Freespace composite manufacturing process and device

The application provides a movable apparatus for forming a thermo-softening part. The apparatus includes a first placement unit, a second placement unit, and a heat source. The first placement unit comprises one or more first rollers, which are movable in a first predetermined path. The second placement unit comprises one or more second rollers, which correspond to the first rollers. The second rollers are movable in a second predetermined path. The heat source is provided for heating an elongated thermo-softening material to a predetermined temperature. The first rollers and the second rollers are provided on opposite sides of the elongated thermo-softening material for compressing the thermo-softening material to form the thermo-softening material.

The application relates to a fiber placement apparatus. In particular, the application relates to an apparatus to form fiber-reinforced composite parts.

The fiber reinforced composite part usually has a large number of aligned fibers that are embedded in a matrix material. The matrix material usually refers to a viscous material that binds together the fibers and then hardens to provide shape to the composite part. The fibers can be in a dry form. The fiber can also be in the form of a reinforcing fabric, which is impregnated with thermo-softening matrix.

The fiber reinforced composite parts generally have superior strength and stiffness per weight when comparing to traditional metal components. The fiber reinforced composite parts are therefore suitable for high performance components, such as aircraft parts.

Traditionally, the fiber-reinforced composite parts are produced using fiber placement methods. The fiber placement methods refer to a kind of an additive manufacturing method that builds a three-dimensional object by adding layer-upon-layer of composite materials. These multiple layers of the composite material are typically placed on a tool surface, on a mould, or on a mandrel. The mandrel refers to a tool for clamping material. These layers are then compacted simultaneously and later cured to form a component of a predetermined shape.

The fiber placement methods allow the fiber-reinforced composite parts to have different designs and shapes.

US007080441 provides a device for automatically laying composite to manufacture a part. Examples of the device include a mandrel, a vertical movement shaft, a platform, one or more arm mechanisms, and one or more material delivery heads.

WO 2008129156 A1 provides a method and a device for making hollow parts of a composite material, in particular a composite material of the aircraft-fuselage section type, which includes a skin and optional reinforcing members.

It is an object of this application to provide an improved fiber placement apparatus.

This application provides a movable material placement apparatus for forming a thermo-softening part.

The material placement apparatus is intended to for attaching to robotic arms, wherein the robotic arm moves the material placement apparatus.

The thermo-softening part is made of or includes a material that softens at high temperatures and hardens at low temperatures. An example of a thermo-softening material is a thermoplastic material, which is in a viscous state at high temperatures and hardens at low temperatures.

The apparatus includes a first placement unit and a second placement unit.

In detail, the first placement unit includes one or more first rollers and a first heat source.

The first rollers are attached to first actuators, wherein the first actuators move the first rollers in a first predetermined path with respect to the material placement apparatus.

The heat source is provided for heating an elongated thermo-softening material to a desired temperature. The elongated thermo-softening material can be in a form of a tape or can be in a form of a bundle of fibers.

This desired temperature can refer to a shaping temperature, at which the thermo-softening material can be bended or shaped to a desired form or geometry. The desired temperature can also refer to a consolidating or fusing temperature, at which the thermo-softening material softens for fusing with another material.

The second placement unit includes one or more second rollers, which correspond to the first rollers.

The second rollers are attached to second actuators, wherein the second actuators move the second rollers in a second predetermined path with respect to the material placement apparatus.

The second predetermined path is often placed parallel essentially to the first predetermined path.

In use, the first rollers and the second rollers are provided on opposite sides of the thermo-softening material, such that the first rollers are placed near to the second rollers.

The first rollers and the second rollers are provided to compress a part of the thermo-softening material.

In one aspect of the application, the first rollers and the second rollers compress and shape the thermo-softening material to form a base structure.

In another aspect of the application, the first rollers and the second rollers compress and fuse the thermo-softening material onto a base structure to form a complete structure. the rollers may fuse more than one layer of the material onto the base structure.

This movable placement apparatus provides several advantages.

Merely one generic placement apparatus can be used for producing different thermo-softening parts. This is different from other devices, which have customized tools for producing different parts. One customized tool is used for producing one part.

The generic placement apparatus reduces production set-up time, which is required by customized tooling.

The placement apparatus also reduces cost, since cost related to the customized tools, which usually is the major cost factor for composite parts production, is avoided.

Similarly, longer lead time and risk related to the customized tooling are also eliminated.

The placement apparatus can produce parts of different sizes and shapes, thereby allowing flexibility of production.

The flexibility of process, in turn, improves or optimizes part supply chain, since production of normal parts can be handled together with production of urgently needed parts.

The placement apparatus also allows production of near net-shape structures with minimal scrap and minimal trimming.

Moreover, the placement apparatus permits a high degree of automation and allows production capabilities that operate 7 days a week and that operate 24 hours a day. This thus maximizes utility or usage of equipment and facilities.

This process, which is highly automated, also leads to quality improvements over lesser automated procedures.

Referring to the first placement unit, it often includes a first thermo-softening material storage and delivery device for storing the thermo-softening material.

The first thermo-softening material storage and delivery device can include a first reel for storing a first elongated thermo-softening material.

The first reel can be adapted for storing a first thermo-softening material in the form of a tape or a bundle of fibers. The fiber has a shape of a thin thread.

The first placement unit also often includes a first temperature sensor for measuring a temperature of the first thermo-softening material.

The temperature sensor can be provided by a thermal camera that provides a matrix of temperature readings for a given thermal image. In general, it is advisable or desirable to monitor different zones of a nip point, wherein the first thermo-softening material, the roller, and the base structure meet to ensure proper bond quality.

A position of the first temperature sensor is often fixed with respect to the first thermo-softening material storage and delivery device. The temperature reading can be used for controlling or regulating the cooling device or the heating device.

The first placement unit can also include a first distance measuring device for measuring a length of the compressed first thermo-softening material.

The first placement unit can also include a first thermo-softening material inspection device to monitor build quality of the finished part.

The inspection device can include a thermal camera or a vision camera to monitor the build quality. The inspection device can also provide real time process information to document the manufacturing process.

The first placement unit can also comprise a first device for cooling the thermo-softening material. The cooling device can include an active cooling device, which regulates a flow rate of a coolant for reducing the temperature of a part of the first thermo-softening material. The flow rate is increased or decreased such that the first thermo-soften material reaches a desired temperature.

The first heat source of the first placement unit can also include a laser generation device. The laser generation device provides a laser beam for melting an area of the first thermo-softening material.

The laser generation device can produce a laser beam with changeable operating parameters such as intensity, profile, size, and direction. A computer changes said operating parameters according to manufacturing process variation, thereby optimizing or improving a production of the thermo-softening part.

The first placement unit can also include a first pre-heating source. The pre-heating source acts to preheat the first thermo-soften material to a pre-heating predetermined temperature for preparing the thermo-soften material for forming.

The first placement unit can also include a first post-heating source, which acts to reduce mechanical stress and warpage in the first thermo-soften material due to avoid rapid cooling.

Referring to the second placement unit, it can include parts similar to the parts of the first placement unit.

The second placement unit can be configured to be similar to the first placement unit, thereby advantageously allowing the movable apparatus to place and fuse thermo-softening materials onto two different surfaces of the base structure.

The second placement unit often includes a second thermo-softening material storage and delivery device for storing a second thermo-softening material.

The second thermo-softening material storage and delivery device can include a second reel for storing a second elongated thermo-softening material.

The second reel can be adapted for storing a thermo-softening material in the form of a tape or a bundle of fibers.

The second placement unit also often includes a second temperature sensor for measuring a temperature of the second thermo-softening material.

The second placement unit can also include a second distance measuring device for measuring a length of the compressed second thermo-softening material.

The second placement unit can also include a second thermo-softening material inspection device to monitor build quality of the finished part.

The second placement unit can also comprise a second device for cooling the second thermo-softening material.

The second heat source of the second placement unit can also include a laser generation device.

The laser generation device can produce a laser beam with changeable operating parameters such as intensity, profile, size, and direction. The computer changes said operating parameters according to manufacturing process variation, thereby optimizing or improving the manufacturing process.

The second placement unit can also include a second preheating source. The pre-heating source acts to preheat the second thermo-soften material to a pre-heating predetermined temperature for preparing the second thermo-soften material for forming.

The second placement unit can also include a second post-heating source, which acts to reduce mechanical stress and warpage in the second thermo-soften material due to avoid rapid cooling.

The first placement unit and the second placement unit are adapted for immersing in liquid, such as water.

The liquid provides accelerated cooling of heated thermo-softening materials because the liquid has higher heat transfer rate than air, thereby allowing a shorter processing time.

Different shapes of the first and second rollers are possible. The first and second rollers can have a cylindrical shape. The first rollers and the second rollers can also have a shape of a partial cone. The partial cone shape allows finished thermo-soften material to have a curvature.

In one aspect of the application, the movable material placement apparatus includes a magnetic coupling device for attracting the first placement unit to the second placement unit by a magnetic force.

A robotic arm can be attached to the first placement unit to position the first placement unit at a desired position.

The second placement unit, which is attracted to the first placement unit, then follows the first placement unit to the desired position.

The second placement unit can be attached to a second robotic arm but is not necessary.

The magnetic coupling device has a benefit of allowing the rollers to apply a greater compressive force.

This application also provides a further movable material placement apparatus with a gripper for forming a thermo-softening part.

This apparatus includes a first placement unit, a heat source, and a second placement unit.

In detail, the first placement unit includes one or more first rollers. The first rollers are movable in a first predetermined path with respect to the material placement apparatus.

The heat source is provided for heating an elongated thermo-softening material to a desired temperature for shaping or fusing the thermo-softening material.

The second placement unit includes a gripper for supporting and holding a part of the thermo-softening part such that that the part does not slide or move perpendicularly with respect to the first determined path.

In use, the first rollers and the gripper are provided on opposite sides of the thermo-softening material, such that the first rollers are placed near to the gripper.

The first rollers and the gripper are provided to compress and to fuse the thermo-softening material onto a base structure.

The gripper provides support to the thermo-softening part, especially when the thermo-softening part is small. The gripper also prevents the thermo-softening part from slipping.

The gripper provides another means of supporting the thermo-softening material.

The application also provides a robotic structure for producing a thermo-softening part. The robotic structure includes an above-mentioned movable material placement apparatus, as well as a first arm unit with a second arm unit.

The movable material placement apparatus includes the above first placement unit and the above second placement unit.

The first arm unit has a first platform and a number of articulated interconnected first branch members, which are connected to the first platform and are connected to the first placement unit.

The first platform can be provided on the ground and can be movable.

The interconnected first branch members act to move the first placement unit to a first selected position in a three dimensional space, which comprises a length, a width, and a height.

Similarly, the second arm unit has a second platform and a number of articulated interconnected first branch members, which are connected to the second platform and are connected to the second placement unit.

The second platform can be provided on the ground and can be movable.

The articulated interconnected second branch members act to move the second placement unit to a second selected position in a three dimensional space.

Operationally, the second arm unit operates cooperatively with the first arm unit such that the second arm unit moves the second placement unit to move near the first placement unit.

The robotic arms provide a means to position the placement units to desired locations in three-dimensional space for forming a thermo-softening part.

The application also provides another robotic structure with magnetic coupling for forming a thermo-softening part.

The robotic structure includes the movable apparatus and an arm unit.

The movable apparatus comprises a first placement unit and a second placement unit, and a magnetic coupling device. The coupling acts for attracting the first placement unit to the second placement unit by a magnetic force.

The arm unit that comprises a platform and a plurality of articulated interconnected branch members. The plurality of articulated interconnected branch members is connected to the platform, and is connected to the first placement unit.

This robotic structure has an advantage in that it requires only one arm unit.

The application also provides a further apparatus for forming a thermo-softening part, wherein the apparatus is adapted for immersing in liquid.

The liquid provides a means to prevent the thermo-softening part from overheating.

The application also provides a method for forming a thermo-softening part.

The method includes a step of providing one or more first rollers and one or more second rollers on opposite sides of an elongated thermo-softening material, wherein these rollers are positioned near each other.

A pre-heating source can preheat the thermo-softening material to a predetermined preheating temperature for preparing the thermo-softening material for shaping or fusing.

A forming heating device later heats a portion of the thermo-softening material to a predetermined forming temperature.

A first robotic arm unit then moves the one or more first rollers in a first predetermined path and a second robotic arm unit moves the one more second rollers in a second predetermined path in order to compress the thermo-softening material portion.

The movement of the first rollers and the second rollers can later shape the thermo-softening material portion into a desired shape.

The movement of the first rollers and the second rollers can later also press and fuse the thermo-softening material portion onto a base structure, which is provided between the first rollers and the second rollers.

The thermo-softening material portion then cools naturally or cools by a cooling means for hardening it.

In the following description, details are provided to describe embodiments of the application. It shall be apparent to one skilled in the art, however, that the embodiments may be practiced without such details.

Some parts of the embodiment have similar parts. The similar parts may have the same names or similar part numbers with an alphabet symbol. The description of one similar part also applies by reference to another similar part, where appropriate, thereby reducing repetition of text without limiting the disclosure.

FIG. 1shows a fiber placement apparatus1and a base structure3.

The base structure3is made of one or more layers of composite material, such as thermoplastic material.

In a generic sense, the base structure3can constitute or include a thin sheet of material, such as plastic or metal. It can also include a sandwich core material, such as shown inFIG. 31.

The fiber placement apparatus1includes a robot5with a fiber placement module6and a computer7. The fiber placement module6is attached to the robot5.

The fiber placement module6acts as an end-effector of the robot5.

The robot5includes a first articulated robotic arm10and a second articulated robotic arm13.

The robotic arm10includes a movable platform15and a set of three interconnected arms17.

The movable platform15is placed on a ground and is connected to the interconnected arms17. The movable platform15is equipped with one or more wheels16or rollers, which is connected to a wheel actuator. The wheel actuator is electrically connected to the computer7.

The interconnected arms17include a first arm18, a second arm19, and a third arm20.

In detail, a first end of the first arm18is connected to the platform15via a first rotary joint. The first end of the first arm18and platform15are connected to a first actuator21, which is connected electrically to the computer7.

A second end of the first arm18is connected to a first end of the second arm19via a second rotary joint. The second end of the first arm18and the first end of second arm19are connected to a second actuator23, which is connected electrically to the computer7.

Similarly, a second end of the second arm19is connected to a first end of the third arm20via a third rotary joint. The second end of the second arm19and the first end of third arm20are connected to a third actuator24, which is connected electrically to the computer7.

A second end of the third arm20is attached to the fiber placement module6.

The robotic arms10and13have similar parts, which are connected in the similar manner.

The robotic arm13includes a movable platform15aand a set of three interconnected arms17a. The interconnected arms17ainclude a first arm18a, a second arm19a, and a third arm20a.

The fiber placement module6includes an upper fiber tape placement unit22and a lower fiber tape placement unit25.

The upper fiber tape placement unit22is connected to the robotic arm10. The lower fiber tape placement unit25is connected to the robotic arm13.

Referring to the upper fiber tape placement unit22, it includes a supporting frame31, a reel33with a length of tape43, a set of two cylindrical compaction rollers35, a heat source37, a cooling device39, and a temperature sensor41, as shown inFIGS. 2 and 6. The upper fiber tape placement unit22also includes a pre-heating source26, a post-heating source27, and a tape inspection device28, as shown inFIG. 2.

Referring toFIGS. 1 and 2, the supporting frame31is mounted to the third arm20of the first robotic arm10. The supporting frame31is also connected to the tape reel33, the compacting rollers35, the heat source37, the cooling device39, and the temperature sensor41.

The tape reel33is positioned near the compaction rollers35.

The two compaction rollers35are arranged next to each other such that surfaces of the respective cylindrical rollers35face each other while ends of the respective roller35are placed adjacent to each other. Each of the rollers35can rotate about a longitudinal axis of the roller35. Each of the compaction rollers35is also connected to a positional actuator45, which is connected electrically to the computer7.

The heat source37has a laser generation unit38. As better seen inFIG. 2, the heat source37is positioned near the tape reel33such that the laser generation unit38is directed at a point or an area where a part of the tape43is placed near to the upper surface of the base structure3, wherein the tape43is about to meet the upper surface of the base structure3. The heat source37is electrically connected to the computer7.

The cooling device39is placed adjacent to the compaction rollers35and is directed to an area of the upper surface of the base structure3. The cooling device39is electrically connected to the computer7.

The pre-heating source26is placed near the heat source37and is electrically connected to the computer7.

The post-heating source27is electrically connected to the computer7.

The tape inspection device28is electrically connected to the computer7.

The temperature sensor41is electrically connected to the computer7.

Referring to the lower fiber tape placement unit25, it includes a supporting frame50and a set of two cylindrical counter compaction rollers53, which are attached to the supporting frame50.

The compaction rollers35and the counter compaction roller53are also called consolidation or shaping rollers.

The supporting frame50is mounted to the third arm20aof the second robotic arm13.

The two counter compaction rollers53are placed next to each other such that surfaces of the respective cylindrical rollers53face each other while ends of the respective roller53are placed adjacent to each other. Each of the rollers53can rotate about a longitudinal axis of the roller53. Each of the rollers53is also connected to a positional actuator55, which is connected electrically to the computer7.

The tape43comprises a thermoplastic composite material or thermoplastic material. The thermoplastic composite material becomes pliable or moldable above a predetermined temperature and solidifies or hardens upon cooling.

In use, the first robotic arm10and the second robotic arm13are positioned such that the counter compaction rollers53and the compaction rollers35are placed at opposite sides of the base structure3. The counter compaction rollers53are placed near the compaction rollers35such that the compaction rollers35touch the upper surface of the base structure3and the counter compaction rollers53touch the lower surface of the base structure3.

The set of interconnected arms17together with the movable platform15is intended for moving the upper fiber tape placement unit22to a selected position in a three dimensional space, according to instructions from the computer7. The three dimensional space comprise a length, a width, and a height and is thus different from a plane, which refers to a two dimensional space. In other words, the upper fiber tape placement unit22can placed at several positions, as illustrated inFIGS. 3, 4, and 5.

In detail, the movable platform15, upon activation by the computer7, moves in the horizontal plane to a desired position. In particular, the computer7activates the wheel actuator, which rotates the wheels16of the platform15to move the platform15. The moving platform15, in turn, moves the set of interconnected arms17.

The computer7act to activate the first actuator21to rotate the first arm18with respect to the platform15about the first rotary joint that connects the first arm18to the platform15.

The computer7also acts to activate the second actuator23to rotate the second arm19with respect to the first arm18about the second rotary joint that connects the first arm18to the second arm19.

The computer7also acts to activate the third actuator24to rotate the third arm20with respect to the second arm19about the third rotary joint that connects the second arm19to the third arm20.

Together, the first, the second and the third actuators serve to move the upper fiber tape placement unit22to the selected position.

Similarly, the set of interconnected arms17atogether with the movable platform15ais intended for moving the lower fiber tape placement unit25to a selected position in a three dimensional space.

The tape reel33acts to hold the tape43and to release the tape43when needed.

The pre-heating source26acts to preheat a tape part and a upper surface area of the base structure3to a predetermined temperature, as shown inFIG. 2. The preheating prepares the tape part for further heating by the laser generation unit38. The pre-heating source26is activated by the computer7.

The temperature sensor41is intended for measuring temperature of the base structure3and the tape43. The temperature sensor41then sends the measurement to the computer7.

The laser generation unit38is activated by the computer7. The laser generation unit38can provide a laser beam with different radiation operating parameters, such as shape or profile, size, and intensity, as shown inFIGS. 6 and 7.

The laser generation unit38can also be moved such that the direction of the laser beam can be changed according to application of the laser generation unit38.

The adjustment of the radiation device operating parameters provides an advantage for allowing optimization or improvement of the tape fusion or shaping process.

For shaping, the laser generation unit38provides heat to a part of the tape43to a predetermined forming temperature. In effect, the tape portion is heated such that it softens.

The compaction rollers35and the counter compaction roller53serve as consolidation rollers. The compaction rollers35and the counter compaction roller53work together cooperatively for pressing and gripping the tape43.

In detail, the positional actuator45pushes the compaction roller35and the positional actuator55pushes the corresponding counter compaction roller53until the compaction roller35and the corresponding counter compaction roller53compresses and grips a portion of the tape43

The first robotic arm10and the second robotic arm13then move the compaction roller35and corresponding counter compaction roller53, which in turn moves the gripped tape portion for shaping the tape43.

The cooling device39then cools the shaped tape43to harden it. The cooling device39is activated by the computer7.

For fusing, the tape43is placed on the upper surface of the base structure3and is placed near the laser generation unit38.

The laser generation unit38provides heat to a part of the tape43and also to an area of the upper surface of the base structure3, wherein these parts are placed near to each other. These parts are heated to a predetermined fusing temperature. At this temperature, the tape portion and the base structure area have a viscous outer layer for fusing.

The compaction rollers35and the counter compaction roller53then press the tape portion towards the upper surface area. The pressing also drives out any entrapped air and suppresses bubble formation between the pressed tape portion and the pressed upper surface area. The pressing also fuses or joins the tape portion to the upper surface area.

The cooling device39later cools the fused part to harden it.

The post-heating source27acts to relieve any mechanical stress and warpage in the fused portion. If the fused portion cools rapidly, it can develop internal mechanical stress. The post-heating source27acts to re-heat the two or more fused layers to reduce internal stress. This step is often done independently from the tape fusing step.

The inspection device28uses thermal images to monitor build quality for ensuring quality of the finished part. The inspection device28also provides real time process information, which acts as process documents.

In one embodiment, the cooling device includes a coolant and regulates a flow rate of the coolant for reducing the temperature of the tape portion or temperature of the newly fused thermoplastic portion, according to temperature measurement by the sensor41. The flow rate is increased or decreased such that the tape temperature reaches a desired temperature reading.

In another embodiment, the heat source37includes other heating units for transferring heat via conduction, convection, and/or radiation to the tape43and to the base structure3. The convection can be done using gas torches. A combination of one or more of conduction, convection, and radiation can also be used for heating.

In a further embodiment, the compaction rollers35and the counter compaction rollers53include heating devices36for enabling the compaction rollers35and the counter compaction rollers53to provide heat energy to the tape43and to the base structure3, as shown inFIG. 9.

These heating devices36provide one method of the heating the tape43. Other means for heating the tape43are possible.

In a further embodiment, the base structure3comprises other material, instead of thermoplastic material. Examples of the other material include metal, plastic, or ceramic.

In a general sense, the cooling device39can include a passive cooling device, such as a heat sink.

The inspection device28can also use other modules for monitor build quality. Those modules can include a vision camera or an ultrasonic device.

The inspection device28can also include a tape-laying odometer for measuring a length of the shaped or fused thermoplastic tape.

The robotic arm10and13can each include various numbers of interconnect arms. They can each include two or more interconnected arms, instead of just three arms.

The platforms15and15acan be bolted or fixed to the ground, wall, or ceiling instead of being movable. In other words, the robotic arm10and13can be placed on a linear axis or pole to extend their reach. They can also be bolted to the ground.

Different methods of operating the fiber placement apparatus1to manufacture or produce thermoplastic parts are possible.

FIG. 8shows a flow chart60of one method of operating the fiber placement apparatus1to manufacture thermoplastic parts as described below.

The flow chart60comprises a preparation mode62, a shaping mode64, and a fusing mode66.

In the preparation mode62, it includes a step70of the first robotic arm10positioning the compaction rollers35on one side of the tape43and the second robotic arm13positioning the counter compaction rollers53on another side of the tape43. The compaction rollers35are positioned near to the counter compaction rollers53.

The pre-heating source26then provides heat energy to preheat the tape43to a predetermined preheating temperature for preparing the tape43for shaping or fusing, in a step72.

In the shaping mode64, the fiber placement apparatus1is used for shaping the tape43to act as a base structure.

The laser generation unit38later produces a laser beam to heat a portion of the preheated tape43to a predetermined forming temperature, in a step73.

The positional actuators45and the positional actuators55afterward move the compaction rollers35and the counter compaction rollers53to touch and to compress the heated tape43, in a step75.

The compression also acts to grip the tape43, thus allowing the compaction rollers35together with the counter compaction rollers53to move the compressed or gripped portion of the tape43.

Subsequently, the first robotic arm10and the second robotic arm13moves the compaction rollers35and the counter compaction rollers53, which are compressing and gripping the heated tape43, in order to shape the heated tape43.

The movement of the rollers35and53and the compression of the rollers35and53can operate together to cause a portion of the tape43to move to another position thereby shaping the heating tape43.

The temperature sensor41later measures the temperature of the tape43and sends the measured temperature to the computer7, which uses the measured temperature for regulating the cooling device39, in a step77.

The cooling device39afterward cools the shaped tape portion for hardening the shaped tape portion to form a desired thermoplastic part with the desired shape or geometry, in a step80.

In the fusing mode66, the fiber placement apparatus1is used for fusing the tape43with the base structure3to lay one or more layers of the tape43onto the base structure3.

The fusing mode includes a step82of the first robotic arm10positioning the compaction rollers35and the second robotic arm13positioning the counter compaction rollers53on opposite sides of the base structure3. The tape43is also placed between the compaction rollers35and the counter compaction rollers53.

The laser generation unit38later produces a laser beam to heat a part of the preheated tape43and a portion of the preheated upper surface of the base structure3to a predetermined fusing temperature, in a step84. The heated portion of the tape43may have an outer surface that is in a viscous state.

The positional actuators45and the positional actuators55afterward move the compaction rollers35and the counter compaction rollers53to press the heated tape part to the heated surface portion of the base structure3in order to fuse together these two parts, thereby forming a newly bonded structure, in a step87.

The temperature sensor41later measures the temperature of the newly bonded structure and sends the measured temperature to the computer7for regulating the cooling device39, in a step89.

The post-heating source28then provides heat to the newly bonded structure to eliminate or reduce any warpage or internal mechanism stress due to rapid cooling.

The cooling device39afterward cools the newly bonded structure for hardening the tape43and the base structure3, which have been fused together, in a step91.

The above steps can be repeated to provide the base structure3with more layers of the tape43to manufacture the finished thermoplastic part.

In one embodiment, the method includes a first stage and a second stage of a manufacturing process.

In the first stage, the shaping mode is used to form a base structure that comprises a first layer of material.

In the second stage, the base structure is reinforced according to design and load carrying elements.

Different heat transfer sources, different amount of compaction force, and different material placements can be used for the different stages. For instance, methods that are easier to shape in free space may be used for the base structure in the first stage, while methods that result in higher performance,—for example, through higher percentage of fiber content—may be used for subsequent second stages.

In another embodiment, the base layer consists of a compatible material, such as organic sheets with a compatible thermoplastic matrix, which has been pre-formed by another process.

In general, the heated tape43is often cooled and hardened using natural means, without use of the cooling device39. In other words, the cooling device39is not needed to cool the heated tape43. This happens when the laser beam is moving and is not focused on one spot. When the speed of laying the tape43onto the base structure3is increased, the cooling device39may be used.

This method to produce the thermoplastic part provides several benefits.

One fiber placement apparatus1can be used for producing various different finished parts. This fiber placement apparatus1differs from customised tools, wherein one customised tool is required for each finished part.

The fiber placement apparatus1allows reduction of production set-up time, as customised tooling, which takes time to produce, is not needed.

The fiber placement apparatus1also reduces production cost, since no cost is incurred for producing the customised tools. Moreover, no cost is incurred for waiting for delivery of the customised tools. Use of the fiber placement apparatus1also removes risk related to production of the customised tool.

The fiber placement apparatus1can also be used to produce small and large parts. This, in turn, causes part supply chain to be flexible, since production of normal and urgent parts can be handled together by the same apparatus.

Moreover, the fiber placement apparatus1allows production of parts with little scrap and minimal trimming.

The fiber placement apparatus1also permits a high degree of automation and allows non-stop production, thereby improving usage of equipment and facilities.

This highly automated process also leads to higher quality improvements, since manual work is reduced.

FIG. 10shows a further fiber placement apparatus1a. The fiber placement apparatus1aand the fiber placement apparatus1ofFIG. 1have similar parts.

The fiber placement apparatus1aincludes a fiber placement module6and a magnetic clamping device67. The fiber placement module6includes an upper fiber tape placement unit22and a lower fiber tape placement unit25.

In use, the upper fiber tape placement unit22and the lower fiber tape placement unit25are placed on opposite sides of a base structure.

The upper fiber tape placement unit22is connected to a robotic arm10, wherein the robotic arm10acts for positioning the upper fiber tape placement unit22.

The magnetic clamping device67provides a magnetic force that acts to attract the upper fiber tape placement unit22to the lower fiber tape placement unit25.

One method of operating the fiber placement apparatus1ais described below.

The method includes a step of placing the upper fiber tape placement unit22next to an upper surface of the base structure.

The lower fiber tape placement unit25is then placed next to a lower surface of the base structure, which is near the upper fiber tape placement unit22.

The magnetic clamping device67later acts to attract the lower fiber tape placement unit25to the upper fiber tape placement unit22.

The robotic arm10afterward moves the upper fiber tape placement unit22from one area of the upper surface to another area of the upper surface of the base structure.

The magnetic force of the magnetic clamping device67later acts to move the lower fiber tape placement unit25accordingly such that the lower fiber tape placement unit25is placed near the upper fiber tape placement unit22.

This allows compaction rollers of the upper fiber tape placement unit22and counter compaction rollers of the lower fiber tape placement unit25to compress a thermoplastic tape onto the base structure.

FIG. 11shows a fiber placement apparatus1b. The fiber placement apparatus1band the fiber placement apparatus1ofFIG. 1have similar parts.

The parts of the fiber placement apparatus1bare configured or adapted for operating in liquid.

The liquid can refer to deionized water, wherein electrically charged atoms or molecules are removed from the water.

The fiber placement apparatus1bhas several advantages.

The deionized water provides higher heat transfer rate than air, resulting in accelerated cooling of heated thermoplastic materials. This accelerated cooling allows a newly bonded thermoplastic structure to cool faster, thereby increasing operational efficiency of the fiber placement process and the manufacturing time of part produced by the fiber placement apparatus1b.

In addition, the deionized water is electrically neutral and has more buoyancy than air. This will reduce stresses on the newly bonded thermoplastic structure after fusion.

In a generic sense, other fiber placement apparatus can be provided for operating in liquid in order to have the above benefits.

In a general sense, the fiber placement apparatus1can have different numbers of rollers, as illustrated inFIGS. 12 and 17.

Referring toFIG. 12, it shows three set of shaping rollers for fiber placement apparatus1. Each set of shaping rollers comprises a compaction roller and a counter compaction roller.

In use, the rollers can move in different paths for shaping a tape.

These rollers can move in a straight path, as shown inFIG. 13. These rollers can also move in a curved path for shaping a tape, as shown inFIG. 14.

Each of the three rollers can be also positioned differently for providing the tape with different shapes.

The rollers can be positioned to provide the tape with a convex upper surface, as shown inFIG. 15.

The rollers can be positioned to provide the tape with a concave upper surface, as shown inFIG. 16.

Referring toFIG. 17, it shows the fiber placement apparatus ofFIG. 1with just one set of shaping rollers.

The shaping rollers have two circular ends that have the same radius, shown inFIGS. 18 and 19.

When the roller rotates, both ends of the roller turn at the same rotational speed. This allows these rollers to move easily in a straight path or a curved path, as shown inFIG. 20.

FIGS. 14 and 20also show a method of steering a tape vertically upwards and downwards.

Different shapes of the shaping rollers are possible.

FIGS. 21 to 24show a variant of the shaping rollers ofFIG. 6.FIGS. 21 to 24show a further set of shaping rollers.

The further set of shaping rollers includes two rollers35aand53a. Each of the rollers35aand53ahas a shape of a truncated cone. In other words, each of the rollers35aand53ahas two circular ends with different radii.

The rollers35aand53aare arranged such that the smaller end of the roller35ais placed next to the smaller end of the roller53a. Similarly, the larger end of the roller35ais placed next to the larger end of the roller53a.

In use, the rollers35aand53acompress and grip the tape43.

The tape43has a first edge, which is nearer to the smaller ends of the rollers35aand53a. The tape43has a second edge, which is nearer to the larger ends of the rollers35aand53a.

When these rollers35aand53aturn at the same rotational speed, the first edge travels slower than the second edge. This causes the tape43to turn towards the smaller ends of the rollers35aand53a, as shown inFIGS. 21 and 23.

These rollers35aand53ahave a benefit of producing a tape with a curvature.

Different methods of placing fibers and matrix material into a usable compound for the fiber placement apparatus1ofFIG. 1are possible.

FIG. 25shows a method that is using unidirectional fiber thermoplastic tape43aand heating the tape for processing.

FIG. 26shows a method of using filaments or fiber strands44athat are combined in the process itself. This therefore allows variations of the resulting tape structure width and thickness.

In one implementation, fiber reinforced filaments of a “fused deposition molding” (FDM) process can be used. In another implementation “co-mingled yarn”—thermoplastic coated fibers—are used.

FIGS. 27 and 28show another method that includes adding thermoplastic material44b, either liquid, as droplets, powder, film or any other shape to add to other forms of placement, for example, those methods described inFIGS. 25 and 26.

In one implementation, the “tape” could also be a dry, spread roving44c, therefore only fibers.

The fiber placement apparatus1can be provided with different types of end-effectors.

FIG. 29shows the fiber placement apparatus1ofFIG. 1, wherein the counter compaction rollers53of the lower fiber tape placement unit25are replaced by a gripper unit93. The gripper unit is attached to the robotic arm13.

In use, the robotic arm13moves the gripper unit93to a desired position for supporting a base structure3, especially during consolidation of a tape or during fusing of a tape onto the base structure3.

The gripper93acts to absorb compacting forces from the compaction rollers35during the consolidation or the fusing.

The gripper93also prevents the base structure3for slipping or from moving perpendicularly to the movement of the compaction rollers35.

The gripper93is used especially for small base structure where counter compaction rollers are too big for supporting the base structure.

FIG. 30shows the fiber placement apparatus1ofFIG. 1. The fiber placement apparatus1includes two fiber tape placement units, namely an upper fiber tape placement unit22-1and a lower fiber tape placement unit22-2, which act as placement heads.

The lower fiber tape placement unit22-1has parts that are similar to the parts of the upper fiber tape placement unit22-2.

The upper fiber tape placement unit22-1has compaction rollers35-1, a reel33-1, and a heat source37-1.

Similarly, the fiber tape placement unit22-2has compaction rollers35-2, a reel33-2, and a heat source37-2.

In use, the upper fiber tape placement unit22-1and the lower fiber tape placement unit22-2are positioned on opposite side of a base structure3.

In one implementation, as shown inFIG. 30, the reel33-1provides a tape43-1while the heat source37-1acts to heat the tape43-1.

Similarly, the reel33-2provides a tape43-2while the heat source37-2acts to heat the tape43-2.

The compaction rollers35-1and the compaction rollers35-2act to press the tape43-1and the tape43-2together to form one part, which can serve as a base structure.

In another implementation, as shown inFIG. 31, the reel33-1provides a tape43-1on the upper surface of a base structure3.

The heat source37-1acts to heat the tape43-1and an upper surface of the base structure3.

Likewise, the reel33-2provides a tape43-2on a lower surface of the base structure3.

The heat source37-2acts to heat the tape43-2and the lower surface of the base structure3.

The compaction rollers35-1and the compaction rollers35-2act to press the tape43-1onto the upper surface of the base structure3and to press the tape43-2and the lower surface of the base structure3.

The base structure3can include a sandwich core material, as shown inFIG. 31.

The sandwich core material is usually lightweight and is practically incompressible. The sandwich core material can be in the form of a honeycomb with multiple hollow cores or can include a piece of structural foam that is able to bear load without deforming.

FIGS. 32 and 33show the fiber placement apparatus1using the tape43to cover an opening57of a base structure3.

In summary, the above embodiments provide a fiber placement apparatus that does not use tooling, molds, which can be in a negative form, or closed molds for injection molding.

The above embodiments also provide a composite manufacturing process that removes various distinct steps and does not require multiple apparatuses, which are used in the other fiber placement processes.

These embodiments therefore reduce cost and time in manufacturing of composites parts.

The embodiments can also be described with the following lists of features or elements being organized into an item list. The respective combinations of features, which are disclosed in the item list, are regarded as independent subject matter, respectively, that can also be combined with other features of the application.1. A movable apparatus for forming a thermo-softening part, the apparatus comprisinga first placement unit that comprisesat least one first roller, wherein the first roller is movable in a first predetermined path, anda first heat source, anda second placement unit that comprisesat least one second roller, which corresponds to the at least one first roller, wherein the second roller is movable in a second predetermined path,whereinthe first heat source isprovided for heating an elongated thermo-softening material to a predetermined temperature, andthe at least one first roller and the at least one second roller areprovided on opposite sides of the thermo-softening material, andprovided to compress the thermo-softening material.2. The movable apparatus according to item1, whereinthe first placement unit further comprises a first thermo-softening material storage and delivery device.3. The movable apparatus according to item2, whereinthe first thermo-softening material storage and delivery device comprises a first reel.4. The movable apparatus according to item3, whereinthe first reel is adapted for storing a first thermo-softening material in the form of a tape or in a form of a bundle of fibers.5. The movable apparatus according to one of the above-mentioned items, whereinthe first placement unit further comprises a first temperature sensor for measuring a temperature of the first thermo-softening material.6. The movable apparatus according to one of the above-mentioned items, whereinthe first placement unit further comprises a first distance measuring device for measuring a length of the compressed first thermo-softening material.7. The movable apparatus according to one of the above-mentioned items, whereinthe first placement unit further comprises a first thermo-softening material inspection device.8. The movable apparatus according to one of the above-mentioned items, whereinthe first placement unit further comprises a first device for cooling the first thermo-softening material.9. The movable apparatus according to one of the above-mentioned items, whereinthe first heat source comprises a first laser generation device.10. The movable apparatus according item9, whereinthe first laser generation device produces a laser beam with changeable intensity, profile, size, and/or direction.11. The movable apparatus according to one of the above-mentioned items, whereinthe first placement unit further comprises a first preheating source and/or a first post-heating source.12. The movable apparatus according to one of the above-mentioned items, whereinthe second placement unit further comprises a second heat source.13. The movable apparatus according to one of the above-mentioned items, whereinthe second placement unit further comprises a second thermo-softening material storage and delivery device.14. The movable apparatus according to item13, whereinthe second thermo-softening material storage and delivery device comprises a second reel.15. The movable apparatus according to item14, whereinthe second reel is adapted for storing a second thermo-softening material in the form of a tape or in a form of a bundle of fibers.16. The movable apparatus according to one of the above-mentioned items, whereinthe second placement unit further comprises a second temperature sensor for measuring a temperature of the second thermo-softening material.17. The movable apparatus according to one of the above-mentioned items, whereinthe second placement unit further comprises a second distance measuring device for measuring a length of the compressed second thermo-softening material.18. The movable apparatus according to one of the above-mentioned items, whereinthe second placement unit further comprises a second thermo-softening material inspection device.19. The movable apparatus according to one of the above-mentioned items, whereinthe second placement unit further comprises a second device for cooling the second thermo-softening material.20. The movable apparatus according to one of the above-mentioned items, whereinthe second placement unit further comprises a second preheating source and/or a second post-heating source.21. The movable apparatus according to one of the above-mentioned items, whereinthe first placement unit and the second placement unit are adapted for immersing in liquid.22. The movable apparatus according to one of the above-mentioned items, whereinthe first roller and the second roller comprise a shape of a partial cone.23. The movable apparatus according to one of the above-mentioned items further comprising a coupling device for attracting the first placement unit to the second placement unit by a magnetic force.24. A movable apparatus for forming a thermo-softening part, the apparatus comprisinga first placement unit that comprisesat least one first roller, wherein the first roller is movable in a first predetermined path, anda heat source, anda second placement unit that comprisesa gripper for supporting [and holding a part of] the thermo-softening part [such that the part does not slide or move perpendicularly with respect to the first determined path],whereinthe heat source isprovided for heating an elongated thermo-softening material to a predetermined temperature, andthe at least one first roller and the gripper areprovided on opposite sides of the thermo-softening material, andprovided to compress [a part of] the thermo-softening material.25. A robotic structure for forming a thermo-softening part comprisinga movable apparatus according to one of the above-mentioned items, the apparatus comprisinga first placement unit anda second placement unit,a first arm unit that comprisesa first platform anda plurality of articulated interconnected first branch members being connected to the first platform, and being connected to the first placement unit, anda second arm unit that comprisesa second platform anda plurality of articulated interconnected second branch members being connected to the second platform, and being connected to the second placement unit.26. A robotic structure for forming a thermo-softening part comprisinga movable apparatus according to one of the items1to24, the apparatus comprisinga first placement unit,a second placement unit, anda coupling device for attracting the first placement unit to the second placement unit by a magnetic force, andan arm unit that comprisesa platform anda plurality of articulated interconnected branch members being connected to the platform, and being connected to the first placement unit.27. An apparatus for forming a thermo-softening part, the apparatus, whereinthe apparatus is adapted for immersing in liquid28. A method for forming a thermo-softening part, the method comprisingproviding at least one first roller and at least one corresponding second roller on opposite sides of an elongated thermo-softening material,heating the thermo-softening material [to soften it],moving the at least one first roller in a first predetermined path, and moving the at least one second roller in a second predetermined path to compress the thermo-softening materialto shape the thermo-softening material and/orto fuse the thermo-softening material onto a base structure, wherein the base structure is provided between the at least one first roller and the at least one second roller.

Although the above description contains much specificity, this should not be construed as limiting the scope of the embodiments but merely providing illustration of the foreseeable embodiments. The above stated advantages of the embodiments should not be construed especially as limiting the scope of the embodiments but merely to explain possible achievements if the described embodiments are put into practice. Thus, the scope of the embodiments should be determined by the claims and their equivalents, rather than by the examples given.

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