Abstract:
An apparatus for splicing an elongate multi-layered workpiece includes: (a) drives and guides cooperating to drive the workpiece along a working path; (b) a cutter for severing the workpiece; (c) a layer manipulator for separating layers; (d) an applicator for applying adhesive; and (e) a deflector unit for deflecting the workpiece from the working path. The cutter effects the severing to present first and second workpiece segments. The layer manipulator effects inter-layer separation in one segment to present an interlayer zone in the one segment. A drive inserts the other segment in the interlayer zone. The layer manipulator urges the layers together to capture the other segment within the interlayer zone to establish a multi-layer structure. A drive and at least one of the workpiece deflector unit and the applicator situate the multi-layer structure adjacent to the applicator for finishing the splicing by applying adhesive to the multi-layer structure.

Description:
BACKGROUND 
       [0001]    Elongate workpieces may include, by way of example and not by way of limitation, a multilayered tape stored on a reel Such tape workpieces may be used, by way of further example and not by way of limitation, in a manufacturing process that may include a material having a backing layer covering one face of the material. The backing layer may protect an adhesive or another feature of the covered face of the material until the material is used. It may be advantageous to be able to splice lengths of an elongate workpiece such as a tape workpiece in order to reduce waste, to reuse reels for storing the workpiece material, to consolidate partial reels to a full reel so as to conserve space or material or for another reason. It may also be advantageous for a spliced workpiece to be substantially as strong as an unspliced workpiece. While a splice may initially be weaker than the unspliced material, the initial splice may only need to be strong enough to maintain integrity though a process in which a workpiece is employed, such as a laminating process using a tape-like workpiece to create a surface area of a part. Once a part in which a workpiece is included may be cured, any discontinuity occasioned by a splice may have little influence on the strength of the finished and cured part. It may further be advantageous for a spliced workpiece to be substantially free of significant gaps or other discontinuities. 
         [0002]    There is a need for an apparatus and method for splicing an elongate multi-layered workpiece that can present a spliced elongate workpiece that is substantially as strong as an unspliced workpiece. 
         [0003]    There is a need for an apparatus and method for splicing an elongate multi-layered workpiece that can present a spliced elongate workpiece having few significant gaps or other discontinuities. 
       SUMMARY 
       [0004]    An apparatus for splicing an elongate multi-layered workpiece includes: (a) drives and guides cooperating to drive the workpiece along a working path; (b) a cutter for severing the workpiece; (c) a layer manipulator for separating layers; (d) an applicator for applying adhesive; and (e) a deflector unit for deflecting the workpiece from the working path. The cutter effects the severing to present first and second workpiece segments. The layer manipulator effects inter-layer separation in one segment to present an interlayer zone in the one segment. A drive inserts the other segment in the interlayer zone. The layer manipulator urges the layers together to capture the other segment within the interlayer zone to establish a multi-layer structure. A drive and at least one of the workpiece deflector unit and the applicator situate the multi-layer structure adjacent to the applicator for finishing the splicing by applying adhesive to the multi-layer structure. The apparatus may include sensors for detecting defects and splices. The apparatus may also include a measurement unit for determining the amount of material remaining on a returned supply reel. When recovering unused material, a take up reel may be filled to a level that may allow the material on the returned supply reel to finish filling the take up reel. This may result in “older” material being situated on the outside of the take up reel so the older material will be used first. When recovering unused material, any previously made splices in the returned material may be removed. If the splice is not removed and replaced, the orientation of the layers may be incompatible with the laminating equipment with which the workpiece may be employed, such as for laminating a surface for an aircraft wing. 
         [0005]    A method for splicing an elongate workpiece having a plurality of materials substantially abuttingly oriented in a plurality of layers includes: (a) in no particular order: (1) providing a plurality of drive units arranged for driving the workpiece along a working path; and (2) providing a plurality of guide structures arranged for cooperating with the plurality of drive units for guiding the workpiece along the working path; (b) operating a cutting unit for effecting severing of the workpiece to present a first segment of the workpiece and a second segment of the workpiece; (c) operating a layer manipulating unit to effect an inter-layer separation in a portion of one segment of the first segment and the second segment to present an interlayer zone in the one segment; (d) operating at least one drive means of the plurality of drive means to insert the other segment in the interlayer zone; (e) operating the layer manipulating unit to urge the selected layers together to generally capture the other segment within the interlayer zone to establish a multi-layer structure; and (f) operating the plurality of drive units and the adhering unit to situate the multi-layer structure adjacent to the adhering unit for finishing the splicing by applying the adhesive to the multi-layer structure. 
         [0006]    It is, therefore, a feature of embodiments of the invention to present an apparatus and method for splicing an elongate multi-layered workpiece that can present a spliced elongate workpiece that is substantially as strong as an unspliced workpiece. 
         [0007]    It is another feature of embodiments of the invention to present an apparatus and method for splicing an elongate multi-layered workpiece that can present a spliced elongate workpiece having few significant gaps or other discontinuities. 
         [0008]    Further features of embodiments of the invention will be apparent from the following specification and claims when considered in connection with the accompanying drawings, in which like elements are labeled using like reference numerals in the various figures, illustrating embodiments of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is a schematic illustration of an embodiment of the apparatus. 
           [0010]      FIG. 2  is a schematic illustration of an embodiment of the apparatus effecting a severing of the workpiece. 
           [0011]      FIG. 3  is a schematic illustration of an embodiment of the apparatus effecting a clearing of the workpiece path to carry out a splicing operation. 
           [0012]      FIG. 4  is a schematic illustration of an embodiment of the apparatus effecting an advancing of the workpiece path to carry out a splicing operation. 
           [0013]      FIG. 5  is a schematic illustration of an embodiment of the apparatus effecting an interlayer separation of the workpiece path to carry out a splicing operation. 
           [0014]      FIG. 6  is an enlarged schematic illustration showing details of an interlayer separation. 
           [0015]      FIG. 7  is a schematic illustration of an embodiment of the apparatus effecting an advancing of a portion of a workpiece toward an interlayer zone to carry out a splicing operation. 
           [0016]      FIG. 8  is a schematic illustration of an embodiment of the apparatus effecting an establishing of a multi-layer structure to carry out a splicing operation. 
           [0017]      FIG. 9  is an enlarged schematic illustration showing details of a multi-layer structure. 
           [0018]      FIG. 10  is a schematic illustration of an embodiment of the apparatus effecting an orientation of a workpiece to accommodate application of adhesive to a multi-layer structure to carry out a splicing operation. 
           [0019]      FIG. 1   1 is a schematic illustration of an embodiment of the apparatus effecting an application of adhesive to a multi-layer structure in a workpiece to carry out a splicing operation. 
           [0020]      FIG. 12  is an enlarged schematic illustration showing details of application of adhesive to a multi-layer structure. 
           [0021]      FIG. 13  is a schematic illustration of an embodiment of the apparatus effecting a testing of a splice in a workpiece. 
           [0022]      FIG. 14  is a flow chart illustrating an embodiment of the method of the invention. 
           [0023]      FIG. 15  is a functional chart illustrating an embodiment of the apparatus of the invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0024]      FIG. 1  is a schematic illustration of an embodiment of the apparatus. In  FIG. 1 , a splicing apparatus  10  may process an elongate workpiece  12  flowing generally from left to right in  FIG. 1 . Workpiece  12  may be a multi-layered elongate material such as a tape material layer  18  having a backing or other protective material layer  19  on one side of tape material  18 . Apparatus  10  may include drive units  14 ,  16  and guide units or structures  20 ,  22 ,  24 ,  26   28 ,  30 ,  32  may cooperate to drive and guide workpiece  12  along a working path  38 . Working path  38  may generally trace the pattern traversed by workpiece  12  in  FIG. 1 , and may lie substantially in the plane in which  FIG. 1  may be displayed. By way of example and not by way of limitation, drive units  14 ,  16  may be embodied in paired nip roller assemblies. 
         [0025]    Apparatus  10  may include a defect detector unit  40  situated to carry out inspection of workpiece  12  at a locus “X” as workpiece  12  travels past defect detector unit  40  along working path  38 . Guide units  24 ,  26 ,  28  may create a material buffer by increasing the length of workpiece  12  between defect detector unit  40  and cutting unit  42 . If a second defect is found in workpiece  12  before the first defect reaches cutting unit  42 , all workpiece  12  between the two defects may be discarded to ensure that two splices are not located closer than the length of the material buffer established by guide units  24 ,  26 ,  28 . Apparatus  10  may further include a cutting unit  42  situated generally next to or astride working path  38  in an orientation permitting severing of workpiece  12  as workpiece  12  traverses working path  38 . Apparatus  10  may also include a workpiece redirecting unit  44 , a layer manipulating unit  46 , a heater element  48 , a workpiece deflecting unit  50  and an adhering unit  52 . 
         [0026]    A supply reel or other supply mechanism (not shown in  FIG. 1 ) may provide workpiece  12  from the upstream end  34  of working path  38  at the left side of  FIG. 1 . A take-up reel or other collecting mechanism (not shown in  FIG. 1 ) may collect workpiece  12  at the downstream end  36  of working path  38  at the right side of  FIG. 1 . 
         [0027]      FIG. 2  is a schematic illustration of an embodiment of the apparatus effecting a severing of the workpiece. In  FIG. 2 , workpiece  12  may have progressed along working path  38  to an orientation placing the observed defect first appearing at locus X at a new locus X′ upstream of cutting unit  42 . Cutting unit  42  may reoriented to a cutting position traversing working path  38  so as to begin removing the detected defect at locus X′ by cutting workpiece  12  at a locus Y 1 . Loci Y 1 , Y 2  may bound an interval that spans the defect at locus X′. 
         [0028]      FIG. 3  is a schematic illustration of an embodiment of the apparatus effecting a clearing of the workpiece path to carry out a splicing operation. In  FIG. 3 , cutting unit  42  may have completed severing of workpiece  12  at locus Y 1 . Cutting unit  42  may be retracted to a position displaced from and clearing working path  38 , as shown in  FIG. 3 , and workpiece redirecting unit  44  may be tilted to clear a leading segment  12   1  of workpiece  12  from working path  38 , also as shown in  FIG. 3 . A trailing segment  12   2  of workpiece  12  may remain generally in working path  38 . 
         [0029]      FIG. 4  is a schematic illustration of an embodiment of the apparatus effecting an advancing of the workpiece path to carry out a splicing operation. In  FIG. 4 , drive unit  16  may advance leading segment  12   1  of workpiece  12  to substantially fully orient leading segment  12   1  within layer manipulating unit  46 , and layer manipulating unit  46  may be closed upon leading segment l 2   1  in preparation for separating layers  18 ,  19  of leading segment  12   1 . Drive unit  14  may advance trailing segment  12   2  of workpiece  12  to encounter workpiece redirecting unit  44  so as to cause trailing segment  12   2  to deviate from working path  38 . Drive unit  14  may advance trailing segment  12   2  to substantially align locus Y 2  with cutting unit  42   
         [0030]      FIG. 5  is a schematic illustration of an embodiment of the apparatus effecting an interlayer separation of the workpiece path to carry out a splicing operation.  FIG. 5  may also show severing of the upstream segment of a workpiece to remove a scrap portion. In  FIG. 5 , cutting unit  42  may have effected severing of workpiece  12  at locus Y 2  (see  FIG. 4 ) and the severed segment Y 1 -Y 2  (see  FIG. 4 ) may have been discarded. Layer manipulation unit  46  may have separated layers  18 ,  19  of leading segment  12   1  to present an interlayer zone  60  between separated layers  18 ,  19 . 
         [0031]      FIG. 6  is an enlarged schematic illustration showing details of an interlayer separation. In  FIG. 6 , layer manipulation unit  46  may include a first jaw member  47  in hinged relation with a second jaw member  49 . Jaw members  47 ,  49  may be generally symmetrically arranged with respect to working path  38 . Jaw members  47 ,  49  may be provided with vacuum ports (not shown in  FIG. 6 ; well known to those skilled in the art of elongate workpiece handling equipment) to substantially fix layer  18  against jaw member  47  and substantially fix layer  19  against jaw member  49 . When ready to separate layers  18 ,  19  jaw members  47 ,  49  may hingedly swing apart to separate and thereby effect separation of layers  18 ,  19 . Separation of layers  18 ,  19  may present interlayer zone  60  between layers  18 ,  19 . 
         [0032]      FIG. 7  is a schematic illustration of an embodiment of the apparatus effecting an advancing of a portion of a workpiece toward an interlayer zone to carry out a splicing operation. In  FIG. 7 , cutting unit  42  may have cleared working path  38 , workpiece redirecting unit  44  may have been reoriented to permit passage of trailing segment  12   2  of workpiece  12  along working path  38  past or through workpiece redirecting unit  44  and drive unit  14  may have advanced trailing segment  12   2  forward (i.e., to the right in  FIG. 7 ) to extend a portion of trailing segment  12   2  into interlayer zone  60 . Heater element  48  may begin to heat trailing segment  12   2 . Some tape material layers  18  may contain uncured resin material, such as by way of example and not by way of limitation when tape material layer  18  may be configured as a graphite tape material. Such uncured resin material may be affected when subjected to heat to increase stickiness of tape material layer  18 . Heating element  48  may be advantageously employed in aiding inter-layer adhesion for splicing of workpiece  12  when such heat-susceptible tape material  18  is included in workpiece  12 . 
         [0033]      FIG. 8  is a schematic illustration of an embodiment of the apparatus effecting an establishing of a multi-layer structure to carry out a splicing operation. In  FIG. 8 , layer manipulating unit  46  may be closed to generally capture a portion of trailing segment  122  of workpiece  12  between layers  18 ,  19  of leading portion  12   1  of workpiece  12  to establish a multi-layer structure in a spliced portion  62  in now-spliced workpiece  12 . 
         [0034]      FIG. 9  is an enlarged schematic illustration showing details of a multi-layer structure. In  FIG. 9 , jaw members  47 ,  49  of layer manipulating unit  46  may be closed to establish a multi-layer structure in a spliced portion  62 . The multi-layer structure may include layers  18   2 ,  19   2 , of trailing segment  12   2  of workpiece  12  in captive relation between layers  18   1 ,  19   1  of leading segment  12   1  of workpiece  12 . 
         [0035]      FIG. 10  is a schematic illustration of an embodiment of the apparatus effecting an orientation of a workpiece to accommodate application of adhesive to a multi-layer structure to carry out a splicing operation. In  FIG. 10 , layer manipulating unit  46  may have been opened to permit workpiece  12  to pass through or past layer manipulating unit  46 . Workpiece deflecting unit  50  may cooperate with adhering unit  52  to situate workpiece  12  in an applying position for adhering unit  12  applying adhesive to workpiece  12  in an area generally situated about splice portion  62 . At least one of drive units  14 ,  16  may have advanced workpiece  12  to situate splice portion  62  generally in the applying position for adhering unit  52 . 
         [0036]      FIG. 11  is a schematic illustration of an embodiment of the apparatus effecting an application of adhesive to a multi-layer structure in a workpiece to carry out a splicing operation. In  FIG. 11 , adhering unit  52  applies an adhesive in the vicinity of splice portion  62 . Adhesive applied by adhering unit  52  may be brushed on, spot-dabbed on or otherwise applied. In  FIG. 11 , adhesive may be applied using a length of adhesive tape  64  having sufficient length to overlay splice portion  62  and being substantially in register with workpiece  12 . Application of adhesive tape  64  may be effected as workpiece  12  is driven past adhering unit  52  by one of both of drive units  14 ,  16 . 
         [0037]      FIG. 12  is an enlarged schematic illustration showing details of application of adhesive to a multi-layer structure. In  FIG. 12 , guide structure  30  and workpiece deflecting unit  50  may cooperate with adhering unit  52  to situate workpiece  12  generally adjacent to adhering unit  52 . Adhering unit  52  may include adhesive tape  64  stored on a supply reel  70  or similar supply mechanism, an anvil  72  or similar bearing surface and a cutting structure  74  or knife. Workpiece  12  may be routed between workpiece deflecting unit  50  and adhesive tape  64 . Adhesive tape  64  may be oriented between workpiece  12  and anvil  72 . With such an orientation among workpiece deflecting unit  50 , workpiece  12 , adhesive tape  64  and anvil  72  pressure may be exerted by workpiece deflecting unit  50  against anvil  72  to urge adhesive tape  64  against workpiece  12 . Such an arrangement may effect application of adhesive tape  64  to workpiece  12  in the vicinity of splice portion  62  as at least one of drive units  14 ,  16  drives workpiece  12  along working path  38 . Once adhesive tape  64  is applied along a sufficient length of workpiece  12  spanning splice portion  62 , cutting structure  74  may be reoriented to a cutting position (indicated in phantom as a cutting unit  74   1  in  FIG. 12 ) for severing adhesive tape  64  without severing workpiece  12 . Alternately, cutting structure  74  may be fixed within adhering unit  52 , and adhering unit  52  may be reoriented in its entirety (e.g., to the left in  FIG. 12 ; not shown in  FIG. 12 ) to situate cutting structure  74  for severing adhesive tape  64  without severing workpiece  12 . If adhesive is embodied in a form other than adhesive tape  64 , application of adhesive to splice portion  62  may be effected in an expanse of workpiece  12  short of spanning splice portion  62 . 
         [0038]      FIG. 13  is a schematic illustration of an embodiment of the apparatus effecting a testing of a splice in a workpiece. In  FIG. 13 , after adhesive tape  64  (or another adhesive material) is applied to splice portion  62  of workpiece  12  may be subjected to tension to test splice portion  62 . By way of example and not by way of limitation, a tension force may be applied to workpiece  12  by grippingly engaging trailing segment  12   2  of workpiece  12  using one or both of drive units  14 ,  16  and operating a take-up reel  80  to collect leading segment  12   1  of workpiece  12 . A tension force may thereby be applied between, for example, drive unit  16  and take-up reel  80  to effect tension-testing of splice portion  62 . 
         [0039]    Splicing apparatus  10  may include a control unit  82  for generally coordinating operation of various components of apparatus  10  in proper sequence to effect the steps described above on connection with  FIGS. 1-13 . Control unit  82  may be coupled with various components of apparatus  10  in wired connection, in wireless connection or in combination of wired and wireless connection. Connection loci  84   1  included in  FIG. 13  may indicate connection among various components of apparatus  10  and control unit  82 . The indicator “n” is employed to signify that there can be any number of connection loci in splicing apparatus  10 . The inclusion of eleven connection loci  84   1 - 84   11  (described below) in  FIG. 13  is illustrative only and does not constitute any limitation regarding the number of connection loci that may be included in an embodiment of the splicing apparatus of the present invention. A connection locus  84   1  may indicate a wireless or wired connection with control unit  82 . A connection locus  842  may indicate a wireless or wired connection between defect detector unit  40  and control unit  82 . A connection locus  843  may indicate a wireless or wired connection between drive unit  14  and control unit  82 . A connection locus  84   4  may indicate a wireless or wired connection between cutting unit  42  and control unit  82 . A connection locus  84   5  may indicate a wireless or wired connection between workpiece redirecting unit  44  and control unit  82 . A connection locus  84   6  may indicate a wireless or wired connection between layer manipulating unit  46  and control unit  82 . A connection locus  84   7  may indicate a wireless or wired connection between heater element  48  and control unit  82 . A connection locus  848  may indicate a wireless or wired connection between workpiece deflecting unit  50  and control unit  82 . A connection locus  849  may indicate a wireless or wired connection between adhering unit  52  and control unit  82 . A connection locus  84   10  may indicate a wireless or wired connection between drive unit  16  and control unit  82 . A connection locus  84   11  may indicate a wireless or wired connection between take-up reel  80  and control unit  82 . 
         [0040]      FIG. 14  is a flow chart illustrating an embodiment of the method of the invention. In  FIG. 14 , a method  100  for splicing an elongate workpiece begins at a START locus  102 . The workpiece may include a plurality of materials substantially abuttingly oriented in a plurality of layers. 
         [0041]    Method  100  may continue by severing the workpiece to present a first segment of the workpiece and a second segment of the workpiece, as indicated by a block  108 . Prior to severing the workpiece, a flaw or splice may be detected that may be removed from the workpiece before continuing with method  100 . Method  100  may continue by separating a portion of one segment of the first segment and the second segment to present an interlayer zone in the one segment, as indicated by a block  110 . 
         [0042]    Method  100  may continue by inserting an other segment of said first segment and said second segment than said one segment in the interlayer zone, as indicated by a block  112 . Method  100  may continue by urging the selected layers together to generally capture the other segment within the interlayer zone to effect said splicing in a multi-layer structure, as indicated by a block  114 . Method  100  may continue by situating the multi-layer structure adjacent to the adhering unit, as indicated by a block  116 . Method  100  may continue by strengthening the splicing by applying the adhesive to the multi-layer structure, as indicated by a block  118 . 
         [0043]    Method  100  may continue by testing the splice established in the workpiece such as, by way of example and not by way of limitation, applying a tensioning force to the multi-layer structure, as indicated by a block  120 . Method  100  may terminate at an end locus  122 . 
         [0044]      FIG. 15  is a functional chart illustrating an embodiment of the apparatus of the invention. In  FIG. 15 , an apparatus  210  configured for splicing of an elongate workpiece including a plurality of materials substantially abuttingly oriented in a plurality of layers may include a control unit, indicated by a block  214 . A plurality of drive units, indicated by a block  216 , may be coupled with control unit  214  and arranged for driving the workpiece along a working path. The workpiece and workpath are not shown in  FIG. 15 ; see  FIGS. 1-13 . 
         [0045]    A plurality of guide structures, indicated by a block  216 , may be arranged for cooperating with the plurality of drive units  214  for guiding the workpiece along the working path. The arrangement for cooperating is indicated by a dotted line in  FIG. 15 ; guide structures  216  may or may not be coupled with drive units  214 . 
         [0046]    A cutting unit, indicated by a block  218 , may be coupled with control unit  212  for selectively severing the workpiece. A layer manipulating unit, indicated by a block  220 , may be coupled with control unit  212  for moving selected layers of the plurality of layers. An adhering unit, indicated by a block  222 , may be coupled with control unit  212  for applying an adhesive to at least one portion of the workpiece. A workpiece deflecting unit, indicated by a block  224 , may be coupled with control unit  212  for selectively deflecting the workpiece from the working path. 
         [0047]    Cutting unit  218  may cooperate with control unit  212  for effecting the severing to present a first segment of the workpiece and a second segment of the workpiece. Layer manipulating unit  220  may cooperate with control unit  212  after the severing for effecting an inter-layer separation in a portion of one segment of the first segment and the second segment to present an interlayer zone in the one segment. 
         [0048]    At least one drive means of the plurality of drive means  214  may cooperate with control unit  212  after the separation for inserting the other segment in the interlayer zone. Layer manipulating unit  220  may cooperate with control unit  212  after the inserting for urging the selected layers together to generally capture the other segment within the interlayer zone to establish a multi-layer structure. Plurality of drive units  214  and at least one of workpiece deflecting unit  224  and adhering unit  222  may cooperate with control unit  212  after the urging to situate the multi-layer structure adjacent to adhering unit  222 . Adhering unit  222  may cooperate with control unit  212  after the situating for finishing the splicing by applying adhesive to the multi-layer structure. 
         [0049]    It is to be understood that, while the detailed drawings and specific examples given describe embodiments of the invention, they are for the purpose of illustration only, that the apparatus and method of the invention are not limited to the precise details and conditions disclosed and that various changes may be made therein without departing from the spirit of the invention which is defined by the following claims: