Patent Description:
Composite laminate components generally include a plurality of layers or plies of composite material assembled together to provide the composite component with improved engineering properties. Composite components are typically manufactured by stacking a plurality of plies on top of each other until a desired thickness and shape is achieved. For example, the manufacturing process typically includes cutting plies of composite material to a desired shape, stacking the plies layer by layer, and compacting the plies after each additional ply is layered over the previously stacked plies. The plies of composite material may be produced with a pre-impregnated resin covered by a removable polyfilm extending over at least one side of the plies, and that facilitates handling of the material prior to layup. During manufacture of composite components, the polyfilm is removed from the plies of composite material before a subsequent ply is stacked on top of the previously layered ply.

Conventionally, removing the backing layer(s) from the composite layer is a manual process performed by an individual. Thus, manually separating and removing the backing layer(s) from the composite layer relies on the skill of the individual to ensure that the backing layer is removed properly and swiftly. Further, sharp objects often are used in the manual process for releasing the backing layer and subsequently removing the backing layer from the composite layer. As such, manually releasing and removing the backing layer(s) is tedious and may cause damage to the composite material; further, manual processes may not be time and/or cost efficient for loosening and/or removing the backing layer(s) from the composite layer. Additionally, the manual processes of releasing and removing the backing layer(s) may lack repeatability and reliability. In short, removal of the polyfilm after each ply has been stacked can be a time-consuming and laborious task and automated efforts have, to date, failed to accomplish the removal of the entire polyfilm with an acceptable level of consistency.

In addition to the manufacture of composite components, myriad other manufacturing processes exist where a polyfilm must be removed either during the process or at its conclusion. <CIT> relates to a gripping device with a Bernoulli gripper. <CIT> relates to a peeling device for release of paper from a prepreg. An automated system capable of reliably removing the polyfilm is desirable.

Aspects and advantages will be set forth in part in the following description.

The invention is defined in the accompanying claims.

These and other features, aspects and advantages will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain certain principles of the invention, the scope of the invention being defined by the appended claims.

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended Figs. , in which:.

In the present disclosure, when a layer is being described as "on" or "over" another layer or substrate, it is to be understood that the layers can either be directly contacting each other or have another layer or feature between the layers, unless expressly stated to the contrary. Thus, these terms are simply describing the relative position of the layers to each other and do not necessarily mean "on top of" since the relative position above or below depends upon the orientation of the device to the viewer.

As used herein, the term "polyfilm" generally includes a film made from, but not limited to, homopolymers; copolymers, such as, for example, block, graft, random and alternating copolymers; and terpolymers; and blends and modifications thereof. Furthermore, unless otherwise specifically limited, the term "polyfilm" shall include all possible geometrical polymer configurations. These configurations include, but are not limited to isotactic, syndiotactic, and random symmetries.

In one aspect, a layup system for use in forming a composite layup structure from a plurality of plies of composite material, including an outermost ply of composite material with a backing layer adhered thereto, is provided. The system includes a robotic device and an end effector coupled to the robotic device. The end effector includes a separating tool designed to remove the backing layer by developing a void between the composite layer and the backing layer and a means to mechanically secure the backing layer. The robotic device is configured to translate the effector relative to the composite layup structure such that the backing layer is peeled from the outermost ply of composite material.

Referring now to the drawings, <FIG>, is a simplified drawing of one embodiment of the present disclosure. In this embodiment, an automated machine <NUM> is connected to a controller <NUM> and has an end effector <NUM> affixed to a movable component <NUM>. A separating tool <NUM> is affixed to the end effector <NUM>. The moveable component <NUM> is configured to place the end effector <NUM> into a selected position to perform a desired function upon a layer stack <NUM> positioned by a first work support <NUM>.

Referring again to <FIG>, the end effector <NUM> may be a device for lifting a portion of the layer stack <NUM>, a cutting device designed to separate a portion of the layer stack <NUM>, or any other implement designed to interact with the layer stack <NUM>. For example, in an embodiment designed for lifting a portion of the layer stack <NUM> and not covered by the appended claims, the end effector <NUM> may be an impactive gripper, such as a mechanical or pneumatic gripper; an ingressive gripper, such as a needle or pin gripper; an astrictive gripper, such as a vacuum, magnetic, or electro-adhesive gripper; a contigutive gripper, such as a glue or freezing gripper, or any combination thereof. Likewise, in an embodiment designed to separate a portion of the layer stack <NUM> and not covered by the appended claims, an exemplary end effector <NUM> may be an ultrasonic cutter, a blade cutter, a bit cutter, a laser cutter, a plasma cutter, a wire cutter, or a waterjet cutter. In still other exemplary embodiments not covered by the appended claims, the end effector <NUM> may include a drill, a deburring tool, a welder, a sprayer, a stamp, or a driver. In still other embodiments not covered by the appended claims, the end effector <NUM> may be a device with multiple tools or grippers designed to accomplish a specified operation.

Referring still to the end effector <NUM> of <FIG>, and to <FIG>, as recited in claim <NUM>, the end effector <NUM> is configured as a vacuum roller <NUM> enabled to lift a portion of the layer stack <NUM>. The vacuum roller <NUM> is attached to moveable component <NUM> via an attachment structure <NUM>. A support arm <NUM> is secured to the attachment structure <NUM> and mounts a perforated drum <NUM>. Power, vacuum, and commands are delivered to the vacuum roller <NUM> by cables and hoses <NUM>. The perforated drum is rotated at the command of the controller <NUM> (not shown) by a servo motor <NUM>. Positioning and functioning input is provided to the controller from affixed sensors <NUM>. The separating tool <NUM> is coupled to the vacuum roller <NUM> in a selected location able to be brought into contact with the layer stack <NUM> (not shown).

The layer stack <NUM> of <FIG> includes a backer layer <NUM> and a material layer <NUM>. In one embodiment, the backer layer <NUM> generally refers to a removable polyfilm but may also include other removable materials; for example, release paper, waxed paper, peel-able coating systems, and masking tapes. The material layer <NUM> refers to a material being used in the production of an end item or the end item itself. For example, in some instances the material layer <NUM> may be a pre-impregnated composite ply. In still other instances, the material layer <NUM> may be, but is not limited to, a metal object, glass plate, or a digital display.

<FIG> depict a sequential operation of an exemplary embodiment of the present disclosure. The exemplary operation depicted relates to the forming of a composite layup structure from a plurality of plies of pre-impregnated composite material. In the exemplary operation, a desired portion pre-impregnated composite material, represented by the layer stack <NUM>, has been separated from a stock of pre-impregnated composite material (not depicted) and <FIG> shows the end effector <NUM> in position over the layer stack <NUM>. In this instance, the end effector <NUM> is configured to be a device for lifting a portion of the layer stack <NUM>, and is the vacuum roller depicted in <FIG>. <FIG> shows the automated machine <NUM> after the end effector <NUM> has captured a portion of the layer stack <NUM> and the automated machine <NUM> has lifted the portion from the first work support <NUM>. Between <FIG> and <FIG>, the automated machine proceeds from the first work support <NUM> to a second work support <NUM>. <FIG> depicts the end effector <NUM> holding a portion of the layer stack <NUM> over an assembly surface <NUM> supported by the second work support <NUM>.

In the present instance, the assembly surface <NUM> depicts, but is not limited to, a male mold designed to shape the material layer <NUM> into the desired shape of the component being produced. In addition to the male mold depicted, the assembly surface <NUM> may also be a planar surface or a female mold. In some embodiments, the assembly surface <NUM> is treated with a compatible resin so as to create a securing substrate for holding a first ply of the material layer <NUM>. For instances in which the material layer <NUM> is pre-impregnated composite material, the compatible resin may be the same as the resin pre-impregnating the composite fibers so as to eliminate the introduction of additional adhesive elements. In some instances, the assembly surface may be externally or internally heated. In still other instances, the material layer <NUM> may be held by the assembly surface <NUM> through the creation of a vacuum or magnetic field at the assembly surface <NUM>.

In <FIG>, the layer stack <NUM> has been positioned on the assembly surface <NUM>, the separating tool <NUM> has captured the backing layer <NUM> and the automated machine <NUM> is separating the backing layer <NUM> from the material layer <NUM>.

Referring now to <FIG>, a close-up, cross-sectional view is provided of an embodiment of the separating tool <NUM>. The separating tool <NUM> is coupled to the end effector <NUM> via an attachment structure <NUM>, which in turn, is coupled to a support column <NUM>. A support column first end <NUM> is coupled to a displacing member <NUM>. The displacing member <NUM> is formed so as to enable the establishment of a void between the backing layer <NUM> and the material layer <NUM>. In the depicted embodiment of <FIG>, the displacement of the backing layer <NUM> occurs in response to the creation of a vacuum in a void <NUM> between an inner face <NUM> of the displacing member <NUM> and the backing layer <NUM> when a mating face <NUM> is in contact with the backing layer <NUM> and a vacuum is drawn through an attached vacuum coupling <NUM>, which is operably coupled to a support structures <NUM> via a vacuum line <NUM>. The depth D of the void <NUM> is selected so as to enable the mechanical securing of a displaced portion (<FIG>; <NUM>) of the backing layer <NUM>. In some embodiments, it may be desirable to ensure a sufficient portion of the backing layer <NUM> is displaced to enable mechanical securing without the securing mechanism penetrating the material layer <NUM>.

Referring still to <FIG>, at least one actuator <NUM> is coupled to an outer face <NUM> of the displacing member <NUM>. The actuator <NUM> is configured to, when directed by controller <NUM>, drive and retract a securing member <NUM> through a sealing member <NUM>. In the exemplary represented by <FIG>, the securing member <NUM> is a plurality of needles.

<FIG> depicts the displaced portion <NUM> of the backing layer <NUM>. The development of this displaced portion <NUM> results in the creation of a void <NUM> between the backing layer <NUM> and the material layer <NUM>. Although, as discussed above, the displacement of the backing layer <NUM> may be accomplished through the establishment of a vacuum within the displacing member <NUM>, additional structure (not shown) may be included in certain embodiments whereby the displacement results from the introduction of a compressed gas between the backing layer <NUM> and the material layer <NUM>.

<FIG> depicts an exemplary embodiment in which the plurality of actuators <NUM> have driven a plurality of securing members <NUM> through the displaced portion <NUM> of the backing layer <NUM> and into the void <NUM> between the backing layer <NUM> and the material layer <NUM>. This action establishes a mechanical connection between the securing member <NUM> and the displaced portion <NUM> to couple the separating tool <NUM> to the backing layer <NUM>. In the embodiment depicted by <FIG>, the securing members <NUM> are at least one needle selected to ensure consistent penetration of the backing layer <NUM> without bending or breaking; for example, an embroidery needle. In other embodiments, the securing member <NUM> may be at least one lancet.

<FIG> depicts an alternative embodiment whereby the securing member <NUM> is a single, curved needle or hook having a first end and a second end opposite thereof. In this exemplary, a single actuator <NUM> drives a single securing member which passes through the displaced portion (not shown) of the backing layer <NUM> in two locations and enters a receiver port <NUM> coupled to the displacing member <NUM> at a point opposite the actuator <NUM>. This action establishes a mechanical connection between the securing member <NUM> and the displaced portion (not shown).

<FIG> depicts an alternative embodiment of the present disclosure whereby the securing members <NUM> are a gripping element. In this instance, the securing members <NUM> do not penetrate the backing layer <NUM>. Instead, the actuators <NUM> are coupled to the displacing member <NUM> at points separated by one hundred and eighty degrees. The opposing actuators <NUM> drive the securing members <NUM> toward each other, capturing a portion of the displaced portion (not shown) of the backing layer <NUM> in a pinch grip. This action establishes a mechanical connection between the securing members <NUM> and the displaced portion (not shown).

<FIG> depicts an alternative embodiment of the present disclosure whereby the securing members <NUM> are a gripping element equipped with a piercing member <NUM>. In this instance, the actuators <NUM> are coupled to the displacing member <NUM> at points separated by one hundred and eighty degrees. The opposing actuators <NUM> drive the securing members <NUM> toward each other, capturing a portion of the displaced portion (not shown) of the backing layer <NUM> in a pinch grip reinforced by the piercing member <NUM>. This action establishes a mechanical connection between the securing members <NUM> and the displaced portion (not shown). It should be appreciated that the piercing member <NUM> may be any protrusion able to pierce the backing layer <NUM>, such as a needle or lancet.

<FIG> depicts an alternative embodiment of the present disclosure whereby the securing members <NUM> are fixed. In this exemplary embodiment, a plurality of securing members <NUM> are coupled to inner face <NUM> of the displacing member <NUM>. The displacement of a portion of the backing layer <NUM> causes the displaced portion (not shown) to be pierced by the securing members <NUM>. It should be appreciated that the securing members <NUM> may be any protrusion able to pierce the backing layer <NUM>, such as a needle or lancet.

<FIG> depicts an alternative embodiment of the present disclosure whereby the securing member <NUM> is fixed. In this exemplary embodiment, the securing member <NUM> is a barbed member and is coupled to the inner face <NUM> of the displacing member <NUM>. The displacement of a portion of the backing layer <NUM> causes the displaced portion (not shown) to be pierced by the securing members <NUM>. It should be appreciated that the securing member <NUM> may be any barbed protrusion which is able to pierce the backing layer <NUM>, such as a barbed needle or a barbed lancet.

<FIG> depict an alternative embodiment of the present disclosure wherein the displacing member <NUM> is deformable. In this exemplary embodiment, a plurality of securing members <NUM> are coupled to the inner face <NUM> of the displacing member <NUM>. As a vacuum is drawn through an attached vacuum coupling <NUM>, a portion of the backing layer <NUM> is displaced and the displacing member <NUM> is drawn towards the displaced portion <NUM>. The deformation of the displacing member <NUM>, as shown in <FIG>, causes the plurality of securing members <NUM> to pierce and mechanically secure the backing layer <NUM>. It should be appreciated that the securing members <NUM> may be any protrusion able to pierce the backing layer <NUM>, such as a needle or lancet.

<FIG>, depicts an alternative embodiment of the present disclosure whereby the displacement of the backing layer <NUM> occurs in response to the injection of gas between the backing layer <NUM> and the material layer <NUM> when a mating face <NUM> is in contact with the backing layer <NUM>. In this alternative embodiment, a hollow needle <NUM> is inserted by an actuator <NUM> between the backing layer <NUM> and the material layer <NUM>. Pressurized gas is delivered to the hollow needle <NUM> via a gas line <NUM>, which is operably coupled to support structures <NUM>. Pressurized gas is delivered by the hollow needle <NUM> between the backing layer <NUM> and the material layer <NUM> to displace a sufficient portion of the backing layer so as to enable mechanical securing of the displaced portion. In some embodiments, it may be desirable to ensure a sufficient portion of the backing layer <NUM> is displaced to enable mechanical securing without the securing mechanism penetrating the material layer <NUM>.

Referring now to <FIG>, this figure is a flow diagram of a method (<NUM>) for separating a layer from a layer assembly or layer stack as recited in claim <NUM>, the layer assembly includes a backing layer and a material layer. The exemplary method (<NUM>) includes at (<NUM>) placing the portion of the layer assembly on an assembly surface that holds the portion in place and at (<NUM>), bringing a separating tool into contact with the portion on a surface of the backing layer, the separating tool attached to a machine.

The exemplary method (<NUM>) includes at (<NUM>) activating the separating tool so as to create a void between the backing layer and material layer, resulting in a displaced portion of the backing layer, and at (<NUM>) establishing a mechanical connection with the displaced portion of the backing layer. Additionally, the exemplary method (<NUM>) includes at (<NUM>) moving the separating tool in a selected direction so as to remove the secured backing layer and expose an entirety of the material layer.

Referring now to <FIG>, a flow diagram of a method (<NUM>) for enabling the automated layup of a composite laminate assembly as recited in claim <NUM> and using the system of claim <NUM> is presented. The exemplary method (<NUM>) includes at 70b2 applying a portion of a resin on an assembly surface, the resin being of the same type as that pre-impregnated into a first composite ply and at (<NUM>) positioning a first uncovered surface defined by a face of the first composite ply in contact with the portion of resin on the assembly surface and with a backing layer facing away from the assembly surface. The exemplary method (<NUM>) includes at (<NUM>) utilizing an automated system employing a separating tool to separate the backing layer from the first composite ply, at (<NUM>) removing the backing layer exposing a second uncovered surface of the first composite ply, and at (<NUM>) disposing of the backing layer. Additionally, the exemplary method (<NUM>) includes at (<NUM>) placing a second composite ply upon the first composite ply orientated so that an uncovered surface of the second composite ply is in contact with the second uncovered surface of the first composite ply, and at (<NUM>) utilizing the automated system to separate the backing layer from the second composite ply. Additional material layers may be added until the desired number of composite plies have been achieved.

Referring again to <FIG>, in the embodiment shown, the automated machine <NUM> is an articulated robotic arm assembly. The exemplary robotic arm assembly depicted generally includes a base <NUM>, a robotic arm <NUM>, and the moveable component <NUM>. The base <NUM> generally includes an actuator pack <NUM> and the controller <NUM>. The controller <NUM> is operably coupled to the actuator pack <NUM> for controlling operation of the automated machine <NUM>. Additionally, the controller <NUM> may be operably coupled to the moveable component <NUM> and/or one or more sensors (not shown) attached to or embedded in the robotic arm <NUM> and/or moveable component <NUM>. Further, the robotic arm <NUM> extends generally between a root end <NUM> and a distal end <NUM>. As will be explained in greater detail below, the robotic arm <NUM> includes an attachment section <NUM> at the root end <NUM>, with the attachment section <NUM>, for the embodiment depicted, attached to the actuator pack <NUM> of the base <NUM>. Additionally, the robotic arm <NUM> includes the end effector <NUM> coupled to the moveable component <NUM> at a distal end <NUM>.

Moreover, the robotic arm <NUM> of the exemplary automated machine <NUM> depicted is generally formed of a plurality of links <NUM> and a plurality of joints <NUM>, with the plurality of links <NUM> sequentially arranged and movably coupled to one another with the plurality of joints <NUM>. At least certain of the plurality of links <NUM> are operable with the actuator pack <NUM>, such that one or more actuators or motors (not shown) of the actuator pack <NUM> may control operation (such as a position and/or orientation) of the robotic arm <NUM>. However, in other embodiments, any other suitable configuration may be provided for manipulating or otherwise controlling the plurality of links <NUM> of the robotic arm <NUM> of the exemplary automated machine <NUM>.

Further, as is depicted, the base <NUM> includes one or more support structures <NUM> operable with the end effector <NUM> for assisting the end effector <NUM> and performing certain operations. For example, when the end effector <NUM> is configured as a welder, the one or more support structures <NUM> may include, e.g., a gas supply, a wire supply, an electric power supply, etc. When the end effector <NUM> is configured as an astrictive gripper employing vacuum, the one or more support structures <NUM> may include, a vacuum pump coupled to vacuum lines <NUM>.

In further embodiments, the automated machine <NUM> may be any other suitable form of automated machine. For example, the automated machine <NUM> may be a cartesian robot, a scara robot, a cylindrical robot, a polar robot, or a delta robot.

In some instances, the material layer <NUM> may be a ceramic matrix composite (CMC) material. CMC materials are more frequently being used for various high temperature applications. For example, because CMC materials can withstand relatively extreme temperatures, there is particular interest in replacing components within a combustion gas flow path of a gas turbine engine with components made from CMC materials. Typically, CMC materials comprise ceramic fibers embedded in a matrix material such as silicon carbide (SiC), silicon, silica, alumina, or combinations thereof. Plies of the CMC material may be laid up to form a preform component that may then undergo thermal processing, such as a cure or burnout to yield a high char residue in the preform, and subsequent chemical processing, such as melt-infiltration with silicon, to arrive at a component formed of a CMC material having a desired chemical composition.

<FIG> provides a block diagram of an example computing system <NUM> that is representative of controller <NUM> that may be used to implement the methods and systems described herein according to exemplary embodiments of the present disclosure. As shown, the computing system <NUM> may include one or more computing device(s) <NUM>. The one or more computing device(s) <NUM> may include one or more processor(s) <NUM> and one or more memory device(s) <NUM>. The one or more processor(s) <NUM> may include any suitable processing device, such as a microprocessor, microcontroller, integrated circuit, logic device, or other suitable processing device. The one or more memory device(s) <NUM> may include one or more computer-readable media, including, but not limited to, non-transitory computer-readable media, RAM, ROM, hard drives, flash drives, or other memory devices.

The one or more memory device(s) <NUM> may store information accessible by the one or more processor(s) <NUM>, including computer-readable instructions <NUM> that may be executed by the one or more processor(s) <NUM>. The instructions <NUM> may be any set of instructions that when executed by the one or more processor(s) <NUM>, cause the one or more processor(s) <NUM> to perform operations. The instructions <NUM> may be software written in any suitable programming language or may be implemented in hardware. In some embodiments, the instructions <NUM> may be executed by the one or more processor(s) <NUM> to cause the one or more processor(s) <NUM> to perform operations, such as implementing one or more of the processes mentioned above.

The memory device(s) <NUM> may further store data <NUM> that may be accessed by the processor(s) <NUM>. For example, the data <NUM> may include a third instance of shared data for a gas turbine engine, as described herein. The data <NUM> may include one or more table(s), function(s), algorithm(s), model(s), equation(s), etc. according to example embodiments of the present disclosure.

The one or more computing device(s) <NUM> may also include a communication interface <NUM> used to communicate, for example, with the other components of system. The communication interface <NUM> may include any suitable components for interfacing with one or more network(s), including for example, transmitters, receivers, ports, controllers, antennas, or other suitable components.

Claim 1:
An automated system for separating a layer from a layer assembly, the layer assembly comprising a backing layer (<NUM>) and a material layer (<NUM>), the automated system comprising:
an automated machine (<NUM>) having a controller (<NUM>) and an end effector (<NUM>); and
a separating tool (<NUM>) attached to the end effector (<NUM>) of the automated machine (<NUM>), the separating tool (<NUM>) including,
a displacing member (<NUM>) configured to establish a void (<NUM>) between the backing layer (<NUM>) and the material layer (<NUM>) by displacing a portion of the backing layer (<NUM>), the displacing member (<NUM>) further comprising a displacing member (<NUM>) outer face (<NUM>), and
a securing member (<NUM>) configured to establish a mechanical connection with a displaced portion (<NUM>) of the backing layer (<NUM>),
wherein the end effector (<NUM>) comprises a vacuum roller (<NUM>) configured to lift at least a portion of the layer assembly, wherein the vacuum roller (<NUM>) is attached to a movable component (<NUM>) via an attachment structure (<NUM>), wherein a support arm (<NUM>) is secured to the attachment structure (<NUM>) and mounts a perforated drum (<NUM>), wherein the perforated drum (<NUM>) is rotated at the command of the controller (<NUM>) by a servo motor (<NUM>), wherein positioning and functioning input for the end effector (<NUM>) is provided to the controller (<NUM>) from affixed sensors (<NUM>); and
wherein the separating tool (<NUM>) is coupled to the vacuum roller (<NUM>) in a selected location able to be brought into contact with the layer assembly.