Patent Description:
The manufacturing of a composite part typically involves the lamination of multiple plies of fiber-reinforced polymer matrix material. Each layer is comprised of reinforcing fibers that are pre-impregnated with resin (e.g., prepreg). The fibers in each ply of a composite part are typically oriented at a different fiber angle than the fiber angle of adjacent plies, as a means to optimize the strength and stiffness properties of the composite part, and to improve the quality of the cured composite part. For example, a composite part may include <NUM>-degree plies, and cross-directional plies which typically comprise -<NUM>-degree plies, +<NUM>-degree plies, and <NUM>-degree plies.

Unidirectional prepreg is a type of prepreg in which the fibers are oriented parallel to the lengthwise direction of the material (i.e., a <NUM>-degree fiber angle). Unidirectional prepreg tape is available in continuous lengths, and is supported on a backing layer and is wound on a roll for use in automated layup equipment. Rolls of unidirectional prepreg tape are available in different widths. For example, unidirectional prepreg tape is typically available in widths of up to <NUM>,<NUM> (<NUM> inches) or more for use in an automated tape laying (ATL) machine.

ATL machines are very efficient in laying up long courses of unidirectional prepreg tape to form <NUM>-degree plies of a composite part. However, the use of unidirectional prepreg tape in an ATL machine to lay up short courses (e.g., less than <NUM>,<NUM> (<NUM> feet)) of cross-directional plies of a long composite part requires that the ATL machine traverses the part numerous times as each cross-directional ply is laid up. The numerous stops and starts required of the ATL machine for laying up each cross-directional ply significantly increases the total amount of time required to complete the layup process. In addition, the ATL machine requires excessive turn-around space at the end of each cross-directional ply.

The document <CIT> states, in accordance with its abstract, that a prepreg sheet manufacturing apparatus is provided with: a gap detection device that detects a gap between a preceding first prepreg cut sheet and a following first prepreg cut sheet on a prepreg web; a welding device that welds a rear end edge of the preceding first prepreg cut sheet and a front end edge of the following first prepreg cut sheet by way of the prepreg web; and a pressing device that presses the preceding first prepreg cut sheet in a planar manner on the downstream side of the welding device.

The document <CIT> states, in accordance with its abstract, that, for automatically manufacturing prepreg, the direction of fiber orientation of which is set arbitrarily, by a method wherein drawn prepreg is cut off at the predetermined angle to the direction of fiber orientation and turned so as to arranging its direction of fiber orientation with the predetermined direction and, after that, successively and abuttingly arranged and, finally pasted with adhesive tape. In a cutting device, which cuts off the prepreg delivered from base stock, the cutting angle to the longitudinal direction or direction of fiber orientation of the prepreg can be properly set. In addition, a turning device is provided beyond a carrying path on the downstream side of the cutting device. A carrying path acts so as to re-arrange a prepreg piece, the direction of which is turned with the turning device, so as to abut against the preceding prepreg piece in order to make the gap between the pieces to the minimum. A pasting device pastes adhesive tape to the under surface of the abutting part of the preceding prepreg piece against the following prepreg piece. A second feeding device feeds the prepreg piece towards a take-up by the distance, by which the rear end of the prepreg piece is brought to the position corresponding to the pasting position of the pasting device.

The document <CIT> states, in accordance with its abstract, a method for producing a two-ply or multi-ply web-like semi-finished material with at least one unidirectionally fiber-reinforced layer comprising steps (A) to (I). It also relates to a system for carrying out the method.

As can be seen, there exists a need in the art for a system and method for manufacturing continuous lengths of cross-directional prepreg material on a backing layer for use in an ATL machine, to thereby avoid the need for laying up numerous short courses traversing a composite part. Ideally, the system is capable of manufacturing multi-layer cross-ply prepreg material, such as dual-layer cross-ply prepreg (or triple-layer cross-ply prepreg, or quadruple-layer cross-ply prepreg, etc.), to further reduce the amount of time required for laying up the cross-directional plies of a composite part.

According to the present disclosure, a manufacturing system, and a method of manufacturing a backed cross-ply prepreg as defined in the independent claims are provided. Further embodiments of the claimed invention are defined in the dependent claims. Although the claimed invention is only defined by the claims, the below embodiments, examples, and aspects are present for aiding in understanding the background and advantages of the claimed invention.

The above-noted needs associated with cross-ply prepreg material are address by the present disclosure, which provides a manufacturing system for manufacturing a backed cross-ply prepreg. The manufacturing system includes a cutting machine, an adhesion machine, and a pick-and-place system. The cutting machine includes a cutting station configured to cut a continuous length of a unidirectional prepreg into prepreg segments. Each prepreg segment has an opposing pair of segment cut edges that are non-parallel to a lengthwise direction of the unidirectional prepreg. The adhesion machine has a conveyor belt and an adhesion station. The pick-and-place system is configured to pick up the prepreg segments from the cutting machine, and place the prepreg segments in end-to-end relation on the conveyor belt, and in an orientation such that the segment cut edges are generally parallel to a lengthwise direction of the conveyor belt. The conveyor belt is configured to feed the prepreg segments to the adhesion station. The adhesion station is configured to adhere the prepreg segments to a continuous length of a backing material, thereby transferring the prepreg segments from the conveyor belt to the backing material, and resulting in a continuous length of a backed cross-ply prepreg.

Also disclosed is a method of manufacturing a backed cross-ply prepreg. The method includes cutting, using a cutting station of a cutting machine, a first continuous length of a unidirectional prepreg into first prepreg segments. As mentioned above, each prepreg segment has an opposing pair of segment cut edges that are non-parallel to a lengthwise direction of the unidirectional prepreg. The method also includes picking up, using a pick-and-place system, the first prepreg segments off of the cutting machine, and placing the first prepreg segments in end-to-end relation onto a conveyor belt of an adhesion machine, and in an orientation such that the segment cut edges are generally parallel to a lengthwise direction of the conveyor belt. In addition, the method includes feeding, using the conveyor belt, the first prepreg segments to an adhesion station of the adhesion machine, and adhering, using the adhesion station, the first prepreg segments to a continuous length of a backing material.

Additionally disclosed is a further method of manufacturing a backed cross-ply prepreg, comprising cutting, using a cutting machine, a first continuous length of a unidirectional prepreg into first prepreg segments. In addition, the method includes picking up, using a pick-and-place system, the first prepreg segments off of the cutting machine, and placing the first prepreg segments in end-to-end relation onto a conveyor belt of an adhesion machine, and in an orientation such that the segment cut edges are generally parallel to a lengthwise direction of the conveyor belt. Furthermore, the method includes feeding, using the conveyor belt, the first prepreg segments to an adhesion station of the adhesion machine. The method also includes adhering, using the adhesion station, the first prepreg segments to a continuous length of a backing layer, to thereby form a continuous length of an intermediate backed cross-ply prepreg. Additionally, the method includes adhering, using the adhesion station, either a second continuous length of a unidirectional prepreg or an end-to-end series of second prepreg segments to the first prepreg segments of the intermediate backed cross-ply prepreg, thereby resulting in a final backed cross-ply prepreg.

The features, functions and advantages that have been discussed can be achieved independently in various examples of the present disclosure or may be combined in yet other examples, further details of which can be seen with reference to the following description and drawings below.

These and other features of the present disclosure will become more apparent upon reference to the drawings wherein like numbers refer to like parts throughout and wherein:.

Referring now to the drawings which illustrate preferred and various examples of the disclosure, shown in <FIG> is an example of a manufacturing system <NUM> for automated manufacturing of a continuous length of a backed cross-ply prepreg <NUM>. The backed cross-ply prepreg <NUM> comprises at least one layer of end-to-end prepreg segments <NUM> supported on a backing layer <NUM>. The manufacturing system <NUM> includes a cutting machine <NUM>, an adhesion machine <NUM>, and a pick-and-place system <NUM>. The cutting machine <NUM> is configured to support a roll of the continuous length of the unidirectional prepreg <NUM>. The unidirectional prepreg <NUM> (e.g., unidirectional prepreg tape) contains continuous reinforcing fibers <NUM> (<FIG> and <FIG>) that are oriented at a fiber angle of <NUM>-degrees relative to the lengthwise direction of the unidirectional prepreg <NUM>. The reinforcing fibers <NUM> are pre-impregnated with resin. The reinforcing fibers <NUM> may be formed of any one of a variety of materials such as plastic, glass, ceramic, carbon, metal, or any combination thereof. The resin may be a thermosetting resin or a thermoplastic resin, and may be formed of any one of a variety of organic or inorganic materials. The unidirectional prepreg <NUM> is supported on a backing layer <NUM>. The backing layer <NUM> may be a paper material and/or the backing layer <NUM> may be a polymeric film.

The cutting machine <NUM> is configured to peel the backing layer <NUM> from the continuous length of unidirectional prepreg <NUM>, and feed the peeled unidirectional prepreg <NUM> to a cutting station <NUM> where the unidirectional prepreg <NUM> is sequentially cut into prepreg segments <NUM>. Each prepreg segment <NUM> has an opposing pair of segment side edges <NUM> (<FIG>), and an opposing pair of segment cut edges <NUM> (<FIG>). The cutting station <NUM> cuts the unidirectional prepreg <NUM> such that the segment cut edges <NUM> are non-parallel to the lengthwise direction of the unidirectional prepreg <NUM>. For example, as described below, the cutting station <NUM> is capable of cutting the unidirectional prepreg <NUM> at an orientation of -<NUM> degrees, +<NUM> degrees, <NUM> degrees, or any one of a variety of other angles, relative to the lengthwise direction of the unidirectional prepreg <NUM>.

The adhesion machine <NUM> has a conveyor belt <NUM> and an adhesion station <NUM>, and is configured to support a roll of a continuous length of a backing material <NUM>. As described below, the backing material <NUM> may comprise a backing layer <NUM> similar to the above-mentioned backing layer <NUM> that the cutting machine <NUM> peels off of the unidirectional prepreg <NUM> prior to cutting into prepreg segments <NUM>. Alternatively, the backing material <NUM> may comprise a roll of backed cross-ply prepreg <NUM>, which may have been previously manufactured by the presently-disclosed manufacturing system <NUM>, as described below. Even further, the backing material <NUM> may comprise a continuous length (e.g., a roll) of unidirectional prepreg <NUM>.

The pick-and-place system <NUM> is configured to sequentially pick up the prepreg segments <NUM> from the cutting machine <NUM>, and place the prepreg segments <NUM> in end-to-end relation on the moving conveyor belt <NUM>. The pick-and-place system <NUM> places the prepreg segments <NUM> on the conveyor belt <NUM> in an orientation such that the segment cut edges <NUM> of the prepreg segments <NUM> are aligned with each other, and are generally parallel to a lengthwise direction of the conveyor belt <NUM>. Once the prepreg segments <NUM> are placed on the conveyor belt <NUM>, the segment cut edges <NUM> become the sides of the backed cross-ply prepreg <NUM> that is produced by the manufacturing system <NUM>. The pick-and-place system <NUM> preferably places the prepreg segments <NUM> in non-overlapping relation to each other, and at a maximum gap of <NUM>,<NUM> (<NUM> inch) between adjacent prepreg segments <NUM>, although the manufacturing system <NUM> can be adjusted to accommodate any overlap requirements or gap requirements between the end-to-end prepreg segments <NUM>. In addition, the pick-and-place system <NUM> preferably orients the prepreg segments <NUM> such that the fiber angles of the prepreg segments <NUM> are parallel to each other.

The conveyor belt <NUM> is configured to feed the series of prepreg segments <NUM> to the adhesion station <NUM>. In one example, the conveyor belt <NUM> is moved at a constant speed, and the backing material <NUM> is moved over the conveyor belt <NUM> in synchronization with the conveyor belt <NUM> and/or at the same speed as the conveyor belt <NUM>. The adhesion station <NUM> is configured to adhere the prepreg segments <NUM> to the continuous length of the backing material <NUM>, thereby transferring the prepreg segments <NUM> from the conveyor belt <NUM> to the backing material <NUM>, and resulting in the continuous length of the backed cross-ply prepreg <NUM> which is wound onto a drum, as described below. In the present disclosure, a backed cross-ply prepreg <NUM> contains a backing layer <NUM>, and at least one layer of an end-to-end series of prepreg segments <NUM> of which the reinforcing fibers <NUM> are oriented non-parallel to the lengthwise direction of the backed cross-ply prepreg <NUM>. As shown in <FIG> and described below, the manufacturing system <NUM> has the capability to manufacture a single-layer backed cross-ply prepreg <NUM> (i.e., a single layer of end-to-end prepreg segments <NUM> defining cross-directional prepreg material on a backing layer <NUM>). In addition, as shown in <FIG> and described below, the manufacturing system <NUM> has the capability to manufacture a dual-layer backed cross-ply prepreg <NUM> in which at least one of the layers of prepreg material comprises cross-directional prepreg material. Although not shown in the figures, the manufacturing system <NUM> also has the capability to manufacture a backed cross-ply prepreg <NUM> having more than two layers of prepreg material on a backing layer <NUM>. For example, the manufacturing system <NUM> also has the capability to manufacture a backed cross-ply prepreg <NUM> containing three or more layers of prepreg material on a backing layer <NUM>.

As shown in <FIG>, the cutting machine <NUM> is supported on a cutting machine framework <NUM>. The adhesion machine <NUM> is located proximate the cutting machine <NUM>, and is supported on an adhesion machine framework <NUM>. The pick-and-place system <NUM> is located proximate the downstream end of the cutting machine <NUM>, and proximate the upstream end of the adhesion machine <NUM>. In the example shown, the pick-and-place system <NUM> is a robotic device <NUM>, as described in greater detail below. However, in other examples not shown, the pick-and-place system <NUM> may be configured as a gantry system configured to pick up the prepreg segments <NUM> from the cutting machine <NUM>, reorient the prepreg segments <NUM>, and place the prepreg segments <NUM> onto the conveyor belt <NUM>. Although not shown, the manufacturing system <NUM> is coupled to and/or includes a variety of utility lines interconnecting the various components, and enabling operation of the manufacturing system <NUM>. Such utility lines may include pneumatic lines, vacuum lines, compressed air lines, data and communication lines, and power lines, all of which have been omitted, for clarity of the figures.

In the example of <FIG>, the cutting machine <NUM> is positioned in alignment with the adhesion machine <NUM>, such that the direction of movement of the unidirectional prepreg <NUM> through the cutting machine <NUM> is aligned with the direction of movement of the conveyor belt <NUM>. As described below, aligning the cutting machine <NUM> with the adhesion machine <NUM> allows for the ability to produce a continuous length of backed cross-ply prepreg <NUM> having a first layer of prepreg comprising a series of prepreg segments <NUM> on a backing layer <NUM>, and a second layer of prepreg comprising a continuous length (i.e., uncut) of unidirectional prepreg <NUM> (i.e., <NUM>-degree fiber angle) on top of the first layer of prepreg segments <NUM>. In this regard, the robotic device <NUM> is positioned to the side of the manufacturing system <NUM> to avoid interfering with the unidirectional prepreg <NUM> (i.e., uncut) passing from the cutting machine <NUM> to the adhesion machine <NUM>.

However, in other examples not shown, the manufacturing machine may be configured such that the cutting machine <NUM> and the adhesion machine <NUM> are non-aligned with each other. For example, the cutting machine <NUM> and the adhesion machine <NUM> may be positioned side by side, and may be oriented such that the downstream end of the cutting machine <NUM> is located immediately adjacent to the upstream end of the adhesion machine <NUM>, to allow the pick-and-place system <NUM> (e.g., a robotic device <NUM>) to easily transfer the prepreg segments <NUM> from the cutting machine <NUM> to the conveyor belt <NUM>. However, in such a side-by-side arrangement, a continuous length of unidirectional prepreg <NUM> (i.e., uncut) is incapable of passing from the cutting machine <NUM> to the adhesion machine <NUM>.

Referring to <FIG>, shown is an example of the cutting machine <NUM>, which includes a backed unidirectional prepreg chuck <NUM> configured to support a backed unidirectional prepreg drum <NUM>. The backed unidirectional prepreg drum <NUM> is configured to support a roll of the continuous length of unidirectional prepreg <NUM>, which itself is supported on a backing layer <NUM> as mentioned above. In addition, the cutting machine <NUM> includes a backing layer collection chuck <NUM> configured to support a backing layer collection drum <NUM>. The backing layer collection drum <NUM> is configured to collect the backing layer <NUM> as the backing layer <NUM> is peeled off of the unidirectional prepreg <NUM> as the unidirectional prepreg <NUM> is fed through the cutting machine <NUM>. The backed unidirectional prepreg chuck <NUM> and the backing layer collection chuck <NUM> are each rotatably driven by a chuck servomotor <NUM> (<FIG>). Each chuck includes pneumatic clamps mounted on separate legs of the chuck. When a drum is mounted on a chuck, compressed air is provided to the pneumatic clamps to urge the pneumatic clamps against the inner wall of the drum, thereby securing the drum to the chuck. Removal of the drum from the chuck is effected by decoupling the compressed air source from the pneumatic clamps.

The cutting machine <NUM> includes a plurality of rollers (e.g., idler rollers <NUM>, dancer roller <NUM>, etc.) for supporting the unidirectional prepreg <NUM>, and to facilitate directional changes of the unidirectional prepreg <NUM> through the cutting machine <NUM>. In some examples of the manufacturing system <NUM>, the rollers may each include circumferential alignment ridges (not shown) protruding from the cylindrical outer surface of the rollers. A pair of the circumferential alignment ridges are located respectively on opposing ends of each roller. The circumferential alignment ridges are spaced apart at a width that is equivalent to the width of the unidirectional prepreg <NUM>, and are configured to maintain the alignment of the unidirectional prepreg <NUM> as the unidirectional prepreg <NUM> moves through the cutting machine <NUM>. The adhesion machine <NUM> may also include rollers (e.g., idler rollers <NUM>) that have circumferential alignment ridges. On the adhesion machine <NUM>, the circumferential alignment ridges are spaced apart by a distance equivalent to the width of the backing material <NUM>, and provide a means for maintaining the backing material <NUM> in alignment with the prepreg segments <NUM> on the conveyor belt <NUM> during adhesion.

Referring to <FIG>, the cutting machine <NUM> includes a nip roller assembly <NUM> configured to draw the unidirectional prepreg <NUM> through the cutting machine <NUM>, and feed a predetermined length of the unidirectional prepreg <NUM> into the cutting station <NUM>. In the example shown, the nip roller assembly <NUM> has opposing nip rollers <NUM> which are positioned relative to each other to define a roller interface <NUM> between the nip rollers <NUM>. In the example shown, the nip rollers <NUM> include an upper nip roller <NUM> and a lower nip roller <NUM>.

The nip roller assembly <NUM> further includes a nip roller servomotor <NUM> having a rotary encoder (not shown). The nip roller servomotor <NUM> is configured to rotatably drive the lower nip roller <NUM>. In the example shown, the lower nip roller <NUM> is a rigid cylinder (e.g., solid aluminum) having a textured outer surface (e.g., sandblasted) configured to frictionally engage the backing layer <NUM> that supports the unidirectional prepreg <NUM>. The upper nip roller <NUM> is freely rotatable, and is formed of a softer, elastomeric material for bearing against the unidirectional prepreg <NUM> without damaging the material. For example, the upper nip roller <NUM> may be comprised of ethylene-propylene-diene-monomer (EPDM) rubber or other elastomeric material.

The nip roller assembly <NUM> includes a nip roller actuator <NUM>, which may comprise a pneumatically-driven linear actuator. The nip roller actuator <NUM> extends between an actuator mounting bracket <NUM> and a nip roller support fitting <NUM> (<FIG>). The nip roller actuator <NUM> is configured to move the upper nip roller <NUM> toward and away from the lower nip roller <NUM>, between a closed position and an open position. In the open position, the unidirectional prepreg <NUM> may be threaded into the roller interface <NUM>, after which the nip roller actuator <NUM> moves the upper nip roller <NUM> downwardly into the closed position, thereby clamping onto the unidirectional prepreg <NUM>. When prompted by the controller <NUM> (<FIG>) of the manufacturing system <NUM>, the nip roller servomotor <NUM> is activated to rotate the lower nip roller <NUM>, causing a predetermined length of the unidirectional prepreg <NUM> to be fed into the cutting station <NUM> for cutting into a prepreg segment <NUM>. The rotary encoder of the nip roller servomotor <NUM> provides a means for metering the predetermined length that is extended from the nip roller assembly <NUM> into the cutting station <NUM>.

Referring to <FIG>, the cutting machine <NUM> further includes a pneumatic dancer assembly <NUM> located between the backed unidirectional prepreg drum <NUM> and the nip roller assembly <NUM>. The pneumatic dancer assembly <NUM> is configured to apply a substantially constant tension load on the unidirectional prepreg <NUM> as the nip roller assembly <NUM> draws the unidirectional prepreg <NUM> off of the backed unidirectional prepreg drum <NUM>. In this regard, the pneumatic dancer assembly <NUM> maintains a limited amount of tension (e.g., approximately <NUM>,<NUM> N (<NUM> pounds) of force) on the unidirectional prepreg <NUM>, and avoids exceeding the tension limit, to avoid stretching damage to the unidirectional prepreg <NUM>. In addition, the tension in the unidirectional prepreg <NUM> enables the nip roller assembly <NUM> to dispense a precise length of the unidirectional prepreg <NUM> into the cutting station <NUM>.

As shown in <FIG>, the pneumatic dancer assembly <NUM> includes a pair of idler rollers <NUM> and a dancer roller <NUM>. The dancer roller <NUM> and the idler rollers <NUM> are located in a manner that provides obtuse wraparound angles for the unidirectional prepreg <NUM> moving through the pneumatic dancer assembly <NUM>, and which allows for accurately controlling the tension load on the unidirectional prepreg <NUM> and preventing fraying and other damage to the unidirectional prepreg <NUM>. The pneumatic dancer assembly <NUM> includes a dancer arm <NUM>, and a dancer mounting stand <NUM> to support the dancer arm <NUM>. The dancer arm <NUM> is pivotally coupled to the dancer mounting stand <NUM>, and has a roller mounting portion <NUM>, and an actuator mounting portion <NUM>. The roller mounting portion <NUM> supports the dancer roller <NUM>. A dancer actuator <NUM> extends between the actuator mounting portion <NUM> and the actuator mounting bracket <NUM>. In the example shown, the dancer actuator <NUM> is a linear actuator, such as a low-stiction air cylinder. The pneumatic dancer assembly <NUM> includes a rotational encoder (not shown) that outputs the position of the dancer arm <NUM> to a control loop (not shown), to thereby provide feedback to the dancer actuator <NUM> for maintaining substantially constant tension in the unidirectional prepreg <NUM>.

Referring to <FIG>, shown is an alternative arrangement of the cutting machine <NUM> in which the backing layer collection drum <NUM> is located proximate the cutting station <NUM>. In contrast to the arrangement of <FIG> in which the backing layer collection drum <NUM> is located immediately adjacent to the backed unidirectional prepreg drum <NUM>, the backing layer collection drum <NUM> in <FIG> is located downstream of the nip roller assembly <NUM> and upstream of the cutting station <NUM>, and is configured to peel the backing layer <NUM> from the unidirectional prepreg <NUM> as the unidirectional prepreg <NUM> exits the nip roller assembly <NUM> prior to entering the cutting station <NUM>. By peeling the backing layer <NUM> off of the unidirectional prepreg <NUM> after exiting the nip roller assembly <NUM> as shown in <FIG>, the unidirectional prepreg <NUM> remains fully supported on the backing layer <NUM> from the point where the unidirectional prepreg <NUM> spools off of the backed unidirectional prepreg drum <NUM>, to the point where the unidirectional prepreg <NUM> passes through the nip roller assembly <NUM> prior to entering the cutting station <NUM>. By supporting the unidirectional prepreg <NUM> on the backing layer <NUM> just prior to entering the cutting station <NUM>, the stability and accuracy of the handling of the unidirectional prepreg <NUM> is improved, relative to the arrangement of <FIG> where the backing layer collection drum <NUM> is located immediately adjacent to the backed unidirectional prepreg drum <NUM>. In <FIG>, the backing layer collection drum <NUM> is supported above the cutting station <NUM> via a chuck support structure <NUM>. An idler roller <NUM> (<FIG>) is included for redirecting the backing layer <NUM> from the nip roller assembly <NUM> to the backing layer collection drum <NUM>. As mentioned above, the backing layer collection drum <NUM> is rotatably driven by a chuck servomotor <NUM>, as shown in <FIG>.

Referring to <FIG>, shown is an example of the cutting station <NUM> for cutting the continuous length of the unidirectional prepreg <NUM> into prepreg segments <NUM>. In the example shown, the cutting station <NUM> is configured to cut the unidirectional prepreg <NUM> into prepreg segments <NUM> (<FIG>) that have segment cut edges <NUM> (<FIG>) oriented at -<NUM> degrees, +<NUM> degrees, or <NUM> degrees, relative to the lengthwise direction of the unidirectional prepreg <NUM>. Toward this end, the cutting station <NUM> includes a cutting assembly <NUM> supported on a cutting assembly frame <NUM>. The cutting assembly <NUM> includes a cutting device <NUM>, and a turntable <NUM> (<FIG>) configured to support the cutting assembly <NUM>. The turntable <NUM> is configured to lock the orientation of the cutting device <NUM> relative to the lengthwise direction of the unidirectional prepreg <NUM>. In the example shown, the cutting device <NUM> is suspended below the turntable <NUM>. The turntable <NUM> has detents <NUM> for locking the orientation of the cutting device <NUM> at <NUM> degrees (<FIG>), +<NUM> degrees (<FIG>), or -<NUM> degrees (<FIG>). However, the turntable <NUM> may include detents <NUM> at any one of a variety of other angular orientations relative to the lengthwise direction of the director prepreg, as may be dictated by the desired fiber angle of the backed cross-ply prepreg <NUM> to be manufactured by the manufacturing system <NUM>.

In <FIG>, the cutting device <NUM> is shown as a cutting wheel. However in other examples, the cutting device <NUM> may be configured as an ultrasonic device, a cutting blade, or other cutting device configuration that provides a high degree of accuracy and repeatability in cutting the unidirectional prepreg <NUM>. The cutting device <NUM> is coupled to a cutting device carriage <NUM>. The cutting assembly <NUM> includes a cutting device actuator <NUM> for driving the cutting device <NUM> across the width of the unidirectional prepreg <NUM> for cutting into the prepreg segments <NUM>. In the example shown, the cutting device actuator <NUM> is a linear actuator configured as a pneumatic air slide (e.g., a pneumatically-driven actuator). However, the cutting device actuator <NUM> may be configured as a screw drive mechanism, or other actuator arrangement.

Referring to <FIG>, the cutting station <NUM> includes a cutting surface <NUM> for supporting the unidirectional prepreg <NUM> during cutting. The cutting surface <NUM> may be porous or may have a plurality of pores, and is fluidically coupled to a vacuum source such as a compressed air-powered vacuum generator, or a shop vacuum source or pump. The application of vacuum pressure to the cutting surface <NUM> provides for vacuum coupling of the unidirectional prepreg <NUM> to the cutting surface <NUM>, and prevents movement of the unidirectional prepreg <NUM> during cutting by the cutting device <NUM>, which allows for precise cutting and a reduction in the risk of damage to the prepreg segments <NUM>.

In the example shown in <FIG>, the cutting surface <NUM> has an upper plate <NUM> and a lower plate <NUM>. The lower plate <NUM> includes a chamber, and a recess configured to receive the upper plate <NUM>. The upper plate <NUM> and the lower plate <NUM> are formed of a rigid material (e.g., metallic material, such as aluminum), and each contain grooves <NUM> respectively aligned with the cutting orientations of the cutting device <NUM> as defined by the detents <NUM> associated with the turntable <NUM>. The grooves <NUM> are configured to receive a sacrificial cutting material <NUM> against which the cutting device <NUM> bears when cutting the unidirectional prepreg <NUM>. Examples of the sacrificial cutting material <NUM> include, but are not limited to, a non-porous material such as rubber (e.g., EPDM), or a porous material such as Vyon™ that is capable of vacuum coupling to the unidirectional prepreg <NUM>.

The cutting surface <NUM> is optionally configured to be fluidically coupled to a pressurized air source (e.g., a compressed air source) for discharging air out of the pores or porous surface, as a means for forcing the prepreg segment <NUM> away from the cutting surface <NUM>. Forcing the prepreg segment <NUM> away from the cutting surface <NUM> prevents stiction to the cutting service, and thereby promotes sliding translation of the prepreg segment <NUM> off of the cutting surface <NUM>.

Referring to <FIG>, the cutting machine <NUM> includes the above-mentioned segment pickup location <NUM> where each prepreg segment <NUM> is accessible for pickup by the pick-and-place system <NUM>. Toward this end, the cutting machine <NUM> includes a segment delivery system <NUM> configured to transport each prepreg segment <NUM> from the cutting surface <NUM> to the segment pickup location <NUM>. At the segment pickup location <NUM>, the prepreg segment <NUM> is in an openly accessible location that provides clearance for the pick-and-place system <NUM> to pick up the prepreg segment <NUM>. The segment delivery system <NUM> is located immediately downstream of the cutting surface <NUM>.

In <FIG>, the segment delivery system <NUM> includes a segment clamping system <NUM> comprising a pair of prepreg clamps <NUM> configured to clamp onto the side edges of a downstream portion of the unidirectional prepreg <NUM> prior cutting by the cutting device <NUM> to produce a prepreg segment <NUM>. Each prepreg clamp <NUM> has a prepreg clamp actuator <NUM> for vertically moving the prepreg clamp <NUM> between a clamped position (<FIG>) and an unclamped position (<FIG>). The prepreg delivery system includes a delivery system support table <NUM> located adjacent to the cutting surface <NUM>, and a delivery system vacuum table <NUM> located downstream of the delivery system support table <NUM>. The delivery system support table <NUM> is configured to support the unidirectional prepreg <NUM> prior to and after cutting into a prepreg segment <NUM>. The delivery system vacuum table <NUM> is configured to be fluidically coupled to a vacuum source for vacuum coupling each prepreg segment <NUM> to the segment pickup location <NUM> after being transported by the segment delivery system <NUM>.

Each one of the prepreg clamps <NUM> is supported on a linear guide rail <NUM>. In addition, the segment clamping system <NUM> includes a clamp transporter actuator <NUM>, such as a linear actuator (e.g., a pneumatically-driven actuator). The clamp transporter actuator <NUM> is coupled to the prepreg clamps <NUM> via a transporter base plate <NUM> that is located underneath the delivery system support table <NUM> and delivery system vacuum table <NUM>. The transporter base plate <NUM> extends between and interconnects the lower portions of the pair of prepreg clamps <NUM>. Prior to vacuum coupling the unidirectional prepreg <NUM> to the cutting surface <NUM>, the clamp transporter actuator <NUM> is configured to apply a small amount of tension (e.g., less than <NUM>,<NUM> N (<NUM> pounds) of force) to the unidirectional prepreg <NUM> as a means to remove any slack. The tension load applied to the unidirectional prepreg <NUM> by the clamp transporter actuator <NUM> is resisted by the nip roller assembly <NUM>. Once tension load is applied to the unidirectional prepreg <NUM>, vacuum pressure is activated at the cutting surface <NUM>, after which the clamp transporter actuator <NUM> is disabled to thereby stop the application of tension to the unidirectional prepreg <NUM>. The cutting device <NUM> is then driven across the unidirectional prepreg <NUM>, resulting in a prepreg segment <NUM>.

After cutting the unidirectional prepreg <NUM>, the prepreg clamps <NUM> remain clamped to the prepreg segment <NUM>. The vacuum pressure is deactivated at the cutting surface <NUM>, and the clamp transporter actuator <NUM> moves the segment clamps along the linear guide rails <NUM> to thereby transport each prepreg segment <NUM> from the cutting station <NUM> to the segment pickup location <NUM> (<FIG>), which may occupy at least a portion of the delivery system vacuum table <NUM>. Upon arrival at the segment pickup location <NUM>, vacuum pressure is activated at the delivery system vacuum table <NUM> to secure the prepreg segment <NUM> in position, and the prepreg clamps <NUM> are moved upwardly into the unclamped position. The clamp transporter actuator <NUM> returns the prepreg clamps <NUM> back to the delivery system support table <NUM> (<FIG>) in preparation for clamping onto another downstream portion of the unidirectional prepreg <NUM>, when fed into the cutting station <NUM> by the nip roller assembly <NUM>.

Referring to <FIG> and <FIG>, shown is an example of the pick-and-place system <NUM> configured as a robotic device <NUM>. However, in another example not shown, the pick-in-place system may comprise an overhead gantry. As shown in <FIG>, the robotic device <NUM> has a robotic arm <NUM> configured to sequentially pick up the prepreg segments <NUM> at the segment pickup location <NUM> (<FIG>), and place the prepreg segments <NUM> on the conveyor belt <NUM> in end-to-end relation to each other, and in an orientation such that the segment cut edges <NUM> of the prepreg segments <NUM> are aligned with each other, and are parallel to a lengthwise direction of the conveyor belt <NUM>.

As shown in <FIG>, the robotic arm <NUM> includes a vacuum end effector <NUM> configured for vacuum coupling to the prepreg segments <NUM>. The vacuum end effector <NUM> includes a vacuum plenum <NUM> (<FIG>) having a porous surface, such as a Vyon sheet having a plurality of small pores (e.g., a pore size of <NUM>-<NUM> microns). The vacuum plenum <NUM> is divided into two or more (e.g., three) vacuum zones <NUM> (<FIG>) that are shaped complementary to the shape of the prepreg segments <NUM>, as cut by the cutting station <NUM>. The vacuum plenum <NUM> includes a rigid plenum frame <NUM> to support the vacuum plenum <NUM>. As shown in <FIG>, the plenum frame <NUM> is configured to be attached to the robotic arm <NUM> via a plenum adapter fitting <NUM>. Each one of the vacuum zones <NUM> (<FIG>) of the vacuum plenum <NUM> is fluidically coupled to a vacuum source such as a compressed air-powered vacuum generator, or to central shop vacuum. The vacuum zones <NUM> are independently activatable with vacuum pressure to allow the vacuum end effector <NUM> to engage with different shapes of the prepreg segment <NUM>.

In the example vacuum end effector <NUM> of <FIG>, the vacuum plenum <NUM> includes vacuum zone A, vacuum zone B, and vacuum zone C, and which are shaped and configured specific to a situation where the width of the unidirectional prepreg <NUM> (i.e., the input material) is equivalent to the width of the backed cross-ply prepreg <NUM> (i.e., the output material). For example, the width of the unidirectional prepreg <NUM> may be <NUM>,<NUM> (<NUM> inches), and the width of the backed cross-ply prepreg <NUM> may also be <NUM>,<NUM> (<NUM> inches). However, for examples where the width of the unidirectional prepreg <NUM> (e.g., <NUM>,<NUM> (<NUM> inches)) is different than the width of the backed cross-ply prepreg <NUM> (e.g., <NUM>,<NUM> (<NUM> inches)), the vacuum zones would be shaped differently than the vacuum zones shown in <FIG>.

<FIG> illustrates a -<NUM>-degree prepreg segment <NUM>, and the activation of vacuum zones A and B for vacuum coupling the vacuum end effector <NUM> to the <NUM>-degree prepreg segment <NUM>. <FIG> illustrates a -<NUM>-degree prepreg segment <NUM>, and the activation of vacuum zones B and C for vacuum coupling the vacuum end effector <NUM> to the -<NUM>-degree prepreg segment <NUM>. <FIG> illustrates a +<NUM>-degree prepreg segment <NUM>, and the reorientation of the vacuum end effector <NUM> for vacuum coupling of the vacuum end effector <NUM> to the +<NUM>-degree prepreg segment <NUM>.

<FIG> shows a -<NUM>-degree prepreg segment <NUM> at the segment pickup location <NUM> of the cutting machine <NUM>. <FIG> shows the robotic arm <NUM> positioning the vacuum end effector <NUM> over the -<NUM>-degree prepreg segment <NUM> for vacuum engagement. <FIG> shows the robotic arm <NUM> re-orienting the -<NUM>-degree prepreg segment <NUM>, and placing the -<NUM>-degree prepreg segment <NUM> on the conveyor belt <NUM> such that the segment cut edges <NUM> are parallel to the lengthwise direction of the conveyor belt <NUM>. <FIG> shows the -<NUM>-degree prepreg segment <NUM> on the conveyor belt <NUM> after release from the vacuum end effector <NUM>.

In the example of the manufacturing system <NUM>, the conveyor belt <NUM> is configured to move at a constant speed, and the pick-and-place system <NUM> (e.g., the robotic arm <NUM>) is configured to match the speed of the conveyor belt <NUM> when placing a prepreg segment <NUM> on the conveyor belt <NUM>. In this regard, the speed at which the manufacturing system <NUM> produces backed cross-ply prepreg <NUM> is dictated by the speed of the conveyor belt <NUM>, which may be independently driven and controlled using a manufacturer-provided drive and controller.

In the example shown, the conveyor belt <NUM> is a vacuum conveyor belt configured to be fluidically coupled to a vacuum source (not shown) for non-movably securing the prepreg segments <NUM> to the vacuum conveyor belt upon placement by the pick-and-place system <NUM>. In this regard, the target for placement of the first prepreg segment <NUM> on the conveyor belt <NUM> may be nominally set to a global x,y coordinate location on the conveyor belt <NUM>. Once the first prepreg segment <NUM> is placed on the conveyor belt <NUM>, the conveyor belt <NUM> begins motion, and the pick-and-place system <NUM> continuously places prepreg segments <NUM> in end-to-end relation on the moving conveyor belt <NUM>. The conveyor belt <NUM> may include a rotary encoder mounted to a conveyor belt shaft (not shown) for determining when the prepreg segments <NUM> has moved an appropriate distance to allow placement of the next prepreg segment <NUM>. The robotic device <NUM> may be programmed to follow the conveyor belt <NUM> for a short distance in order to match the speed of the conveyor belt <NUM>. Once the speed is matched, the end effector places the prepreg segment <NUM> on the conveyor belt <NUM>, and vacuum pressure is disengaged from the vacuum end effector <NUM>, thereby transferring the prepreg segment <NUM> to the conveyor belt <NUM>.

Although not shown, the manufacturing system <NUM> may further include a vision system for increasing the accuracy of pickup and placement of the prepreg segments <NUM>. The vision system may include an imaging device (e.g., a camera) configured to image each prepreg segment <NUM> at the segment pickup location <NUM>, and transmit to the controller <NUM>, the actual location (e.g., in x,y coordinates) and orientation (e.g., in angular degrees) relative to the nominal location and nominal orientation of the prepreg segment <NUM> at the segment pickup location <NUM>. The controller <NUM> is configured to control the robotic device <NUM> in a manner to compensate for the difference between the actual location/orientation and the nominal location/orientation, to better align the end effector to the prepreg segment <NUM> at the segment pickup location <NUM>. In this same regard, the vision system may facilitate increased accuracy of the pick-and-place system <NUM> in placing each prepreg segment <NUM> on the conveyor belt <NUM>. The vision system may be mounted at any one of a variety of locations on the manufacturing system <NUM>. For example, the vision system may be mounted on the robotic arm <NUM>, on the end effector, on the cutting machine <NUM> at a location above and/or below the segment pickup location <NUM>, and/or on the adhesion machine <NUM> above the location where the prepreg segments <NUM> are placed on the conveyor belt <NUM>.

Referring now to <FIG>, shown is an example of the adhesion machine <NUM>. As mentioned above, the adhesion machine <NUM> is configured to sequentially adhere the prepreg segments <NUM> to the backing material <NUM> in a manner transferring the prepreg segments <NUM> from the conveyor belt <NUM> to the backing material <NUM>. In this regard, the adhesion force between the prepreg segments <NUM> in the backing material <NUM> is greater than the vacuum force coupling the prepreg segments <NUM> to the conveyor belt <NUM>, resulting in each prepreg segment <NUM> gradually adhering to the backing material <NUM> while gradually releasing from vacuum engagement with the conveyor belt <NUM>, and thereby resulting in the continuous length of backed cross-ply prepreg <NUM>. The adhesion machine <NUM> is configured to wind the backed cross-ply material onto a cross-ply material collection drum <NUM> at a specified tension, as described in greater detail below.

Referring to <FIG> and <FIG>, the adhesion machine <NUM> includes a backing material chuck <NUM> configured to support a backing material drum <NUM>. The backing material drum <NUM> supports a roll of the backing material <NUM>. The backing material <NUM> is spooled off of the backing material drum <NUM>, and is fed through the adhesion machine <NUM> at the same speed as the conveyor belt <NUM>. The adhesion machine <NUM> further includes a cross-ply material collection chuck <NUM> configured to support a cross-ply material collection drum <NUM>. The cross-ply material collection drum <NUM> is configured to collect the backed cross-ply prepreg <NUM> resulting from the adhesion of the prepreg segments <NUM> to the backing material <NUM>. The backing material chuck <NUM> and the cross-ply material collection chuck <NUM> each have a chuck servomotor <NUM> (<FIG>) for rotatably driving the backing material chuck <NUM> and the cross-ply material collection chuck <NUM>.

Referring to <FIG>, the adhesion machine <NUM> may include at least one idler roller <NUM> for redirecting the backing material <NUM> as it is spooled off of the backing material drum <NUM>. Although not shown, the idler roller <NUM> may include a pair of circumferential alignment ridges spaced apart by a distance equivalent to the width of the backing material <NUM>. As mentioned above with regard to the rollers of the cutting machine <NUM>, the circumferential alignment ridges on the idler roller <NUM> of the adhesion machine <NUM> provide a means for maintaining the alignment of the backing material <NUM> with the prepreg segments <NUM> on the conveyor belt <NUM>, thereby preventing the prepreg segments <NUM> from overhanging the edges of the backing material <NUM>.

Referring to <FIG>, the manufacturing system <NUM> includes at least one compaction stage <NUM> configured to compact the backing material <NUM> against the prepreg segments <NUM> for transferring the prepreg segments <NUM> to the backing material <NUM>. For example, <FIG> shows an initial compaction stage <NUM> and a secondary compaction stage <NUM>, each of which is configured to apply compaction pressure to the prepreg segments <NUM> against the backing material <NUM>. In <FIG>, several of the structural supports (e.g., see <FIG>) on one side of the initial compaction stage <NUM> and the secondary compaction stage <NUM> have been removed to better illustrate the components of the compaction stages <NUM>, <NUM>.

In <FIG>, the initial compaction stage <NUM> is located upstream of a downstream end of the conveyor belt <NUM>. The initial compaction stage <NUM> has an initial compaction roller <NUM> configured to apply an initial compaction pressure to the backing material <NUM> against the prepreg segments <NUM> on the conveyor belt <NUM>. The initial compaction stage <NUM> includes a pair of compaction actuators <NUM> (e.g., linear pneumatic actuators) located respectively on opposing ends of the initial compaction roller <NUM>, for vertically applying compaction pressure of the initial compaction roller <NUM> against the prepreg segments <NUM> supported on the conveyor belt <NUM>.

Referring to <FIG>, the secondary compaction stage <NUM> is located downstream of the downstream end of the conveyor belt <NUM>. The secondary compaction stage <NUM> has an upper compaction roller <NUM> and a lower compaction roller <NUM> vertically positioned relative to each other to define a roller interface <NUM>. The vertical positioning of the upper compaction roller <NUM> relative to the lower compaction roller <NUM> negates the possibility of a horizontal force that may induce a horizontal component that would otherwise cause slipping at the interface between the prepreg segments <NUM> and the backing material <NUM>.

The secondary compaction stage <NUM> includes a pair of compaction actuator <NUM> (e.g., linear pneumatic actuators) located respectively on opposing ends of the upper compaction roller <NUM>, for vertically moving the upper compaction roller <NUM> toward and away from the lower compaction roller <NUM> for adjusting the size of the gap at the roller interface <NUM>. The roller interface <NUM> receives the backed cross-ply prepreg <NUM> from the initial compaction stage <NUM>, and applies a secondary compaction pressure of the prepreg segments <NUM> against the backing material <NUM> in a manner that increases the adhesion of the prepreg segments <NUM> to the backing material <NUM>. The initial compaction roller <NUM> of the initial compaction stage <NUM>, and the upper and lower compaction rollers <NUM>, <NUM> of the secondary compaction stage <NUM> may have an outer surface formed of elastomeric material such as rubber (e.g., EPDM) to accommodate the potential nonuniform application of compaction force, and may thereby avoid damaging the prepreg segments <NUM> during compaction against the backing material <NUM>.

Advantageously, the initial compaction stage <NUM> and the secondary compaction stage <NUM> provide two separate locations where the prepreg segments <NUM> are compacted against the backing material <NUM>. In this regard, the two separate compaction stages <NUM> double the dwell time during which the prepreg segments <NUM> and backing material <NUM> are under compaction, thereby reducing the need for excessive compaction at any one of the compaction stages, and correspondingly reducing the potential for damage to the prepreg material. Furthermore, locating the secondary compaction stage <NUM> downstream of the conveyor belt <NUM> addresses the potential for the prepreg segments <NUM> to lose adhesion from the backing material <NUM> after the prepreg segments <NUM> release from the vacuum of the conveyor belt <NUM>. In this regard, the secondary compaction stage <NUM> ensures that the prepreg segments <NUM> remain adhered to the backing material <NUM> as the backed cross-ply prepreg <NUM> is wound onto the cross-ply material collection drum <NUM>. In addition, two separate compacting stages <NUM> provide a means for varying the compaction pressure applied at the initial compaction stage <NUM> and the secondary compaction stage <NUM>. In this regard, the magnitude of the initial compaction force applied by the initial compaction roller <NUM> may be limited as a result of deflection of the structure of the conveyor belt <NUM>. In such case, the secondary compaction stage <NUM> may apply an increased amount of compaction pressure to compensate for reduced compaction pressure at the initial compaction stage <NUM>.

In <FIG>, the lower compaction roller <NUM> is rotatably driven by a compaction roller servomotor <NUM> (<FIG>) for pulling the backing material <NUM> through the adhesion station <NUM>. The compaction roller servomotor <NUM> sets the speed at which the backing material <NUM> is drawn through the adhesion machine <NUM>, which is equivalent to the speed of the conveyor belt <NUM>, to thereby negate the potential for slippage at the interface between the prepreg segments <NUM> and the backing material <NUM>, which may otherwise compromise the quality of the backed cross-ply prepreg <NUM>. Although not shown, the backing material chuck <NUM> may include a brake that is configured to halt rotation of the backing material drum <NUM> if the secondary compaction stage <NUM> ceases to pull the backing material <NUM> through the adhesion station <NUM>.

Referring to <FIG>, the adhesion machine <NUM> further include one or more heating devices <NUM> configured to heat the backing material <NUM> and/or the prepreg segments <NUM>, as a means for increasing the adhesion of the prepreg segments <NUM> to the backing material <NUM>. In the example shown, the adhesion machine <NUM> includes one or more heating devices <NUM> supported on a heating device support frame <NUM>. The heating devices <NUM> are located above the conveyor belt <NUM> and upstream of the adhesion station <NUM>. The heating devices <NUM> are configured to heat the prepreg segments <NUM> as a means to increase the tack of the resin in the prepreg segments <NUM> and/or slightly reduce the resin viscosity, all of which facilitates adhesion to the backing material <NUM>.

In one example, the heating devices <NUM> are infrared emitters <NUM> configured as infrared heater bulbs. The infrared emitters <NUM> are located at a spaced distance away from the prepreg segments <NUM> and the backing material <NUM>, to thereby avoid contamination that would otherwise occur using heating devices that require direct contact with the prepreg segments <NUM> or the backing material <NUM>. Advantageously, infrared emitters <NUM> allow for precise control of the heat applied to the prepreg segments <NUM> and backing material <NUM> to avoid damage to the prepreg segments <NUM> or the backing material <NUM>. Furthermore, infrared heaters allow for focusing heat accurately on the surfaces toward which they are aimed, thereby avoiding the heating of nearby components that may result in adverse effects, such as excessive resin buildup on indirectly heated components. In the example shown, the adhesion machine <NUM> includes a first ceramic infrared heater facing downwardly toward the prepreg segments <NUM> on the conveyor belt <NUM>, and a second ceramic infrared heater facing horizontally toward the backing material <NUM> prior to contact with the prepreg segments <NUM> on the conveyor belt <NUM>.

Referring to <FIG> and <FIG>, the adhesion machine <NUM> includes at least one tension-measuring device <NUM> configured to measure tension load in the backing material <NUM> and/or in the backed cross-ply prepreg <NUM>. In the example shown, the tension-measuring devices <NUM> each comprise a cantilevered load cell <NUM> which has a cylindrical surface configured to measure tension load based on a side force applied to the cylindrical surface. For example, as shown in <FIG>, the adhesion machine <NUM> includes a load cell <NUM> between the idler roller <NUM> and the first compaction roller for measuring tension in the backing material <NUM>, after spooling off of the backing material drum <NUM> and prior to making contact with the prepreg segments <NUM>. <FIG>, <FIG>, and <FIG> show a load cell <NUM> between the secondary compaction stage <NUM> and the cross-ply material collection drum <NUM> for measuring tension in the backed cross-ply prepreg <NUM> prior to winding onto the cross-ply material collection drum <NUM>.

Each load cell <NUM> is configured to transmit tension measurements to a controller <NUM>, which uses the tension measurements to control the torque load of the drums, as a means for maintaining tension load in the backing material <NUM> and in the backed cross-ply prepreg <NUM> within predetermined ranges. For example, the controller <NUM> uses the tension measurements from the load cell <NUM> between the idler roller <NUM> and the first compaction roller, to control the chuck servomotor <NUM> of the backing material chuck <NUM> to adjust the torque load on the backing material drum <NUM> in a manner maintaining the tension load on the backing material <NUM> within a predetermined load range. The controller <NUM> uses the tension measurements from the load cell <NUM> between the secondary compaction stage <NUM> and the backed cross-ply material collection drum <NUM> to control the chuck servomotor <NUM> of the cross-ply material collection chuck <NUM> to adjust the torque load on the cross-ply material collection drum <NUM> in a manner maintaining the tension load on the backed cross-ply prepreg <NUM> within a predetermined load range (e.g., <NUM>,<NUM>-<NUM>,<NUM> N (<NUM>-<NUM> pounds) of force).

Referring to <FIG>, shown is a flowchart of operations included in a method <NUM> of manufacturing a roll of a continuous length of a backed cross-ply prepreg <NUM>. The method <NUM> includes supporting a first continuous length of unidirectional prepreg <NUM> (e.g., unidirectional prepreg tape) on a backed unidirectional prepreg drum <NUM>. As mentioned above, the first continuous length of unidirectional prepreg <NUM> is backed by a backing layer <NUM> such as a backing paper or a polymeric film. The method includes separating the backing layer <NUM> from the first continuous length of unidirectional prepreg <NUM> while feeding the unidirectional prepreg <NUM> into the cutting station <NUM>. In addition, the method includes collecting, on the backing layer collection drum <NUM>, the backing layer <NUM> as the backing layer <NUM> is peeled off of the first continuous length of unidirectional prepreg <NUM>.

The method <NUM> further comprises receiving the unidirectional prepreg <NUM> within a roller interface <NUM> of opposing nip rollers <NUM> of a nip roller assembly <NUM>, and feeding, using the nip rollers <NUM>, a lengthwise section of the unidirectional prepreg <NUM> into the cutting station <NUM> of the cutting machine <NUM>. As mentioned above, the nip roller assembly <NUM> has an upper nip roller <NUM> and a lower nip roller <NUM> defining the roller interface <NUM>. The upper nip roller <NUM> is movable, via a nip roller actuator <NUM>, to adjust the gap of the roller interface <NUM> for receiving and clamping onto the unidirectional prepreg <NUM>. The nip roller servomotor <NUM> rotatably drives the lower nip roller <NUM>, causing the predetermined length of the unidirectional prepreg <NUM> to be fed into the cutting station <NUM> for cutting into a prepreg segment <NUM>. The method <NUM> further comprises applying a substantially constant tension load on the unidirectional prepreg <NUM> as the nip roller assembly <NUM> feeds the unidirectional prepreg <NUM> into the cutting station <NUM>. The substantially constant tension load in the unidirectional prepreg <NUM> is controlled by the pneumatic dancer assembly <NUM>, which is located between the backed unidirectional prepreg drum <NUM> and the nip roller assembly <NUM>.

As shown in <FIG> and described above, the backing layer collection drum <NUM> may optionally be located proximate the cutting station <NUM>, in contrast to the arrangement shown in <FIG> in which the backing layer collection drum <NUM> is located immediately adjacent to the backed unidirectional prepreg drum <NUM>. In <FIG>, the step of separating the backing layer <NUM> from the first continuous length of unidirectional prepreg <NUM> comprises, separating the backing layer <NUM> from the unidirectional prepreg <NUM> as the unidirectional prepreg <NUM> exits the nip roller assembly <NUM> prior to entering the cutting station <NUM>. The backing layer <NUM> is collected on the backing layer collection drum <NUM>, which is located downstream of the nip roller assembly <NUM> and upstream of the cutting station <NUM>. As mentioned above, the arrangement shown in <FIG> improves the stability and accuracy with which the unidirectional prepreg <NUM> is controlled while passing through the cutting machine <NUM>.

Step <NUM> of the method <NUM> includes cutting, using the cutting station <NUM>, the first continuous length of the unidirectional prepreg <NUM> into first prepreg segments <NUM>. Each one of the first prepreg segments <NUM> has an opposing pair of segment cut edges <NUM> that are non-parallel to the lengthwise direction of the unidirectional prepreg <NUM>. Step <NUM> of cutting the unidirectional prepreg <NUM> comprises cutting the unidirectional prepreg <NUM> such that the segment cut edges <NUM> are oriented at +<NUM> degrees, -<NUM> degrees, <NUM> degrees, or other angles, relative to the lengthwise direction of the unidirectional prepreg <NUM>. Toward this end, step <NUM> of cutting the unidirectional prepreg <NUM> comprises locking, via a turntable <NUM> of the cutting station <NUM>, the orientation of the cutting device <NUM> (e.g., a cutting wheel, an ultrasonic device) relative to the lengthwise direction of the unidirectional prepreg <NUM>. As described above, the turntable <NUM> has detents <NUM> for locking the orientation of the cutting device <NUM>. Step <NUM> further includes translating the cutting device <NUM> across a width of the unidirectional prepreg <NUM> to cut the unidirectional prepreg <NUM> into the prepreg segments <NUM>. In the example shown, the cutting assembly <NUM> includes a cutting device actuator <NUM> configured as a pneumatic air slide for translating the cutting device <NUM> across the width of the unidirectional prepreg <NUM>.

Step <NUM> of cutting the first continuous length of unidirectional prepreg <NUM> additionally comprises securing, via vacuum pressure, the unidirectional prepreg <NUM> to the cutting surface <NUM> of the cutting station <NUM>. As described above, the cutting surface <NUM> is porous or has a plurality of pores that are fluidically coupled to a vacuum source. Each time the nip roller assembly <NUM> extends a predetermined length of unidirectional prepreg <NUM> into the cutting station <NUM>, the vacuum source is activated to vacuum couple the prepreg to the cutting surface <NUM> for securing the unidirectional prepreg <NUM> in position during cutting by the cutting device <NUM>.

The method includes using the prepreg clamps <NUM> to clamp onto opposing sides of the unidirectional prepreg <NUM>, and apply tension to the unidirectional prepreg <NUM> via the clamp transporter actuator <NUM> (e.g., a linear pneumatic actuator) of the segment delivery system <NUM>. Once tension is applied, vacuum pressure is then applied to the cutting surface <NUM> to secure the unidirectional prepreg <NUM> to the cutting surface <NUM>, after which the clamp transporter actuator <NUM> is deactivated to halt the application of tension on the unidirectional prepreg <NUM>. The cutting device <NUM> is then driven across the unidirectional prepreg <NUM> to result in a prepreg segment <NUM>. After cutting the unidirectional prepreg <NUM>, the prepreg clamps <NUM> remain clamped onto the prepreg segment <NUM>, and vacuum pressure is deactivated at the cutting surface <NUM> to allow the prepreg segment <NUM> to be translated off of the cutting surface <NUM>. In some examples, the cutting surface <NUM> may discharge compressed air from the pores or porous surface of the cutting surface <NUM>, to urge the prepreg segment <NUM> away from the cutting surface <NUM>, and promote the sliding translation of the prepreg segment <NUM> off of the cutting surface <NUM>.

The method <NUM> further comprises transporting, using the segment delivery system <NUM>, each prepreg segment <NUM> from the cutting surface <NUM> to the segment pickup location <NUM> for pickup by the pick-and-place system <NUM>. As described above, the segment delivery system <NUM> is located immediately downstream of the cutting surface <NUM>. Transporting each prepreg segment <NUM> comprises moving, via the clamp transporter actuator <NUM>, the prepreg clamps <NUM> along a pair of linear guide rails <NUM>, to thereby transport each prepreg segment <NUM> to the segment pickup location <NUM>. Upon arrival at the segment pickup location <NUM>, vacuum pressure is applied to the delivery system vacuum table <NUM> to secure the prepreg segment <NUM> in position at the segment pickup location <NUM>, and the prepreg clamps <NUM> are then moved to the unclamped position. The clamp transporter actuator <NUM> then translates the prepreg clamps <NUM> back to the delivery system support table <NUM> in preparation for clamping another downstream portion of unidirectional prepreg <NUM> that is fed into the cutting station <NUM> by the nip roller assembly <NUM>.

Step <NUM> of the method <NUM> includes sequentially picking up, using the pick-and-place system <NUM>, the first prepreg segments <NUM> at the segment pickup location <NUM>, and placing the first prepreg segments <NUM> in end-to-end relation onto the conveyor belt <NUM>, and in an orientation such that the segment cut edges <NUM> are generally parallel to a lengthwise direction of the conveyor belt <NUM>. In the example shown in the figures, step <NUM> of picking up the first prepreg segments <NUM> comprises picking up each prepreg segment <NUM> using a robotic arm <NUM> of a robotic device <NUM>. However, in other examples not shown, the prepreg segments <NUM> may be picked up by an overhead gantry system, or other mechanisms capable of transferring the prepreg segments <NUM> from the cutting machine <NUM> to the adhesion machine <NUM>.

In the example shown, step <NUM> of picking up the first prepreg segments <NUM> comprises vacuum coupling, using a vacuum plenum <NUM>, each prepreg segment <NUM> to the robotic arm <NUM>. As described above, the vacuum plenum <NUM> has a porous surface coupled to a vacuum source. Vacuum coupling of each prepreg segment <NUM> to the robotic arm <NUM> comprises positioning the vacuum plenum <NUM> over the prepreg segment <NUM> at the segment pickup location <NUM>, and applying vacuum pressure to one or more vacuum zones <NUM>, based on the shape of the prepreg segment <NUM>. In the above-described example of <FIG>, the vacuum plenum <NUM> includes vacuum zones A, B, and C. As described above, each one of the vacuum zones <NUM> is independently fluidically coupled to a vacuum source, to enable independently providing vacuum pressure to any combination of vacuum zones <NUM> to enable vacuum engagement to different shapes of the prepreg segment <NUM>.

To facilitate alignment of the vacuum end effector <NUM> with the prepreg segment <NUM> prior to pickup, the method <NUM> may include imaging, using a vision system (e.g., a camera - not shown), each prepreg segment <NUM> at the segment pickup location <NUM>, and indexing the robotic arm <NUM> to the prepreg segment <NUM> based on the imaging, as described above. As an alternative to mounting on the robotic arm <NUM>, the vision system may be mounted to the cutting machine <NUM> at a location above and/or below the segment pickup location <NUM>. Additionally, a vision system (e.g., a camera) may be mounted to the adhesion machine <NUM> above the location where the prepreg segments <NUM> are placed on the conveyor belt <NUM>.

Step <NUM> of the method <NUM> includes feeding, using the conveyor belt <NUM>, the first prepreg segments <NUM> to the adhesion station <NUM> of the adhesion machine <NUM>. As mentioned above, step <NUM> of feeding the first prepreg segments <NUM> to the adhesion station <NUM> comprises moving the conveyor belt <NUM> at a constant speed, and matching the speed of the pick-and-place system <NUM> (e.g., the vacuum end effector <NUM>) to the speed of the conveyor belt <NUM> when placing a prepreg segment <NUM> on the conveyor belt <NUM>. To prevent movement of the prepreg segments <NUM> once placed on the conveyor belt <NUM>, step <NUM> of feeding the first prepreg segments <NUM> to the adhesion station <NUM> comprises vacuum coupling the first prepreg segments <NUM> to a vacuum conveyor belt.

Step <NUM> of the method <NUM> includes sequentially adhering, using the adhesion station <NUM>, the first prepreg segments <NUM> to a continuous length of a backing material <NUM>. Vacuum coupling of the first prepreg segments <NUM> to the conveyor belt <NUM> may prevent movement of the first prepreg segments <NUM> when being adhered to the backing material <NUM>. Step <NUM> of adhering the first prepreg segments <NUM> includes spooling the backing material <NUM> off of the backing material drum <NUM>, and feeding the backing material <NUM> over the conveyor belt <NUM>. As the backing material <NUM> is spooled off of the backing material drum <NUM> and the prepreg segments <NUM> are adhered to the backing material <NUM>, the method includes collecting the resulting backed cross-ply prepreg <NUM> onto the cross-ply material collection drum <NUM>. As described above, the backing material drum <NUM>, and the cross-ply material collection drum <NUM> are each rotatably driven by a chuck servomotor <NUM>.

Step <NUM> of adhering the first prepreg segments <NUM> to the backing material <NUM> comprises compacting, using at least one compaction stage <NUM>, the backing material <NUM> against the prepreg segments <NUM> in such a manner causing the prepreg segments <NUM> to adhere to the backing material <NUM>, and resulting in a continuous length of backed cross-ply prepreg <NUM>. In the example shown, compacting the backing material <NUM> against the prepreg segments <NUM> comprises applying an initial compaction pressure to the backing material <NUM> against the prepreg segments <NUM> supported on the conveyor belt <NUM>. The initial compaction pressure is applied using an initial compaction roller <NUM> at an initial compaction stage <NUM> located upstream of the downstream end of the conveyor belt <NUM>. Following the application of the initial compaction pressure, the method additionally includes applying a secondary compaction pressure of the backing material <NUM> and the prepreg segments <NUM> against each other. The secondary compaction pressure is applied on the backed cross-ply prepreg <NUM> which his sandwiched between an upper compaction roller <NUM> and a lower compaction roller <NUM> at a secondary compaction stage <NUM> located downstream of the downstream end of the conveyor belt <NUM>, as described above.

The method <NUM> further includes rotatably driving the upper compaction roller <NUM> and/or the lower compaction roller <NUM> to pull the backing material <NUM> through the adhesion station <NUM>. As a safety precaution, method <NUM> may comprise halting, using a brake of the backing material chuck <NUM>, rotation of the backing material drum <NUM> if the secondary compaction stage <NUM> ceases to pull the backing material <NUM> through the adhesion station <NUM>. In the example shown, the lower compaction roller <NUM> is rotatably driven by a compaction roller servomotor <NUM> configured to pull the backing material <NUM> through the adhesion station <NUM> at the same speed as the conveyor belt <NUM>. By applying compaction pressure at two separate compaction stages, the total amount of dwell time during which the prepreg segments <NUM> and backing material <NUM> are under compaction is doubled, relative to configurations (not shown) where a single compaction stage is relied upon to compact the prepreg segments <NUM> against the backing material <NUM>.

To facilitate adhesion of the prepreg segments <NUM> to the backing material <NUM>, the method <NUM> further comprises heating, using at least one heating device <NUM>, the backing material <NUM> and/or the prepreg segments <NUM> prior to compaction. Heating the backing material <NUM> is performed using one or more heating devices <NUM> located above the conveyor belt <NUM>. In one example, heating the backing material <NUM> may include heating the backing material <NUM> using one or more infrared emitters <NUM>. For example, a first ceramic infrared heater may face downwardly toward the prepreg segments <NUM> on the conveyor belt <NUM>. A second ceramic infrared heater may face horizontally toward the backing material <NUM> prior to contact with the prepreg segments <NUM> on the conveyor belt <NUM>.

The method <NUM> further comprises measuring, using at least one tension-measuring device <NUM>, tension load in the backing material <NUM> and/or tension load in the backed cross-ply prepreg <NUM>. For example, tension load in the backing material <NUM> may be measured using a load cell <NUM> having a cylindrical outer surface configured to bear against the backing material <NUM> as it spools off of the backing material drum <NUM> prior to contacting the prepreg segments <NUM>. Tension load in the backed cross-ply prepreg <NUM> may be measured using a similar load cell <NUM> located between the secondary compaction stage <NUM> and the cross-ply material collection drum <NUM>. Advantageously, the tension-measuring devices <NUM> allow the controller <NUM> to control the chuck servomotors <NUM> to adjust the amount of torque load on the backing material drum <NUM> and the cross-ply material collection drum <NUM>, as a means to maintain the tension load within predetermined limits.

Referring to <FIG>, shown are schematic illustrations of the processes for manufacturing different orientation combinations of the backed cross-ply prepreg <NUM>. <FIG> represent the processes for manufacturing <NUM> different orientations of a backed cross-ply prepreg <NUM> that has a single layer of prepreg material supported on a backing layer <NUM> (i.e., a single layer of cross-directional prepreg material on a backing layer126). <FIG> represent the processes for manufacturing <NUM> different orientations of a backed cross-ply prepreg <NUM> that has two layers of prepreg material supported on a backing layer <NUM>, and in which at least one of the layers of prepreg material comprises a cross-directional prepreg material (i.e., the reinforcing fibers are non-parallel to the lengthwise direction of the backed cross-ply prepreg <NUM>).

In <FIG>, each of the <NUM> processes involves the above-described steps <NUM>, <NUM>, and <NUM>. Step <NUM> of the process comprises adhering the first prepreg segments <NUM> to a continuous length of a backing layer <NUM> that is devoid of prepreg material. <FIG> shows prepreg segments <NUM> being cut from the first continuous length of unidirectional prepreg <NUM> via the cutting machine <NUM>, re-oriented via the pick-and-place system <NUM>, and placed on the adhesion machine <NUM> as <NUM>-degree prepreg segments <NUM>, after which compaction pressure is applied by one or more compaction stages <NUM> for adhering the <NUM>-degree prepreg segments <NUM> to the backing layer <NUM>, and resulting in a <NUM>-degree backed prepreg <NUM>. <FIG> shows -<NUM>-degree prepreg segments <NUM> being cut from a first continuous length of unidirectional prepreg <NUM>, re-oriented and placed on the adhesion machine <NUM>, and then adhered via the compaction stages to a backing layer <NUM>, and resulting in a -<NUM>-degree backed prepreg <NUM>. <FIG> shows +<NUM>-degree prepreg segments <NUM> being cut from a first continuous length of unidirectional prepreg <NUM>, re-oriented and placed on the adhesion machine <NUM>, and then adhered via the compaction stages to a backing layer <NUM>, and resulting in a +<NUM>-degree backed prepreg <NUM>.

Referring to <FIG>, each of the <NUM> respectively represented processes involves the above-described steps <NUM>, <NUM>, and <NUM>. <FIG> represent processes in which step <NUM> comprises adhering, using the adhesion station <NUM>, the first prepreg segments <NUM> to a continuous length of a prepreg-backing assembly <NUM>, which comprises prepreg material backed by a backing layer <NUM>. <FIG> shows prepreg segments <NUM> being cut from a first continuous length of unidirectional prepreg <NUM> via the cutting machine <NUM>, re-oriented via the pick-and-place system <NUM>, and placed on the conveyor belt <NUM> of the adhesion machine <NUM> as <NUM>-degree prepreg segments <NUM>, after which compaction pressure is applied by one or more compactions stages <NUM> for adhering the <NUM>-degree prepreg segments <NUM> to a second continuous length of a unidirectional prepreg <NUM> (i.e., <NUM>-degree prepreg) backed by a backing layer <NUM>, and resulting in a <NUM>/<NUM>-degree backed prepreg <NUM>, wherein the <NUM>-degree prepreg is sandwiched between the backing layer <NUM> and the <NUM>-degree prepreg. <FIG> shows -<NUM>-degree prepreg segments <NUM> being cut from a first continuous length of unidirectional prepreg <NUM>, re-oriented and placed on the conveyor belt <NUM>, and then adhered via the compaction stages to a second continuous length of a unidirectional prepreg <NUM> backed by a backing layer <NUM>, and resulting in a <NUM>/-<NUM>-degree backed prepreg <NUM>, wherein the <NUM>-degree prepreg is sandwiched between the backing layer <NUM> and the -<NUM>-degree prepreg. <FIG> shows +<NUM>-degree prepreg segments <NUM> being cut from a first continuous length of unidirectional prepreg <NUM>, and adhered to a second continuous length of a unidirectional prepreg <NUM> backed by a backing layer <NUM>, and resulting in a <NUM>/+<NUM>-degree backed prepreg <NUM>, wherein the <NUM>-degree prepreg is sandwiched between the backing layer <NUM> and the +<NUM>-degree prepreg.

<FIG> represent processes in which step <NUM> comprises adhering, using the adhesion station <NUM>, the first prepreg segments <NUM> to a continuous length of a prepreg-backing assembly <NUM>, which comprises a backed cross-ply prepreg <NUM> (i.e., an intermediate backed cross-ply prepreg <NUM>) previously manufactured by the manufacturing system <NUM>. The backed cross-ply prepreg <NUM> to which the first prepreg segments <NUM> are adhered comprises a series of second prepreg segments <NUM> on a backing layer <NUM>. In this regard, <FIG> represent processes for which a series of first prepreg segments <NUM> are adhered to a series of second prepreg segments <NUM> of a previously-manufactured backed cross-ply prepreg <NUM>, to result in a final backed cross-ply prepreg <NUM>. In each example, the fiber angles of the first prepreg segments <NUM> are non-parallel to the fiber angles of the second prepreg segments <NUM>.

<FIG> shows <NUM>-degree prepreg segments <NUM> being cut from a first continuous length of unidirectional prepreg <NUM>, re-oriented, and adhered to a series of -<NUM>-degree prepreg segments <NUM> backed by a backing layer <NUM> (i.e., the intermediate backed cross-ply prepreg <NUM>), and resulting in a -<NUM>/<NUM>-degree backed prepreg <NUM> (i.e., the final backed cross-ply prepreg <NUM>), wherein the -<NUM>-degree prepreg is sandwiched between the backing layer <NUM> and the <NUM>-degree prepreg. <FIG> shows -<NUM>-degree prepreg segments <NUM> being cut from a first continuous length of unidirectional prepreg <NUM>, and adhered to a series of <NUM>-degree prepreg segments <NUM> backed by a backing layer <NUM>, and resulting in a <NUM>/-<NUM>-degree backed prepreg <NUM>, wherein the <NUM>-degree prepreg is sandwiched between the backing layer <NUM> and the -<NUM>-degree prepreg. <FIG> shows -<NUM>-degree prepreg segments <NUM> being cut from a first continuous length of unidirectional prepreg <NUM>, and adhered to a series of +<NUM>-degree prepreg segments <NUM> backed by a backing layer <NUM>, and resulting in a +<NUM>/-<NUM>-degree backed prepreg <NUM>, wherein the +<NUM>-degree prepreg is sandwiched between the backing layer <NUM> and the -<NUM>-degree prepreg.

<FIG> shows +<NUM>-degree prepreg segments <NUM> being cut from a first continuous length of unidirectional prepreg <NUM>, and adhered to a series of -<NUM>-degree prepreg segments <NUM> backed by a backing layer <NUM> (i.e., the intermediate backed cross-ply prepreg <NUM>), and resulting in a -<NUM>/+<NUM>-degree backed prepreg <NUM> (i.e., the final backed cross-ply prepreg <NUM>), wherein the -<NUM>-degree prepreg is sandwiched between the backing layer <NUM> and the +<NUM>-degree prepreg. <FIG> shows +<NUM>-degree prepreg segments <NUM> being cut from a first continuous length of unidirectional prepreg <NUM>, and adhered to a series of <NUM>-degree prepreg segments <NUM> backed by a backing layer <NUM>, and resulting in a <NUM>/+<NUM>-degree backed prepreg <NUM>, wherein the <NUM>-degree prepreg is sandwiched between the backing layer <NUM> and the +<NUM>-degree prepreg. <FIG> shows <NUM>-degree prepreg segments <NUM> being cut from a first continuous length of unidirectional prepreg <NUM>, and adhered to the continuous length of a series of +<NUM>-degree prepreg segments <NUM> backed by a backing layer <NUM>, and resulting in a +<NUM>/<NUM>-degree backed prepreg <NUM>, wherein the +<NUM>-degree prepreg is sandwiched between the backing layer <NUM> and the <NUM>-degree prepreg.

<FIG> represent processes in which, after performing step <NUM> of adhering the first prepreg segments <NUM> to a continuous length of backing material <NUM> devoid of other prepreg material, the method <NUM> further comprises feeding a second continuous length of unidirectional prepreg <NUM> to the adhesion station <NUM>, and adhering the second continuous length of unidirectional prepreg <NUM> to the first prepreg segments <NUM> on the continuous length of backing material <NUM> (i.e., the intermediate backed cross-ply prepreg <NUM>). The second continuous length of unidirectional prepreg <NUM> is fed through the cutting station <NUM> (without cutting), and into the adhesion station <NUM>. Manufacturing the orientation combinations that are shown in <FIG> requires that the cutting machine <NUM> is aligned with the adhesion machine <NUM>, as shown in <FIG>. In this regard, the direction of movement of the second continuous length of unidirectional prepreg <NUM> through the cutting machine <NUM> is aligned with the direction of movement of the conveyor belt <NUM>.

The processes represented by <FIG> require mounting, on the adhesion machine <NUM>, a roll of backed cross-ply prepreg comprising the first prepreg segments <NUM> on a backing layer <NUM> (i.e., an intermediate backed cross-ply prepreg <NUM>). In addition, the processes require mounting, on the cutting machine <NUM>, a roll of a second continuous length of unidirectional prepreg <NUM>, and drawing the second continuous length of unidirectional prepreg <NUM> through the cutting machine <NUM>, without cutting into prepreg segments <NUM>. Instead, the processes of <FIG> include feeding, using the conveyor belt <NUM>, the second continuous length of unidirectional prepreg <NUM> onto the conveyor belt <NUM> of the adhesion station <NUM>, while drawing over the conveyor belt <NUM>, the continuous length of the first prepreg segments <NUM> on the backing layer <NUM>. The processes also include adhering the second continuous length of unidirectional prepreg <NUM> to the continuous length of the first prepreg segments <NUM> on the backing layer <NUM>, thereby resulting in two layers of prepreg segments <NUM> on the backing layer <NUM> (i.e., the final backed cross-ply prepreg <NUM>).

<FIG> shows a second continuous length of unidirectional prepreg <NUM> (i.e., <NUM>-degree prepreg) being adhered to a continuous length of a backed cross-ply prepreg <NUM> comprising a series of <NUM>-degree prepreg segments <NUM> backed by a backing layer <NUM>, and resulting in a <NUM>/<NUM>-degree backed prepreg <NUM>, wherein the <NUM>-degree prepreg is sandwiched between the backing layer <NUM> and the <NUM>-degree prepreg. <FIG> shows a second continuous length of unidirectional prepreg <NUM> being adhered to a continuous length of a backed cross-ply prepreg <NUM> comprising a series of -<NUM>-degree prepreg segments <NUM> backed by a backing layer <NUM>, and resulting in a -<NUM>/<NUM>-degree backed prepreg <NUM>, wherein the -<NUM>-degree prepreg is sandwiched between the backing layer <NUM> and the <NUM>-degree prepreg. <FIG> shows a second continuous length of unidirectional prepreg <NUM> being adhered to a continuous length of a backed cross-ply prepreg <NUM> comprising a series of +<NUM>-degree prepreg segments <NUM> backed by a backing layer <NUM>, and resulting in a +<NUM>/<NUM>-degree backed prepreg <NUM>, wherein the +<NUM>-degree prepreg is sandwiched between the backing layer <NUM> and the <NUM>-degree prepreg.

There is disclosed manufacturing system for manufacturing a backed cross-ply prepreg, comprising: a cutting machine having a cutting station configured to cut a continuous length of a unidirectional prepreg into prepreg segments, each having an opposing pair of segment cut edges that are non-parallel to a lengthwise direction of the unidirectional prepreg; an adhesion machine having a conveyor belt and an adhesion station; a pick-and-place system configured to pick up the prepreg segments from the cutting machine, and place the prepreg segments in end-to-end relation on the conveyor belt, and in an orientation such that the segment cut edges are generally parallel to a lengthwise direction of the conveyor belt; and wherein the conveyor belt is configured to feed the prepreg segments to the adhesion station, the adhesion station configured to adhere the prepreg segments to a continuous length of a backing material, thereby transferring the prepreg segments from the conveyor belt to the backing material, and resulting in a continuous length of a backed cross-ply prepreg.

Preferably, the cutting machine comprises: a nip roller assembly having opposing nip rollers positioned relative to each other to define a roller interface configured to receive and clamp onto the unidirectional prepreg, and feed a lengthwise section of the unidirectional prepreg into the cutting station.

Preferably, the cutting machine comprises: a backed unidirectional prepreg chuck configured to support a backed unidirectional prepreg drum containing a roll of the continuous length of the unidirectional prepreg supported on a backing layer; and a backing layer collection chuck configured to support a backing layer collection drum for collecting the backing layer as the backing layer is peeled from the unidirectional prepreg.

Preferably, the cutting machine comprises: a pneumatic dancer assembly located between the backed unidirectional prepreg drum and the nip roller assembly, and configured to apply a constant tension load on the unidirectional prepreg as the nip roller assembly draws the unidirectional prepreg through the cutting machine.

Preferably, the backing layer collection drum is located downstream of the nip roller assembly and upstream of the cutting station, and is configured to peel the backing layer from the unidirectional prepreg as the unidirectional prepreg exits the nip roller assembly prior to entering the cutting station.

Preferably, the cutting station is configured to cut the continuous length of the unidirectional prepreg into prepreg segments each having segment cut edges that are oriented at one of +<NUM> degrees, -<NUM> degrees, or <NUM> degrees, relative to the lengthwise direction of the unidirectional prepreg.

Preferably, the cutting station comprises: a cutting assembly having a cutting device and a cutting device actuator configured to translate the cutting device across a width of the unidirectional prepreg for cutting the unidirectional prepreg into the prepreg segments; and a turntable configured to support the cutting assembly, and lock the orientation of the cutting device relative to the lengthwise direction of the unidirectional prepreg.

Preferably, the cutting station comprises: a cutting surface having a plurality of pores configured to be fluidically coupled to a vacuum source for vacuum coupling of the unidirectional prepreg to the cutting surface to prevent movement during cutting. the cutting machine comprises: a segment pickup location where each prepreg segment is picked up by the pick-and-place system; and a segment delivery system configured to transport each prepreg segment from the cutting station to the segment pickup location.

Preferably, the segment delivery system comprises: a segment clamping system comprising a pair of prepreg clamps configured to clamp onto opposing segment side edges of the prepreg segment; a pair of linear guide rails respectively supporting the pair of prepreg clamps; and a clamp transporter actuator configured to move the prepreg clamps along the linear guide rails, and thereby transport each prepreg segment from the cutting station to the segment pickup location.

Preferably, the pick-and-place system comprises a robotic device having a robotic arm configured to pick up the prepreg segments at the cutting machine , and place the prepreg segments on the conveyor belt.

Preferably, the robotic arm includes a vacuum end effector configured for vacuum coupling to the prepreg segments, the vacuum end effector comprising: a vacuum plenum having a porous surface, and configured to be fluidically coupled to a vacuum source, the vacuum plenum divided into two or more vacuum zones; and wherein each one of the vacuum zones is fluidically coupled to a vacuum source, and the vacuum zones are independently activatable with vacuum pressure, based on the shape of the prepreg segment.

Preferably, the conveyor belt is a vacuum conveyor belt configured to be fluidically coupled to a vacuum source for vacuum coupling of the prepreg segments to the vacuum conveyor belt.

Preferably, the adhesion station comprises: at least one compaction stage configured to compact the prepreg segments against the backing material in such a manner causing the prepreg segments to adhere to the backing material.

Preferably, the at least one compaction stage comprises: an initial compaction stage located upstream of a downstream end of the conveyor belt, and having an initial compaction roller configured to apply an initial compaction pressure to the backing material against the prepreg segments on the conveyor belt in such a manner causing the prepreg segments to adhere to the backing material, thereby resulting in the backed cross-ply prepreg; and a secondary compaction stage located downstream of the downstream end of the conveyor belt, and having an upper compaction roller and a lower compaction roller positioned relative to each other to define a roller interface configured to receive the backed cross-ply prepreg, and apply a secondary compaction pressure in such a manner increasing the adhesion of the prepreg segments to the backing material.

Preferably, at least one of the upper compaction roller and the lower compaction roller is rotatably driven in a manner pulling the backing material through the adhesion station.

Preferably, the adhesion machine comprises: at least one heating device configured to heat the backing material and/or the prepreg segments, to facilitate adhesion of the prepreg segments to the backing material.

Preferably, the heating device comprises an infrared emitter.

Preferably, the adhesion machine comprises: a heating device configured to support a backing material drum, supporting a roll of the backing material for spooling off of the backing material drum and feeding through the cutting machine; a cross-ply material collection chuck configured to support a cross-ply material collection drum for collecting the backed cross-ply prepreg; and the heating device and the cross-ply material collection chuck each having a chuck servomotor for respectively rotatably driving the heating device and the cross-ply material collection chuck.

Preferably, ein the adhesion machine comprises: at least one tension-measuring device configured to measure tension load in at least one of the following locations: in the backing material after spooling off of the backing material drum, and prior to contacting the prepreg segments; in the backed cross-ply prepreg prior to winding onto the cross-ply material collection drum; wherein: the tension-measuring device is configured to transmit tension measurements respectively to a controller; and the controller configured to control the chuck servomotor respectively of the heating device and the cross-ply material collection chuck, and adjust a torque load respectively on the backing material drum and the cross-ply material collection drum in a manner maintaining the tension load respectively of the backing material and the backed cross-ply prepreg within predetermined load ranges.

Preferably, the tension-measuring device comprises: a load cell having a cylindrical surface configured to bear against the backing material, and measure tension load based on a side force imparted by the backing material on the load cell.

Preferably, the cutting machine is configured to be positioned in alignment with the adhesion machine, in a manner such that the direction of movement of the unidirectional prepreg through the cutting machine is aligned with the direction of movement of the conveyor belt.

Further, there is disclosed a method of manufacturing a backed cross-ply prepreg, comprising: cutting, using a cutting station of a cutting machine , a first continuous length of a unidirectional prepreg into first prepreg segments, each having an opposing pair of segment cut edges that are non-parallel to a lengthwise direction of the unidirectional prepreg; picking up, using a pick-and-place system, the first prepreg segments off of the cutting machine, and placing the first prepreg segments in end-to-end relation onto a conveyor belt of an adhesion machine, and in an orientation such that the segment cut edges are generally parallel to a lengthwise direction of the conveyor belt; feeding, using the conveyor belt, the first prepreg segments to an adhesion station of the adhesion machine; and adhering, using the adhesion station, the first prepreg segments to a continuous length of a backing material.

Preferably, adhering the first prepreg segments to the backing material comprises: adhering, using the adhesion station, the first prepreg segments to a continuous length of a backing layer that is devoid of prepreg material.

Preferably, adhering the first prepreg segments to the backing material comprises: adhering, using the adhesion station, the first prepreg segments to a continuous length of a prepreg-backing assembly; and wherein the prepreg-backing assembly comprises prepreg material backed by a backing layer.

Preferably, adhering the first prepreg segments to the prepreg-backing assembly comprises: adhering, using the adhesion station, the first prepreg segments to a continuous length of a backed cross-ply prepreg; and wherein the backed cross-ply prepreg comprises an end-to-end series of second prepreg segments on a backing layer.

Preferably, after adhering the first prepreg segments to the continuous length of the backing material, the method further comprising: feeding, using the conveyor belt, a second continuous length of unidirectional prepreg to the adhesion station; and adhering, using the adhesion station, the second continuous length of unidirectional prepreg to the first prepreg segments on a continuous length of backing layer.

Preferably, the method further comprises: positioning the cutting machine upstream of the adhesion machine, in a manner such that the direction of movement of unidirectional prepreg through the cutting machine is aligned with the direction of movement of the conveyor belt; mounting, on the adhesion machine, a roll of a backed cross-ply prepreg comprising the first prepreg segments on a continuous length of a backing layer; mounting, on the cutting machine, a roll of a second continuous length of unidirectional prepreg; drawing the second continuous length of unidirectional prepreg through the cutting machine, without cutting the second continuous length of the unidirectional prepreg into prepreg segments; feeding, using the conveyor belt, the second continuous length of unidirectional prepreg to the adhesion station, while drawing over the conveyor belt the continuous length of the first prepreg segments on the backing layer; and adhering, using the adhesion station, the second continuous length of unidirectional prepreg to the continuous length of the first prepreg segments on the backing layer, thereby resulting in two layers of prepreg segments on the backing layer.

Preferably, the method further comprises: receiving the unidirectional prepreg within a roller interface between opposing nip rollers of a nip roller assembly; and feeding, using the nip rollers, a lengthwise section of the unidirectional prepreg into the cutting station.

Preferably, the method further comprises: supporting the unidirectional prepreg on a backed unidirectional prepreg drum, the unidirectional prepreg backed by a backing layer; separating the backing layer from the unidirectional prepreg while drawing the unidirectional prepreg through the cutting machine; and collecting, on a backing layer collection drum, the backing layer as the unidirectional prepreg is separated from the backing layer.

Preferably, the method further comprises: applying, via a pneumatic dancer assembly located between the backed unidirectional prepreg drum and the nip roller assembly, a substantially constant tension load on the unidirectional prepreg as the nip roller assembly feeds the unidirectional prepreg into the cutting station.

Preferably, separating the backing layer from the unidirectional prepreg, and collecting the backing layer as the unidirectional prepreg is separated from the backing layer, respectively comprise: separating the backing layer from the unidirectional prepreg as the unidirectional prepreg exits the nip roller assembly prior to entering the cutting station; and collecting the backing layer on the backing layer collection drum located downstream of the nip roller assembly and upstream of the cutting station.

Preferably, cutting the unidirectional prepreg comprises: cutting, via the cutting station, the continuous length of the unidirectional prepreg into prepreg segments each having segment cut edges that are oriented at one of +<NUM> degrees, -<NUM> degrees, or <NUM> degrees, relative to the lengthwise direction of the unidirectional prepreg.

Preferably, cutting the unidirectional prepreg comprises: locking, via a turntable included with the cutting station, an orientation of a cutting device relative to the lengthwise direction of the unidirectional prepreg; and translating the cutting device across a width of the unidirectional prepreg and along the orientation locked by the turntable.

Preferably, cutting the unidirectional prepreg comprises: securing, via vacuum pressure, the unidirectional prepreg to a cutting surface having a plurality of pores fluidically coupled to a vacuum source.

Preferably, method further comprises: transporting, using a segment delivery system located adjacent to the cutting station, each prepreg segment from the cutting surface to a segment pickup location where the prepreg segment is picked up by the pick-and-place system.

Preferably, transporting each prepreg segment from the cutting surface to the segment pickup location comprises: clamping, via a pair of prepreg clamps of a segment clamping system, onto opposing segment side edges of the prepreg segment; and moving, via a clamp transporter actuator, the prepreg clamps along a pair of linear guide rails to thereby transport each prepreg segment from the cutting station to the segment pickup location.

Preferably, picking up the first prepreg segments off of the cutting machine comprises: picking up each prepreg segment using a robotic arm of a robotic device.

Preferably, picking up each prepreg segment using a robotic arm comprises: vacuum coupling, using a vacuum plenum, each prepreg segment to the robotic arm.

Preferably, vacuum coupling each prepreg segment to the robotic arm comprises: applying vacuum pressure to one or more vacuum zones of the vacuum plenum.

Preferably, feeding the first prepreg segments to the adhesion station comprises: vacuum coupling the first prepreg segments to a vacuum conveyor belt.

Preferably, feeding the first prepreg segments to the adhesion station comprises: moving the conveyor belt at a constant speed; and matching the speed of the pick-and-place system to the speed of the conveyor belt when placing a prepreg segment on the conveyor belt.

Preferably, adhering the first prepreg segments to the backing material comprises: compacting, using at least one compaction stage, the backing material against the prepreg segments in such a manner causing the prepreg segments to adhere to the backing material.

Preferably, compacting the backing material against the prepreg segments comprises: applying, using an initial compaction roller at an initial compaction stage located upstream of a downstream end of the conveyor belt, an initial compaction pressure to the backing material against the prepreg segments supported on the conveyor belt; and applying, using an upper compaction roller and a lower compaction roller at a secondary compaction stage located downstream of the downstream end of the conveyor belt, a secondary compaction pressure on the backing material and the prepreg segments.

Preferably, the method further comprises: rotatably driving at least one of the upper compaction roller and the lower compaction roller to draw the backing material through the adhesion station.

Preferably, the method further comprises: heating, using at least one heating device, the backing material and/or the prepreg segments on the conveyor belt to facilitate adhesion of the prepreg segments to the backing material.

Preferably, heating the backing material comprises: heating the backing material using an infrared emitter.

Preferably, the method further comprises: spooling the backing material off of a backing material drum (<NUM>); feeding the backing material over the conveyor belt for adhering the first prepreg segments to the backing material to result in the backed cross-ply prepreg; and collecting the backed cross-ply prepreg on a cross-ply material collection drum.

Preferably, the method further comprises: measuring, using at least one tension-measuring device, tension load in at least one of the following locations: in the backing material after spooling off of the backing material drum, and prior to contacting the prepreg segments; in the backed cross-ply prepreg prior to winding onto the cross-ply material collection drum; transmitting tension measurements from the tension-measuring device to a controller; and controlling, using the controller, a torque load respectively on the backing material drum and the cross-ply material collection drum in a manner maintaining the tension load respectively of the backing material and the backed cross-ply prepreg within predetermined load ranges.

Preferably, measuring tension load comprises: measuring tension load using a load cell having a cylindrical surface configured to bear against the backing material.

Still further there is disclosed a method of manufacturing a backed cross-ply prepreg, comprising: cutting, using a cutting machine, a first continuous length of a unidirectional prepreg into first prepreg segments, each having an opposing pair of segment cut edges that are non-parallel to a lengthwise direction of the unidirectional prepreg; picking up, using a pick-and-place system, the first prepreg segments off of the cutting machine, and placing the first prepreg segments in end-to-end relation onto a conveyor belt of an adhesion machine, and in an orientation such that the segment cut edges are generally parallel to a lengthwise direction of the conveyor belt; feeding, using the conveyor belt, the first prepreg segments to an adhesion station of the adhesion machine; adhering, using the adhesion station, the first prepreg segments to a continuous length of a backing layer, to thereby form a continuous length of an intermediate backed cross-ply prepreg; and adhering, using the adhesion station, either a second continuous length of a unidirectional prepreg or an end-to-end series of second prepreg segments to the first prepreg segments of the intermediate backed cross-ply prepreg, thereby resulting in a final backed cross-ply prepreg.

Claim 1:
A manufacturing system (<NUM>) for manufacturing a backed cross-ply prepreg (<NUM>), comprising:
a cutting machine (<NUM>) having a cutting station (<NUM>) configured to cut a continuous length of a unidirectional prepreg (<NUM>) into prepreg segments (<NUM>), each having an opposing pair of segment cut edges (<NUM>) that are non-parallel to a lengthwise direction of the unidirectional prepreg (<NUM>);
an adhesion machine (<NUM>) having a conveyor belt (<NUM>) and an adhesion station (<NUM>);
a pick-and-place system (<NUM>) configured to pick up the prepreg segments (<NUM>) from the cutting machine (<NUM>), and place the prepreg segments (<NUM>) in end-to-end relation on the conveyor belt (<NUM>), and in an orientation such that the segment cut edges (<NUM>) are generally parallel to a lengthwise direction of the conveyor belt (<NUM>); and
wherein the conveyor belt (<NUM>) is configured to feed the prepreg segments (<NUM>) to the adhesion station (<NUM>), the adhesion station (<NUM>) configured to adhere the prepreg segments (<NUM>) to a continuous length of a backing material (<NUM>), thereby transferring the prepreg segments (<NUM>) from the conveyor belt (<NUM>) to the backing material (<NUM>), and resulting in a continuous length of a backed cross-ply prepreg (<NUM>).