TAPE LAMINATION HEAD

A tape lamination head for applying composite tape onto a mold or mandrel amid the formation of a composite workpiece. The tape lamination head is but one component of a larger tape lamination machine and assembly. Among its components, the tape lamination head includes a tape supply reel and multiple rollers. The tape supply reel receives a tape supply spool. The rollers carry composite tape from the tape supply spool downstream of the tape supply reel. The composite tape is carried by the rollers about a composite tape path that is defined by the tape lamination head. At a location along the composite tape path, one or more of the rollers situates the composite tape so that a backing paper side of the composite tape ends up in confrontation with a layup surface upon which the composite tape is applied.

TECHNICAL FIELD

The present application relates to tape lamination machines and, more particularly, to tape lamination heads equipped in tape lamination machines for applying composite tape on molds or mandrels amid the formation of composite workpieces.

BACKGROUND

Tape lamination machines are used in the production of composite workpieces. The machines are employed in aerospace applications for aerospace parts, as well as in other applications for other parts. Composite material, in the form of fibrous material impregnated with resin, is applied by the machines to a mold or mandrel at precise locations and lengths to collectively form a composite workpiece. The tape lamination machine moves a tape lamination head over the mold to precisely apply composite tape in the ultimate shape of the composite workpiece. As the tape lamination head moves, it leaves a plurality of composite tape segments, also referred to as a course, behind on the mold. The automatic application of these composite tape segments to the mold involves the cooperation of a diverse collection of machinery that holds, moves, and ultimately cuts the composite tape.

The composite tape is typically wound in a spool arrangement and loaded into the tape lamination head. The composite tape has a backing paper on its bottom side of winding to avoid tape-on-tape adhesion. When unwound from the spool and routed through the tape lamination head during use, a top side of the composite tape lacking the backing paper (also called a sticky or tacky side) is applied facedown to the mold and brought in direct contact with the mold. The routing of the composite tape through the tape lamination head is hence designed to ensure that the composite tape's bottom side with the backing paper faces upward and outward as the composite tape is exiting the tape lamination head and once it is applied to the mold.

SUMMARY

In one implementation, a tape lamination head may include a tape supply reel and multiple rollers. The tape supply reel receives a tape supply spool. The rollers carry composite tape of the tape supply spool downstream of the tape supply reel. The composite tape is carried about a composite tape path defined at the tape lamination head. At a location along the composite tape path, one or more of the rollers situates the composite tape such that a backing paper side of the composite tape is brought to confront a layup surface before the composite tape is applied to the layup surface.

In another implementation, a tape lamination head may include a tape supply reel, multiple rollers, and a compactor. The tape supply reel receives a tape supply spool. The rollers carry composite tape of the tape supply spool downstream of the tape supply reel. The compactor is located near an exit of the tape lamination head and can come in the form of a compaction roller or can take another form. During use of the tape lamination head, backing paper carried by the composite tape is removed from the composite tape at a location that is upstream of the compactor. A backing paper side of the composite tape exhibits a facedown orientation at the exit of the tape lamination head.

In yet another implementation, a tape lamination head may include a tape supply reel, multiple rollers, and a compactor. The tape supply reel receives a tape supply spool. The rollers carry composite tape of the tape supply spool downstream of the tape supply reel. The composite tape is carried about a composite tape path defined at the tape lamination head. The compactor is located near an exit of the tape lamination head and can come in the form of a compaction roller or can take another form. At a first location along the composite tape path, one or more of the rollers situates the composite tape such that a backing paper side of the composite tape would be brought to confront a layup surface before the composite tape is applied to the layup surface. At a second location along the composite tape path, backing paper carried by the composite tape is removed from the composite tape.

DETAILED DESCRIPTION

The figures present an embodiment of a tape lamination head10that is equipped in a larger tape lamination machine and assembly12. Unlike past tape lamination heads, the tape lamination head10applies composite tape14to an underlying mold or mandrel in a manner in which a backing paper side16of the composite tape14is ultimately brought facedown to the mold. A composite tape path18about which the composite tape14is routed through the tape lamination head10is hence dissimilar and, in the embodiment presented by the figures, generally inverse that of past tape lamination heads. A greater tape effectiveness and enhanced tape-to-tape consistency is provided with use of the tape lamination head10and, in some instances, a reduced need for added heat to effect lamination results. These, as well as other enhancements, are described below in more detail. Furthermore, as used herein, the terms downstream and upstream are used with respect to the direction of composite tape movement at the tape lamination head such that downstream refers to a direction that is with the direction of movement and upstream refers to a direction that is against the direction of movement.

With reference toFIG. 1, the tape lamination machine and assembly12is used to prepare composite workpieces by applying the composite tape14to molds. The aerospace industry employs the machines and assemblies for aerospace workpieces such as long narrow flat parts, nested multi-part laminates, drape-formed skins, spars, stringers, beams, flaps, shear ties, ply packs, wing and tail skins, and many other parts. Still, the machines and assemblies are suitable for use in other industries and for other parts. The tape lamination machine and assembly12can have various layouts, setups, and equipment depending upon the particular application and particular part it is used to prepare. In the implementation ofFIG. 1, the tape lamination machine and assembly12generally includes a gantry20, a vacuum table22, and an operator station24. The tape lamination head10is docked to the gantry20, and the gantry20provides certain movements of the tape lamination head10during the application of the composite tape14. X-axis movement is carried out via a pair of longitudinal ways26and, by way of example, can be effected by rack and pinion drive units. Y-axis movement is carried out via a cross saddle28and, by way of example, can be effected by a linear motor and permanent magnets. Z-axis movement is carried out via a vertical slide30and, by way of example, can be effected by a precision ball screw actuator with a gearbox and a servo motor. The vertical slide30can also provide C-axis rotational movement which, by way of example, can be effected by a servo motor and a gearbox. Still, the tape lamination head10can be carried by other equipment and its movement can be provided in other ways; for example, the tape lamination head10could be mounted to a robotic arm that manipulates its movement in a different manner than described above.

Still referring toFIG. 1, the vacuum table22holds the mold (not shown) while the mold undergoes application of the composite tape14from the tape lamination head10. The operator station24can serve as a human-to-machine interface (HMI) site and permits operator control and management of the tape lamination machine and assembly12. Furthermore, and as shown inFIG. 1, the tape lamination machine and assembly12can include an auxiliary gantry32with trimming capabilities for parts, and can include a secondary tape lamination head and exchange station34for replacing tape lamination heads at the gantry20in need of composite tape supply or for other reasons. While shown and described with these layouts, setups, and equipment, the tape lamination machine and assembly12can have more, less, and/or different layouts, setups, and/or equipment in other implementations.

The precise nature of the composite tape14laid down by the tape lamination head10will depend on the particular application and part. In the aerospace example, the composite tape14can be in the form of a unidirectional carbon fiber tape impregnated with thermoset or thermoplastic resin and having a carrier or backing paper36on one of the two sides of the composite tape14. The edge-to-edge width of the composite tape14can vary—again depending on application and part—and in the aerospace example could be fifty millimeters (50 mm), seventy-five millimeters (75 mm), one hundred and fifty millimeters (150 mm), or three hundred millimeters (300 mm); still, other width dimensions are possible. Prior to its loading in the tape lamination head10, the composite tape14is wound on a tape supply spool38in an arrangement with a sticky or tacky side40of the composite tape14facing radially-outwardly and with the backing paper side16of the composite tape14facing radially-inwardly.

Amid pauses between composite tape application procedures, as well as at other times, composite tape can remain static within tape lamination heads. A length and extent of the static composite tape held taut by rollers can consequently remain exposed to the ambient environment and atmosphere for certain periods of time. It has been found that over such time periods the exposed sticky side of the composite tape that lacks the protection of backing paper can degrade. The sticky side can lose tackiness, can become dry, or can experience other unwanted conditions. In the past, the degraded extent of composite tape has hindered the effectiveness of adhesion of the composite tape when its sticky side is initially laid facedown on a mold and when it is subsequently applied facedown to previously laid tape. Due to the less effective adhesion, increased heat for lamination has often been required.

The tape lamination head10presented by the figures resolves the shortcomings of these past tape lamination heads. The tape lamination head10applies the composite tape14with the backing paper side16brought facedown to the mold, instead of the sticky side40being brought facedown as in previous application procedures. The backing paper side16directly confronts and opposes a layup surface62of the underlying mold upon exit of the composite tape14from the tape lamination head10. It is therefore the backing paper side16that is laid down and applied to the layup surface62, rather than the sticky side40. The backing paper side16is protected by the backing paper36from the ambient environment and atmosphere even when the composite tape14is static and, as a result, unwanted degradation is avoided and adhesion effectiveness is maintained. Greater consistency of adhesion among composite tape segments is therefore achieved with use of the tape lamination head10, and the need for increased heat to effect lamination may be averted. The tape lamination head10can have various designs, constructions, and components depending upon the particular application it is intended for use with and the particular parts it is intended to prepare. In the embodiment ofFIGS. 2-5, the tape lamination head10generally includes a frame42, a coupler44, a tape supply reel46, a set of rollers48, a cutter50, a scrap collector52, a backing paper removal assembly54, a compactor56, and an inspection device58. Still, in other embodiments the tape lamination head10can have more, less, and/or different components than those set forth here.

With particular reference toFIGS. 2 and 3, the frame42serves as the main structure of the tape lamination head10to which other components are mounted and about which other components are arranged. The frame42could form an enclosed housing, or can be an open-sided structure as illustrated in the figures. The coupler44provides a docking interface for attachment and detachment of the tape lamination head10to and from the gantry20. The tape supply reel46receives the tape supply spool38for loading the tape supply spool38and its wound composite tape14in the tape lamination head10. The tape supply reel46can be driven to rotate via a servo motor in order to unwind composite tape14from the tape supply spool38and feed the composite tape14through the tape lamination head10for downstream usage. The cutter50severs the composite tape14during use of the tape lamination head10in order to produce terminal ends of composite tape segments as needed for the particular mold. The scrap collector52gathers scrap pieces of the composite tape14resulting from cutting of the composite tape14. The scrap collector52can include a bin for containing the scrap pieces. The inspection device58detects lap and gap tolerances of the composite tape14as it is laid down on the underlying mold.

The rollers48assist with carrying the composite tape14from the tape supply spool38and downstream of the tape supply reel46. The composite tape14is routed internally through the tape lamination head10to an exit60(FIG. 4) via the rollers48for application to the layup surface62of the underlying mold. Along the way, the composite tape14can be carried and supported by other components apart from the rollers48. The rollers48can have different arrangements and can come in differing quantities. In the embodiment ofFIGS. 2 and 3, the rollers48include a first roller64, a second roller66, a third roller68, and a fourth roller70. The first roller64resides immediately downstream of the tape supply spool38and is the initial roller of the set of rollers48to accept engagement from the composite tape14as the composite tape14comes off of the tape supply spool38. Here, the first roller64is in the form of a dancer roller that functions to maintain tension and tautness of the composite tape14as the composite tape14is routed through the tape lamination head10and as the tape supply spool38is depleted of composite tape. In this regard, the first roller64is moveable forward and backward along a linear guide72. The second roller66resides downstream of the first roller64, and the third and fourth rollers68,70reside downstream of the second roller66.

The precise routing of the composite tape14through the tape lamination head10is set by the location of the rollers48and defines the composite tape path18. The composite tape path18is schematically represented inFIG. 3by numerous arrowed lines residing alongside the composite tape14along its taut extent from the tape supply spool38, over the rollers48, and to the exit60. In the embodiment ofFIG. 3, the composite tape path18routes the composite tape14in a manner which is reverse that of past tape lamination heads. The reversal works to bring the backing paper side16of the composite tape14to its facedown orientation and confrontation with the layup surface62. The reversal can be carried out in various ways in different embodiments. In this embodiment, the direction of movement of the composite tape14as it initially comes off of the tape supply spool38is turned in an opposite direction by the first roller64. The first roller64redirects the composite tape14one-hundred-and-eighty degrees (180°) from its previous direction in the example here; other changes of direction are possible in other examples. This occurs at a first location74along the composite tape path18that is immediately downstream of the tape supply spool38and prior to the composite tape14coming into engagement with downstream rollers. Still, in other embodiments the reversal could occur at other locations along the composite tape path18and by way of other rollers. In the embodiment of the figures, because of the reversed routing of the composite tape14, the sticky side40makes surface-to-surface abutment with exterior surfaces of the rollers64,66,68,70as the composite tape14travels over the rollers.

The backing paper removal assembly54separates and peels the backing paper36from the tape main body of the composite tape14. Referring now toFIG. 4, the separation occurs at a second location84along the composite tape path18. The second location84resides downstream of the first location74and downstream of all of the rollers48. Further, the second location84is immediately upstream of the compactor56and immediately upstream of the exit60. Once separated, a second sticky side76is revealed and ready for surface-to-surface application to the layup surface62. In the embodiment of the figures, and referring now toFIGS. 2 and 3 and 5, the backing paper removal assembly54includes a set of rollers78and a backing paper take-up reel80. The rollers78assist with carrying the backing paper36once the backing paper36is separated from the tape main body. With particular reference toFIG. 5, the rollers78include multiple rollers positioned downstream and upstream one another, one of which is in the form of a dancer roller82that functions to maintain tension and tautness of the backing paper36as the backing paper36is pulled from the tape main body and fed to the backing paper take-up reel80. The backing paper take-up reel80accumulates the backing paper36and winds the backing paper36fed to it downstream of the rollers78. The backing paper take-up reel80can be driven to rotate via a servo motor in order to take-up the peeled-off backing paper36.

The compactor56exerts compaction pressure and load to the tape main body of the composite tape14as the tape main body is being applied to the layup surface62. The compactor56can have various designs, constructions, and components in different embodiments. In this embodiment, and referring toFIGS. 2 and 3 and 4, the compactor56is in the form of a compaction roller86. The compaction roller86is mounted at or near the exit60so that the compaction roller86can come into abutment with the tape main body as the tape main body is dispensed through the exit60. In the example of the figures, the compaction roller86is a single, soft polyurethane compaction roller. Since the backing paper36is removed from the tape main body of the composite tape14upstream of the compaction roller86, the compaction effect on the tape main body is enhanced when application of the tape main body encounters plane transitions in the layup surface62such as ramps, padups, and certain contours.