reversed.

In block412, cap layer material120is laminated to substrate layer material130to produce laminated composite material150.

In block414, edge154at a side of laminated composite material150is delaminated by delaminator160to produce edge154delaminated portion and main portion152of partially laminated composite material151. In some examples, delaminator160is included on an opposite side and is used to delaminate a second opposite side of laminated composite material150.

In block416, composite layer rewind spool170receives partially laminated composite material151that has been delaminated at one or more edges.

In block418, partially laminated composite material151, having been partially delaminated, is provided for further processing by positioning in a substantially flat orientation on a substantially flat surface194and performing additional manufacturing operations while in the flat orientation.

In block420, additional manufacturing operations may be performed on the partially laminated composite material151with delaminated edge154portions (e.g., a re-lamination of edges154or other operations) to provide a manufactured composite product (e.g., wallpaper configured to be affixed to an interior of an aircraft and/or other products). Additional manufacturing operations may include one or more of adding additional layers, texturing the laminated composite material, adding a backing material, re-laminating one or more edge154portions of partially laminated composite material151, and/or other manufacturing operations using post-processing laminator197of post-processing subsystem199.

In view of the present disclosure, it will be appreciated that a lamination system100implemented in accordance with various examples set forth herein may provide for a partially laminated composite material151in a substantially flat orientation that improves downstream processing steps in manufacturing a finished composite product. The lamination system100incorporates a nip roller assembly110to laminate a cap layer material120and a substrate layer material130to provide a laminated composite material150, and a delaminator160positioned to receive the laminated composite material150from an outtake roller140to delaminate an edge154portion of the laminated composite material150to provide a partially laminated composite material151that has been partially delaminated and lies flat, free of waviness, wrinkles and/or other inconsistencies, all to optimize fabrication and manufacturability without the need for additional processing steps to eliminate inconsistencies that add schedule time and cost to the finished composite product.

Examples described above illustrate but do not limit the disclosure. It should also be understood that numerous modifications and variations are possible in accordance with the principles of the present disclosure. Accordingly, the scope of the disclosure is defined only by the following claims.