Laminate head with bidirectional capability

Abstract

The present invention is entitled "A Laminating Head with Bidirectional Capability". The laminating head for laying composite laminates includes a material supply roller supporting a roll of layup material backed by a backing layer, first and second separating devices having first and second angles respectively, and first and second compacting devices. When the first separating device extends, the first angle is close to the first compacting device, and as the laminating head moves along a first travel direction, the layup material separates from the backing layer and moves below the first compacting device. When the second separating device extends, the second angle is close to the second compacting device, and as the laminating head moves along a second travel direction opposite to the first travel direction, the layup material separates from the backing layer and moves below the second compacting device.

Description

Technical Field

[0001] This disclosure generally relates to manufacturing systems, and more specifically to a laminator for laying composite laminates and having bidirectional laying capability. Background Technology

[0002] Composite materials are used in a variety of applications due to their advantageous properties such as high specific strength, high specific stiffness, and high corrosion resistance. The fabrication of composite structures typically involves laying multiple layers of layup material in a stacked manner on a laminated surface to form a composite laminate. The layup material is typically a fibrous material pre-impregnated with an uncured resin (e.g., prepreg). For example, the layup material could be an epoxy resin-impregnated carbon fiber prepreg.

[0003] Due to their relatively high material deposition rate, automated laminators are able to lay composite laminates with relatively high productivity. A belt laminator is a type of automated laminator in which a continuous strip of layup material, such as prepreg tape, is dispensed from the laminator onto the laminating surface as the laminator moves relative to the laminating surface. For example, the laminator can dispense layup material while moving across a stationary laminating surface. Alternatively, the laminator can be stationary while the laminating surface moves beneath it, dispensing layup material simultaneously. Each composite sheet can be formed by the laminator continuously laying rows or courses of tape in a parallel, side-by-side relationship.

[0004] A conventional laminator head can lay each new layer of tape while moving relative to the laminating surface in a first traveling direction. At the end of one layer, the laminator head lifts off the laminating surface and moves back onto it in a second traveling direction opposite to the first, and begins applying another layer of tape in the first direction. This off-part movement of the laminator head each time it moves in the second direction undesirably increases production process time.

[0005] In attempts to reduce component movement, certain types of laminators can be configured to rotate 180 degrees at the end of laying the first layer of material, and then reverse to lay the second layer of material next to or on top of the first. The ability to rotate the laminator increases the complexity of the manufacturing system because it requires the entire weight of the rotating laminator, material supply, support cables, and other associated components. Further adding complexity is the need to temporarily lift the laminator off the lamination surface before rotation and then lower it back onto the lamination surface after rotation is complete.

[0006] In another attempt to reduce off-center movement of components, some conventional manufacturing systems include a first laminating head configured to dispense layup material while moving along a first direction of travel, and a second laminating head configured to dispense layup material while moving along a second direction of travel. However, such a manufacturing system doubles the number of laminating heads, thus increasing the cost, complexity, and overall size of the manufacturing system.

[0007] Therefore, there is a need in the field for laminators that reduce component movement and avoid the costs and complexities associated with conventional manufacturing systems. Summary of the Invention

[0008] The aforementioned needs related to the manufacture of composite laminates are specifically addressed and mitigated by this disclosure, which provides a laminating head with bidirectional layup capability for laying composite laminates. The laminating head includes a material supply roller configured to support a roll of backed material. The backed material includes layup material backed by a backing layer. The laminating head also includes a first separation device and a second separation device, each having a first horn and a second horn, respectively, each horn movable between a retracted separation device position and a protruding separation device position associated with the first and second separation devices. The laminating head further includes a first compaction device and a second compaction device configured to alternately apply compaction pressure against the substrate at compaction points of the layup material. When the first separating device is in the extended position, the first angled object is closely adjacent to the compaction point of the layup material associated with the first compaction device, and the first angled object is configured to separate the layup material from the backing layer and guide the layup material toward the substrate and below the first compaction device as the laminating head moves along the first travel direction. When the second separating device is in the extended position, the second angled object is closely adjacent to the compaction point of the layup material associated with the second compaction device, and the second angled object is configured to separate the layup material from the backing layer and guide the layup material toward the substrate and below the second compaction device as the laminating head moves along a second travel direction opposite to the first travel direction.

[0009] A laminating head with bidirectional laying capability is also disclosed, comprising a material supply roller, a first separating device and a second separating device, as described above, and a first compaction device and a second compaction device. When the first separating device is in the extended position and the second separating device is in the retracted position, a first angular object closely protrudes from the laying material compaction point associated with the first compaction device to separate the laying material from the backing layer as the laminating head moves along a first travel direction. When the second separating device is in the extended position and the first separating device is in the retracted position, a second angular object closely protrudes from the laying material compaction point associated with the second compaction device to separate the laying material from the backing layer as the laminating head moves along a second travel direction opposite to the first travel direction.

[0010] Furthermore, a method for bidirectionally applying layup material to a substrate is disclosed. The method includes a backing layer separation assembly that feeds backing material from a material roll to a laminator head. The material roll is mounted on a material supply roller. The backing material includes layup material supported by a backing layer. The backing layer separation assembly has a first separation device and a second separation device, each having a first horn and a second horn, respectively. The method includes moving the first horn close to a layup material compaction point associated with a first compaction device. Furthermore, the method includes using the first horn to separate the layup material from the backing layer and guiding the layup material toward the layup material compaction point associated with the first compaction device while moving the laminator head along a first travel direction. Additionally, the method includes retracting the first horn from the first compaction device and moving the second horn close to a layup material compaction point associated with a second compaction device. The method also includes using a second horn to separate the lay material from the backing layer, and guiding the lay material toward the lay material compaction point associated with the second compaction device while moving the laminating head in a second travel direction opposite to the first travel direction.

[0011] The features, functions and advantages already discussed can be implemented independently in various instances of this disclosure or can be combined in other instances, further details of which can be seen in the following description and the following figures. Attached Figure Description

[0012] Referring to the accompanying drawings, these and other features of this disclosure will become more apparent, wherein the same numerals always refer to the same parts, and wherein:

[0013] Figure 1 This is a top view of an example of a manufacturing system for laying composite laminates, which includes a series of laminating heads, each having bidirectional laying capability for distributing layup material onto a substrate during relative movement of the laminating heads along a first direction of travel and along a second direction of travel opposite to the first direction of travel.

[0014] Figure 2 yes Figure 1 A side view of the manufacturing system;

[0015] Figure 3 It is by Figure 1 The attached figure shows an enlarged view of a portion of the manufacturing system identified by reference numeral 3, and illustrates a series of laminating heads supported by a laminating head support structure;

[0016] Figure 4 It is by Figure 2 The attached figure shows an enlarged view of a portion of the manufacturing system identified by reference numeral 4, and illustrates a laminating head supported above a laminating mandrel that is movable relative to a fixed laminating head.

[0017] Figure 5 It is a perspective view of an example of a series of laminating heads on a substrate (e.g., a laminating mandrel) that is moving beneath the laminating heads;

[0018] Figure 6 It is by Figure 4 The attached figure shows an enlarged view of the laminating head, identified by reference numeral 6, and shows a material supply roller supporting a material roll of layup material backed by a backing layer, and further shows a backing layer separation assembly for separating the layup material from the backing layer, and additionally shows a first compaction device and a second compaction device for compacting the layup material onto the substrate during the relative movement of the laminating head while the backing layer collection roller collects the backing.

[0019] Figure 7 It is by Figure 6 The attached figure shows an enlarged view of the portion of the laminating head identified by reference numeral 7, and shows the first and second separating devices, each in the retracted position of the separating device, and the first and second compacting devices, each in the retracted position of the compacting device.

[0020] Figure 8 It is along Figure 6 The view of the cutter assembly is taken by line 8-8, and an example of a cutter blade is shown, which is configured to cut the lay-up material along a blade angle path that is complementary to the material feed rate of the backing material.

[0021] Figure 9 This is a view of the cutter assembly, showing further progress as the cutter blade moves along the blade path angle to cut the lay-up material along a predetermined cutting line;

[0022] Figure 10This is a view of the cutter assembly, showing further progress of the cutter blade during cutting of the backing material along a predetermined cutting line, in the example shown, where the predetermined cutting line is oriented perpendicular to the longitudinal direction of the backing material.

[0023] Figure 11 This is a view of the cutter assembly after the material has been cut along a predetermined cutting line;

[0024] Figure 12 A laminator is shown distributing layup material onto a substrate during movement relative to the substrate along a first direction of travel.

[0025] Figure 13 It is by Figure 12 An enlarged view of a portion of the laminating head, identified by reference numeral 13 in the accompanying drawings, showing a first separating device in the extended position of the separating device, which is used to separate the lay-up material from the backing layer and guide the lay-up material toward the substrate and below the first compaction device;

[0026] Figure 14 It is by Figure 13 An enlarged view of the portion of the laminating head identified by reference numeral 14 in the accompanying drawings, showing the distal end of the corner of the first corner located within a first cut area defined between the outer surface of the first compaction device, a horizontal tangent to the outer surface of the compaction device, and a vertical tangent to the outer surface of the compaction device;

[0027] Figure 15 This illustrates the separation of the layup material from the backing layer during the relative movement of the laminating head along the first direction of travel, and the distal end of the corner guiding the layup material toward the substrate and below the first compaction device;

[0028] Figure 16 The relatively short length of the distal end of the corner is shown, closely adjacent to the outer surface of the compaction device, resulting in an unsupported section of the pavement extending between the pavement separation point at the distal end of the corner and the pavement compaction point below the first compaction device.

[0029] Figure 17 An example is shown of a corner with a roller at the distal end, which can rotate freely as the backing layer moves over the distal end of the corner;

[0030] Figure 18 The laminator is shown distributing layup material onto the substrate during movement relative to the substrate along a second direction of travel.

[0031] Figure 19 It is by Figure 18An enlarged view of a portion of the laminating head, identified by reference numeral 19 in the accompanying drawings, and showing a second separating device in the extended position of the separating device, which is used to separate the lay material from the backing layer and guide the lay material toward the substrate and below the second compaction device;

[0032] Figure 20 It is by Figure 19 The attached figure shows an enlarged view of a portion of the laminating head identified by reference numeral 20, and shows the distal end of the corner of the second corner located within a second cut area defined between the outer surface of the second compaction device, a horizontal tangent to the outer surface of the compaction device, and a vertical tangent to the outer surface of the compaction device;

[0033] Figure 21 It shows the separation of the layup material from the backing layer during the relative movement of the laminating head along the second direction of travel, and the distal end of the corner of the second compaction device that guides the layup material toward the substrate and below the second compaction device;

[0034] Figure 22 The outer surface of the compaction device is shown closely adjacent to the second compaction device, resulting in a relatively short length of the unsupported segment of the pavement extending between the pavement compaction points below the second compaction device at the distal end of the corner.

[0035] Figure 23 This is a flowchart of a method for applying laying material to a substrate in both directions. Detailed Implementation

[0036] Referring now to the accompanying drawings, which illustrate preferred and various embodiments of this disclosure, Figure 1 The diagram shows a top view of an example of a manufacturing system 100, which has a laminating table 140 (e.g., a fiber placement head) comprising an end-to-end series of laminating heads 142 for laying uncured composite laminates 196. Figure 5 ). Figure 2 This is a side view of manufacturing system 100. Figure 3 and Figure 4 These are top and side views of the laminating table 140, showing a series of laminating heads 142. Figure 5 This is a perspective view of an example of a series of laminating heads 142, which apply layers 194 of layup material 168 to a substrate 122 or a lamination surface 120, such as a lamination mandrel 124, and move below the laminating head 142. Each laminating head 142 has a bidirectional layup capability for distributing layup material 168 onto the substrate 122. In this respect, each laminating head 142 is configured to travel in a first direction of travel 150 relative to the substrate 122 (e.g., lamination mandrel 124). Figure 12During the movement, the laying material 168 is distributed, and also relative to the base 122 along a second travel direction 152 opposite to the first travel direction 150. Figure 18 168 paving materials were allocated during the relocation.

[0037] The bidirectional layup capability of the laminator 142 enables a relatively higher manufacturing speed than that achievable with a laminator limited to distributing layup material 168 in a single direction of travel. In this respect, the bidirectional capability of the laminator 142 reduces the off-part movement required if each laminator is limited to distributing layup material 168 while moving in a single direction of travel. For example, a laminator (not shown) limited to distributing layup material 168 in a single direction of travel would need to lift the laminator off the substrate 122 at the end of each layer 194 of layup material 168, move back onto the substrate 122 in a second direction of travel 152 opposite to the first direction of travel 150, and begin applying another layer 194 of layup material 168 on or parallel to the previous layer 194 while moving in the first direction of travel 150. It can be recognized that eliminating the external movement of the components of the currently disclosed bidirectional laminator 142 significantly reduces the amount of time required to lay the composite laminate 196.

[0038] As described above, the bidirectional laying capability of the currently disclosed laminator 142 also provides an advantage over a laminator (not shown) configured to rotate 180 degrees at the end of the first layer of layup 168 and then reverse to lay a second layer of layup 168 next to or on top of the first layer. As described above, rotating laminators can be more complex and heavier than non-rotating laminators. In the case of multiple laminators (not shown) arranged in series, rotation of a single laminator may be prohibited due to the proximity of adjacent laminators, which may limit the gap between laminators during rotation. Advantageously, avoiding the need to rotate the currently disclosed laminator 142 can significantly reduce cost and complexity.

[0039] As described in more detail below, the layup material 168 distributed by each laminator 142 Figure 13 Originally composed of a backing layer 180 ( Figure 13 ) Supported and wound around material roll 164 ( Figure 12The backing layer 180 may be formed of a material that prevents adjacent layup materials 168 from sticking together on the material roll 164. Furthermore, the backing layer 180 may provide a mechanism for bearing tension when the layup materials 168 are pulled (e.g., through the backing layer collection roller 190) through the laminator head 142 without applying tension to them. The backing layer 180 may be a paper material coated with siloxane on one side, or the backing layer 180 may be a thin plastic film, such as a polyethylene film, or another material for peelably supporting the layup materials 168. Each laminator head 142 includes a backing layer separation assembly 200 as described below. Figure 6 It is used to separate the layup material 168 from the backing layer 180 just before the layup material 168 is applied to the substrate 122.

[0040] Advantageously, each laminator 142 is configured such that the separation of the layup material 168 from the backing layer 180 occurs at a relatively short distance from the compaction devices 240, 242 (e.g., see...). Figure 16 and 22 At this location, and in a manner that reduces or eliminates tension in the unsupported section 174 of the laying material just before it is compacted onto the substrate 122 by the compaction devices 240, 242 (e.g., see...). Figure 16 and 22 Reducing or eliminating tension in the layup 168 before compaction onto the substrate 122 advantageously reduces the stretching of the layup 168 relative to the increased stretching that might occur in the layup material 168 dispensed from a conventional laminator. When stretched layup material (not shown) is applied to the substrate 122 (e.g., previously applied layup material), the stretched layup material will attempt to shrink back to its nominal or unstretched length. However, previously applied layup material, such as a 0-degree composite strip with axially oriented reinforcing fibers (not shown), resists the shrinkage of the stretched layup material and causes bundled or localized lifting of the composite sheets or layers of the composite laminate. Unless the composite laminate is reprocessed, bundled and / or localized lifting may accumulate with subsequently applied layup material. Advantageously, in the currently disclosed laminator 142, reducing the stretching of the layup material 168 before compaction onto the substrate 122 reduces or eliminates localized bundled (bundling) that might otherwise occur in the composite laminate 196. Figure 5 In this respect, the currently disclosed laminating head 142 improves the quality of the final composite laminate (not shown).

[0041] As mentioned above, in Figure 1-5 In the example manufacturing system 100, the laminating head 142 is stationary and configured to sequentially apply layup material 168 to the movable laminating head 124 and previously applied layup material 168 during one or more passes of the laminating head 124 over the laminating table 140. Figure 5When the laminating mandrel 124 travels along the first direction of travel 150 ( Figure 12 ) and along the second direction of travel 152 ( Figure 18 When passing under the laminating head 142, the laminating head 142 collectively distributes multiple layers 194 of the laying material 168. Figure 5 Each of the laminators 142 in this series can be assigned a layup material 168 having a material configuration corresponding to the desired stacking order of the final composite laminate. The outer surface of the laminator mandrel 124 may include a plurality of holes 126. Figure 5 It can be connected (e.g., via an internal fluid conduit - not shown) to a vacuum pressure source 128. Figure 4 The activation of the vacuum pressure source 128 can generate vacuum pressure via a hole 126 on the outer surface of the lamination mandrel 124, as a means of securing the layup material 168 in place on the lamination mandrel 124 during the dispensing of the layup material 168 through the lamination head 142. In some instances, a release film (not shown) can be applied (e.g., via the lamination head 142) to the lamination surface (e.g., the lamination mandrel 124). The release film can be perforated to allow vacuum pressure at the hole 126 to be vacuum-coupled to the composite laminate 196 laid on top of the release film.

[0042] refer to Figure 1-4 The manufacturing system 100 may include a base member 104 supported on a surface such as a factory floor. As described above, the lamination surface 120 may be configured as a lamination mandrel 124. The lamination mandrel 124 may move or slide along a longitudinal guide rail 130 extending along the length of the base axis 104. For example, the manufacturing system 100 may include a mandrel translation mechanism (not shown), such as a screw drive coupled to a drive motor, for autonomously moving the lamination mandrel 124 under the control of a controller 112. The mandrel translation mechanism may move the lamination mandrel 124 between a home position 132 of the lamination surface on one side of the lamination table 140 and a rear position 134 of the lamination surface on the opposite side of the lamination table 140.

[0043] In the illustrated example, the laminator 142 can be supported by a laminator support structure 102. The laminator support structure 102 may include a longitudinal beam 110 to which the laminator 142 can be mounted. Opposite ends of the longitudinal beam 110 may be respectively connected to a pair of crossbeams 108. Opposite ends of each crossbeam 108 may be supported by vertically oriented supports 106 extending upwards from the plant floor. However, the laminator support structure 102 can be provided in any of a variety of optional configurations and is not limited to this. Figure 1-4 The configuration shown.

[0044] As an alternative to the movable laminating mandrel 124, the laminating surface 120 can be configured as a continuous annular laminating strip (not shown) supported by a series of internal belt rollers (not shown) and rotatably driven by a drive motor (not shown). The laminating strip may include an outer surface onto which the laminating head 142 dispenses layup material 168. In another example of the manufacturing system 100, the laminating surface 120 may be stationary, and the laminating head 142 may be movable above the laminating surface 120 to dispense layup material 168 for laying the composite laminate 196. For example, the laminating head 142 may be supported by a gantry (not shown), a track mounting system (not shown), or a cantilever support system (not shown) for moving the laminating head 142 along a first travel direction 150 and a second travel direction 152 while dispensing layup material 168 onto the laminating surface 120. In another example, manufacturing system 100 may include one or more robotic devices (not shown) for moving laminating heads 142 on laminating surface 120. In any of the above examples, manufacturing system 100 is not limited to a series of end-to-end laminating heads 142, but may include a single laminating head 142 movable relative to laminating surface 120 along a first travel direction 150 and a second travel direction 152 for laying composite laminate 196. Furthermore, laminating surface 120 is not limited to a generally flat, elongated laminating surface 120, such as the currently disclosed laminating mandrel 124. For example, laminating surface 120 may be a movable laying tool, such as a rotatable laying mandrel (not shown).

[0045] refer to Figure 6-7 An example of a laminator 142 with bidirectional laying capability for laying composite laminate 196 is shown. Figure 5 The laminator head 142 includes a material supply roller 160, a cutter assembly 270, a backing layer separation assembly 200, first and second compaction devices 240, 242, and a backing layer collection roller 190, each of which can be supported by a mounting frame 144. The mounting frame 144 can be configured as a flat plate structure or a truss structure and can be mechanically and stably connected to the laminator head support structure 102.

[0046] Material supply roller 160 is configured to support material roll 164 of backing material 166. Backing layer separation assembly 200 is configured to separate layup material 168 from backing layer 180 and guide layup material 168 toward substrate 122. Cutter assembly 270 is configured to cut layup material 168 as laminator head 142 approaches designated start and end positions of layer 194 of layup material 168 dispensed by laminator head 142. Backing layer collection roller 190 is configured to roll up or wind backing layer 180 onto backing layer collection roller 190 after the laminate material 168 has been separated from backing layer 180 by backing layer separation assembly 200.

[0047] exist Figure 6-7 In the image, the laminating head 142 is shown on the backing material 166 ( Figure 12 Before the aforementioned parts pass through the laminating head 142. The backing material 166 comprises a continuous backing layer 180 ( Figure 12 ) The continuous length or strip of backing material 168 ( Figure 12 In some instances, layup material 168 may be a composite material, such as a continuous strip of fiber-reinforced polymer matrix material (e.g., prepreg tape). The matrix material may be a thermosetting or thermoplastic resin. The reinforcing fibers may be glass fibers (e.g., fiberglass), carbon fibers, boron, aramid, metal fibers, ceramic fibers, or other fibrous materials. In one instance, composite layup material 168 may be a carbon fiber epoxy prepreg tape. The composite material may be a unidirectional or multidirectional tape (e.g., woven or fabric tape). The width of layup material 168 may be up to 12 inches or greater.

[0048] As an alternative to composite materials, layup material 168 can be a continuous strip of non-composite material backed by backing layer 180. For example, layup material 168 can be a metal foil or metal mesh backed by backing layer 180. In other instances, layup material 168 can be a processing material that assists in the processing (e.g., shaping, consolidation, curing, treatment) of composite laminate 196. Examples of non-composite layup materials include release films, tackifier films, breathable layers, venting layers, release sheets, or any of a variety of other types of non-composite layers, films, or adhesives that can be dispensed by laminator head 142 before, during, or after the laying of composite laminate 196.

[0049] Still refer to Figure 6-7The laminator head 142 may also include one or more guide rollers 146 mounted to the mounting frame 144. Furthermore, the laminator may include one or more guide surfaces 148, which may have a larger radius of curvature than the guide rollers 146. The larger radius of curvature of the guide surfaces 148 can facilitate the initial passage of the backing material 166 through the laminator head 142. In the example shown, the laminator head 142 includes two guide surfaces 148, each having an approximately quarter-annular shape. The guide rollers 146 and the guide surfaces 148 can guide the backing material 166 (… Figure 12 ) through the cutter assembly 270 of the laminating head 142 Figure 12 ) and backing layer separation assembly 200. For example, guide surfaces 148 located above and below the cutter assembly 270, respectively, can facilitate the separation of backing material 166 ( Figure 12 The tension of the backing layer 180 is controlled to precisely control the laying material 168 without cutting the backing layer 180. Figure 12 ) cut.

[0050] In this respect, guide roller 146 and guide surface 148 can define the path of backing material 166 through laminating head 142 to prevent it from being misaligned during the distribution of layup material 168 when laminating head 142 is in the first travel direction 150 ( Figure 12 When the laminating head 142 moves upward and when the laminating head 142 moves in the second travel direction 152 ( Figure 18 As it moves, the backing material 166 comes into contact with the first and second compaction devices 240, 242, the first and second separation devices 202, 218, and other components of the laminating head 142.

[0051] like Figure 6 As shown, the cutter assembly 270 may include a cutter module 272 and a cutter platen 274. The cutter platen 274 may be fixedly mounted to the mounting frame 144. The cutter module 272 may have at least one cutter blade 276. Figure 8 To provide clearance for the backing material 166 (e.g., at least backing layer 180) to pass through the cutter assembly 270, the cutter module 272 can be configured to horizontally translate away from the cutter table 274 back to its original module position (not shown), in which the cutter module 272 and the cutter table 274 are spaced apart from each other. When ready to cut the layup material 168, the cutter module 272 can be horizontally translated toward the cutter table 274 back to the module engagement position, in which the backing material 166 is sandwiched between the cutter module 272 and the cutter table 274, as shown. Figure 12As shown. The depth of the cutter blade 276 can be precisely controlled to cut only the layup material 168 without cutting the backing layer 180. The processor can control the cutter assembly 270 in such a way that it cuts only the layup material 168 at each layer 194 (as dispensed by the laminating head 142). Figure 5 Cut the laying material 168 before it begins, and cut the laying material 168 just before the laminating head 142 reaches the predetermined end point of layer 194.

[0052] As described below, the cutting line 282 in the laying material 168 (e.g., Figure 9-11 This generates a leading edge 176 of the paving material and a trailing edge 178 of the paving material adjacent to the leading edge 176. When the leading edge 176 of the paving material reaches the first corner 204 ( Figure 15 ) or second horn-shaped object 220 ( Figure 21 When the distal end 206 of the corner is reached, the leading edge 176 of the laying material is peeled off from the backing layer 180 and toward the substrate 122 and respectively in the first compaction device 240 ( Figure 15 ) or second compaction device 242 ( Figure 21 The laminator is guided downwards, depending on whether the laminator head 142 is along the first travel direction 150. Figure 13 ) or second direction of travel 152 ( Figure 19 (Movement, as described in more detail below.)

[0053] refer to Figure 8-11 This illustrates the progress of the cut line 282 formed in the layup material 168 as the backing material 166 moves through the cutter assembly 270 at a material feed rate. Figure 8 The image shows the cutter blade 276 at the starting position of a predetermined cut line 282 before it moves along the blade path angle through the backing material 166. The cutter blade 276 can be configured to cut the laying material 168 as the backing material 166 moves along the cutter table 274. Figure 9-10 The diagram illustrates a cutter blade 276 moving at a blade speed defining a blade travel vector 278 along a flat path angle for cutting the backing material 168 along a predetermined cut line 282. The blade travel vector 278 may have a longitudinal component 282 parallel to the longitudinal direction of the backing material 166. The longitudinal component 282 of the blade travel vector 278 is proportional to the material feed rate. Figure 11 The cutting line 282 formed in the laying material 168 is shown.

[0054] As previously described, the depth of the cutter blade 276 can be precisely controlled so that the backing layer 180 remains at least partially intact after cutting the layup material 168. In the illustrated example, the predetermined cutting line 282 is oriented perpendicular to the longitudinal direction of the backing material 166. Therefore, the longitudinal component 282 of the blade travel vector 278 is equal to the material feed rate. For predetermined cutting lines 282 that are not perpendicular to the longitudinal direction of the backing material 166 (not shown), the longitudinal component 282 of the blade travel vector 278 is less than or greater than the material feed rate. Advantageously, moving the cutter blade 276 along the aforementioned blade travel vector 278 enables the cutting of the layup material 168 without stopping the application of the layup material 168 to the substrate 122.

[0055] Backing layer separation assembly 200 (e.g., Figure 12 It is configured to receive backing material 166 after passing through cutter assembly 270, as described above. Figure 6-7 As shown, the backing layer separation assembly 200 includes a first separation device 202 and a second separation device 218. The first separation device 202 includes a first horn 204, which is available in a retracted position 224 associated with the first separation device 202. Figure 7 ) and the separation device extension position 226 ( Figure 12-13 The second separating device 218 includes a second horn 220, which is also movable between the separating device retracted position 224 associated with the second separating device 218. Figure 7 ) and the separation device extension position 226 ( Figure 18-19 Move between ).

[0056] like Figure 7 As shown, the first separation device 202 may include a first separation device actuator 216, which is configured as a linear actuator 228 to move the first horn 204 between a separation device retracted position 224 and a separation device extended position 226 associated with the first separation device 202. Figure 12-13 The second separation device 218 may include a second separation device actuator 222, which is also configured as a linear actuator 228 to move the first horn 204 between a separation device retracted position 224 and a separation device extended position 226 associated with the second separation device 218. Figure 18-19 In the illustrated example, each linear actuator 228 can be configured as a pneumatic actuator having a cylinder 230 and a rod 232 extending from the cylinder 230. The linear actuator 228 can be a single-acting actuator or a double-acting actuator. Alternatively, the linear actuator 228 can be a hydraulic actuator or an electromechanical actuator.

[0057] Regardless of their specific configuration, the first separating device 202 and the second separating device actuator 222 each provide a simple mechanism for moving the first corner 204 and the second corner 220 close to the first compaction device 240 and the second compaction device 242, respectively. As described above, the ability to position the first corner 204 and the second corner 220 close to the first compaction device 240 and the second compaction device 242, respectively, advantageously reduces the length of the unsupported segment 174 of the layup material between the distal end 206 of the corner and the base 122 (e.g., see...). Figure 16 and 22 This reduces or minimizes undesirable tension and stretching of the material 168 before it is compacted onto the substrate 122. Figure 16 and 22 As shown and described below, the unsupported section 174 of the laying material is located between the laying material compaction point 172 associated with the first or second compaction device 240, 242, and the laying material separation point 170 on the distal end 206 of the corner (i.e., the first or second corner 204, 220, respectively), where the laying material 168 separates from the backing layer 180.

[0058] The laminator 142 also includes a first compaction device 240 and a second compaction device 242, each configured to apply compaction pressure against the substrate 122 as the laminator 142 dispenses the layup material 168. For example, the first compaction device 240 is configured to apply compaction pressure to the layup material 168 when the laminator 142 travels along a first direction of travel 150 (…). Figure 16 The compaction point 172 of the paving material below the first compaction device 240 during movement Figure 16 The second compaction device 242 is configured to apply compaction pressure to the laying material 168 at the location where the laminator 142 is against the substrate 122. The second compaction device 242 is configured to apply compaction pressure to the laying material 168 when the laminator 142 travels along the second direction of travel 152. Figure 22 During movement, the compaction point 172 of the paving material below the second compaction device 242 ( Figure 22 The compaction pressure is applied to the layup material 168 by abutting against the substrate 122. Although shown as a compaction roller 244, the first and second compaction devices 240, 242 can be provided in optional configurations. For example, the first and second compaction devices 240, 242 can each be configured as a compaction shoe (not shown), or as an elastic compressible compaction bladder (not shown) for sliding the layup material 168 onto a corrugated lamination mandrel (not shown) having an outer surface having a non-planar cross-sectional shape.

[0059] Reference Figure 7The first compaction device 240 may include a first compaction device actuator 248, which is configured as a linear actuator 228 to operate in a compaction device retracted position 260 (e.g., raised position) and a compaction device extended position 262 (e.g., lowered position) associated with the first compaction device 240. Figure 12-13 The first compaction device 240 can be moved between [positions]. Similarly, the second compaction device 242 may include a second compaction device actuator 250, which is also configured as a linear actuator 228 to move between a compaction device retracted position 260 (e.g., raised position) and a compaction device extended position 262 (e.g., lowered position) associated with the second compaction device 242. Figure 18-19 The second compaction device 242 moves between the first and second compaction devices 240 and 242. When the compaction device is in the retracted position 260, the first or second compaction device 240, 242 may be in a non-contact relationship with the substrate 122. When the compaction device is in the extended position 262, the first or second compaction device 240, 242 may be in contact with the substrate 122. In this disclosure, the substrate 122 may be described as the surface of the lamination mandrel 124 or the most recently distributed layer 194 of the layup material 168.

[0060] The first compaction device 240 may include a first compaction device actuator 248. The second compaction device 242 may include a second compaction device actuator 250. The first compaction device actuator 248 and / or the second compaction device actuator 250 may be configured as linear actuators 228 to move the first compaction device 240 and the second compaction device 242 between a compaction device retracted position 260 and a compaction device extended position 262, respectively. For example, as Figure 13 As shown and described below, when the first compaction device 240 is in the extended compaction device position 262, the second compaction device 242 can be in the retracted compaction device position 260. Figure 19 As shown, when the second compaction device 242 is in the compaction device extended position 262, the first compaction device 240 can be in the compaction device retracted position 260.

[0061] exist Figure 7 In the example, both the first compaction actuator 248 and the second compaction actuator 250 are configured as linear actuators 228. The linear actuator 228 can be a pneumatic actuator having a cylinder 230 and a rod 232 extending from the cylinder 230. However, as described above with respect to the first and second separation actuators 216, 222, the first and second compaction actuators 248, 250 can be hydraulic or electromechanical actuators. In the illustrated example, the first compaction actuator 248 and the second compaction actuator 250 can be oriented such that the rod 232 of the linear actuator 228 is vertically oriented, which simplifies the installation and operation of the linear actuator 228.

[0062] like Figure 12-13 As shown and described in more detail below, when the first separating device 202 is in the separating device extended position 226, the first angular object 204 is closely adjacent to the laying material compaction point 172 associated with the first compaction device 240. Figure 16 The first angular member 204 is configured to separate the layup material 168 from the backing layer 180 and guide the layup material 168 toward the substrate 122 and below the first compaction device 240 as the laminator head 142 moves along the first travel direction 150. Figure 18-19 As shown and described in more detail below, when the second separating device 218 is in the separating device extended position 226, the second horn 220 is closely adjacent to the laying material compaction point 172 associated with the second compaction device 242. Figure 22 The second horn 220 is configured to separate the layup material 168 from the backing layer 180 and guide the layup material 168 toward the substrate 122 and below the second compaction device 242 when the laminator 142 moves along a second travel direction 152 opposite to the first travel direction 150.

[0063] exist Figure 7 In this configuration, each of the first horn 204 and the second horn 220 has a distal end 206. The distal end 206 may have a relatively small radius of curvature 214 to separate the leading edge 176 of the layup material from the backing layer 180 as the backing layer 180 moves about the distal end 206. As described in more detail below, both the first horn 204 and the second horn 220 are configured such that the leading edge 176 of the layup material separates from the backing layer 180 (e.g., ...). Figure 15 and 21 The separation of the laying material causes the leading edge 176 to face the substrate 122 and is below the first and second compaction devices 240 and 242, respectively. Figure 16 and 22 The radius of curvature 214 of the distal end 206 of the corner causes the bending stiffness of the layup 168 (i.e., in the axial direction) to result in a peel force that pushes the layup 168 away from the backing layer 180 as the backing layer 180 moves about the distal end 206 of the corner. At this point, the relatively small radius of curvature 214 causes the peel force of the layup 168 to exceed the adhesive strength between the layup 168 and the backing layer 180, resulting in the separation of the layup 168 from the backing layer 180.

[0064] In addition to the laying material leading edge 176 ( when the backing layer 180 moves around the distal end 206 of the corner), Figure 15 and 21Apart from being separated from the backing layer 180, the relatively small radius of curvature 214 allows the distal ends 206 of the first and second corners 204 and 220 to be close to the outer surface 246 of the compaction device of the first and second compaction devices 240, 242 (e.g., compaction rollers 244), respectively. Compared to the length of the unsupported section 174 of the layup material that would otherwise occur if the distal ends 206 had a large radius of curvature 214, by positioning the distal ends 206 close to the outer surface 246 of the compaction device, the unsupported section 174 of the layup material between the distal ends 206 and the compaction point 172... Figure 16 and 22 The length of ) can be reduced.

[0065] Still refer to Figure 7 The first separation device actuator 216 and the second separation device actuator 222 may each include an actuator axis 234. The actuator axis 234 of the first separation device actuator 216 may be oriented to intersect with the actuator axis 234 of the second separation device actuator 222, which may allow the first and second separation devices 202, 218 to be positioned close to each other. In the example shown, when the first corner 204 is in the separation device retracted position 224, the first corner 204 is positioned on one side of the actuator axis 234 of the second separation device actuator 222, providing a gap for the second corner 220 to move between the separation device retracted position 224 and the separation device extended position 226. When the second angular member 220 is in the retracted position 224 of the separating device, the second angular member 220 is positioned on one side of the actuator axis 234 of the first separating device actuator 216, providing a gap for the first angular member 204 to move between the retracted position 224 and the extended position 226 of the separating device. As described below, the first separating device 202 is configured to move the first angular member 204 from the retracted position 224 of the separating device. Figure 7 Move to the extended position of the separation device 226 ( Figure 12-13 This allows the laminating head 142 to dispense the layup material 168 while moving along the first travel direction 150. Similarly, the second separating device 218 is configured to retract the second horn 220 from the separating device into position 224. Figure 7 Move to the extended position of the separation device 226 ( Figure 18-19 This allows the laminating head 142 to distribute the layup material 168 while moving along the second travel direction 152.

[0066] exist Figure 7In this configuration, the actuator axes 234 of the first separation device actuator 216 and the second separation device actuator 222 can be oriented at an angle of less than 60 degrees relative to the surface of the substrate 122. Optionally, the orientation angles of the actuator axes 234 of the first and second separation device actuators 216 and 222 can be respectively relative to the first travel direction 150°. Figure 13 ) and second direction of travel 152 ( Figure 19 Measurements are performed. In one example, each actuator axis 234 may be oriented at an angle of less than 30 degrees relative to the surface of the substrate 122. The actuator axis 234 of the first separation device actuator 216 may be oriented in the downstream direction (e.g., relative to the first travel direction 150 of the laminator head) and toward the layup material compaction point 172 of the first compaction device 240, pointing toward the distal end 206 of the corner of the first corner 204. Similarly, the actuator axis 234 of the second separation device actuator 222 may be oriented in the downstream direction (e.g., relative to the second travel direction 152 of the laminator head) and toward the respective layup material compaction point 172 of the second compaction device 240, pointing toward the respective distal end 206 of the corner of the second corner 220.

[0067] By oriented the axes 234 of each actuator of the first and second separation devices 202, 218 at relatively small angles relative to the surface of the substrate 122, the first horn 204 and the second horn 220 can each be positioned at relatively small distances from the compaction points 172 of the layup material associated with the first and second compaction devices 240, 242, respectively, and this results in a shorter length of the unsupported section 174 of the layup material. Figure 16 and 22 In this disclosure, the term "unsupported segment of the layup material" refers to a longitudinal segment of the layup material 168 that is not supported by the backing layer 180 and does not contact the substrate 122. As described below, the combination of the relatively small radius of curvature 214 of the distal end 206 of the corner ridge and the relatively small angle of the actuator axis 234 of the first and second separation device actuators 216, 222 allows the first and second corner ridges 204, 220 to be positioned close to the layup material compaction point 172 of the first and second compaction devices 240, 242, respectively, and this allows for a relatively short length of the unsupported segment 174 of the layup material.

[0068] Now for reference Figure 12-13This illustrates an example of the laminating head 142 dispensing layup material 168 while moving relative to the lamination surface 120 along a first travel direction 150. When the laminating head 142 is ready to move in the first travel direction 150, the first compaction device 240 (e.g., compaction roller 244) descends to the compaction device extended position 262 and contacts the substrate 122 (e.g., the outer surface of the lamination mandrel 124), and the first angle 204 of the first separating device 202 extends toward the first compaction device 240. With the first angle 204 in the separating device extended position 226, the layup material 168 separates from the backing layer 180 and is compacted onto the substrate 122 by the first compaction device 240, while the lamination moves along the first travel direction 150. The second compaction device 242 is in the compaction device retracted position 260 (e.g., raised position). The second angle 220 of the second separating device 218 is in the retracted position 224 (e.g., raised position).

[0069] Reference Figure 14 The diagram shows a first horn 204 in the extended position 226 of the separating device, with its distal end 206 positioned within a first cut region 256 defined by the first compaction device 240 and the base 122. More specifically, the first cut region 256 may be defined by the compaction device outer surface 246 of the first compaction device 240, a horizontal tangent 252 (e.g., coinciding with the base 122) at the lowest point on the compaction device outer surface 246, and a vertical tangent 254 on the compaction device outer surface 246.

[0070] refer to Figure 15 The diagram shows the leading edge 176 of the layup material after it has separated from the backing layer 180 and moved toward the substrate 122 as the backing layer 180 moves around the distal end 206 of the first corner 204. The first corner 204 is oriented and configured to facilitate the separation of the layup material 168 from the backing layer 180 and to guide the layup material 168 toward the substrate 122 and below the first compaction device 240. In this respect, the first corner 204 may have a generally triangular cross-sectional shape with a rounded distal end 206. One side of the triangular cross-sectional shape of the first corner 204 may guide the layup material 168 toward the substrate 122 for compaction below the first compaction device 240. As described above, the distal end 206 may have a relatively small radius of curvature 214, which causes the layup material 168 to separate from the backing layer 180. The opposite sides of the triangular cross-sectional shape of the first angular member 204 can be oriented to be substantially aligned with the backing layer collecting roller 190, such as Figure 12 As shown.

[0071] refer to Figure 16The image shows an enlarged view of the first corner 204 in the separation device extended position 226, while layup material 168 is dispensed from the laminating head 142, which moves relative to the laminating mandrel 124 along a first travel direction 150. The distal end 206 of the corner is close to the outer surface 246 of the compaction device. The relatively small radius of curvature 214 of the distal end 206 causes the bending stiffness of the layup material 168 (i.e., in the axial direction) to result in a peel force exceeding the adhesive strength between the layup material 168 and the backing layer 180, which causes the layup material 168 to separate from the backing layer 180 at a layup separation point 170 on the distal end 206 of the corner. In some examples of the laminating head 142, the radius of curvature 214 of the distal end 206 of the first corner 204 and / or the second corner 220 can be in the range of approximately 0.25-1.0 inches. However, in other instances of the laminator 142, the distal end 206 of the corner may have a radius of curvature 214 of less than 0.25 inches or greater than 1.0 inch.

[0072] Figure 16 The diagram also shows an unsupported segment 174 of the layup material extending between the layup material separation point 170 on the distal end 206 of the corner and the layup material compaction point 172 between the first compaction device 240 and the substrate 122. As described above, the ability to position the distal end 206 of the corner close to the substrate 122 and the outer surface 246 of the compaction device results in a relatively short length of the unsupported segment 174 of the layup material, which reduces undesirable stretching of the unsupported segment 174 of the layup material. As described above, reducing the stretching of the layup material 168 reduces or eliminates localized bunching and / or lifting of the layup material 174, which can accumulate in the continuously applied layers 194 of the composite laminate 196 unless the composite laminate 196 is reprocessed. Figure 5 )middle.

[0073] Reference Figure 17 The arrangement of the first horn 204 is shown, wherein the distal end 206 of the horn includes a roller 210 configured to rotate freely about the roller axis 212 as the backing layer 180 moves over the distal end 206 of the horn. Figure 17 Roller 210 in the middle is Figure 16 An alternative embodiment of the distal end 206 of the corner shown is configured as a sliding surface 208 or a low-friction surface to facilitate free sliding of the backing layer 180 on the distal end 206 of the corner. The sliding surface 208 may be a relatively smooth or polished surface and may be formed of a metallic or non-metallic material. For example, the sliding surface 208 of the distal end 206 of the corner may include a low-friction coating, such as Teflon. TM .

[0074] As described above, when the laminating head 142 approaches the end of its stroke, the cutter assembly 270 ( Figure 12 ) forming a cutting line 282 across the width of the paving material 168 ( Figure 11 Simultaneously, the backing material 166 moves through the cutter assembly 270. The cutting line 282 defines the leading edge 176 and trailing edge 178 of the layup material. When the cutting line 282 in the layup material 168 reaches the layup separation point 170 on the first corner 204... Figure 16 When the backing layer collecting roller is 190 ( Figure 12 The rotation of the backing material 166 can be temporarily stopped to halt the movement of the backing material 166 through the laminating head 142, thereby preventing the leading edge 176 of the layup material from being laid. Figure 11 ) Follow the rear edge of the paving material 178 ( Figure 11 The laminating head 142 continues to move along the first travel direction 150 until the trailing edge 178 of the layup material has been compacted onto the substrate 122 by the first compaction device 240. The trailing edge 178 of the layup material defines the end of layer 194 of the layup material 168. The movement of the laminating head 142 can then stop, the first compaction device 240 retracts from the substrate 122, and the first corner 204 retracts from the first compaction device 240, as... Figure 18 As shown.

[0075] refer to Figure 18-19 Approximately simultaneously with the retraction of the first compaction device 240 and the first separation device 202, the second compaction device 242 descends to its compaction device extension position 262 onto the substrate 122, and the second horn 220 extends to its separation device extension position 226 near the second compaction device 242. As the second horn 220 moves to the separation device extension position 226, the laminating head 142 begins to move along a second travel direction 152 opposite to the first travel direction 150, and the rotation of the backing layer collection roller 190 resumes, thus restoring the pulling of the backing material 166 over the laminating head 142. When the aforementioned layup material leading edge 176 ( Figure 11 ) Reaching the material separation point 170 on the second angular object 220 ( Figure 22 When laying the material, the leading edge 176 separates from the backing layer 180 and faces the substrate 122. Figure 21 The compactor moves below the second compaction device 242 to begin laying another layer 194 of material 168. This process continues until layer 194 of material 168 is laid. Figure 5 A predetermined amount of ) is applied to the substrate 122, resulting in an uncured composite laminate 196 ( Figure 5 ).

[0076] like Figure 20 As shown, the distal end 206 of the second horn 220 at the extension position 226 of the separating device can extend into the second cut area 258 associated with the second compaction device 242, similar to the above description. Figure 14 The first cut region 256 associated with the first angular member 204 is shown. Figure 20 In the second angle 220, the second cut area 258 can be defined by the outer surface 246 of the second compaction device 242, the horizontal tangent 252 of the lowest point of the outer surface 246 of the compaction device 242 (e.g., coinciding with the base 122), and the vertical tangent 254 of the outer surface 246 of the second compaction device 242.

[0077] Figure 21 The image shows the leading edge 176 of the layup material after it separates from the backing layer 180 and moves toward the substrate 122 as the backing layer 180 moves around the distal end 206 of the second corner 220. The second corner 220 can be configured similarly to the first corner 204 described above. For example, the second corner 220 can have a triangular cross-sectional shape, wherein one side of the triangular cross-sectional shape guides the layup material 168 toward the substrate 122 for compaction under the second compaction device 242. The opposite side of the triangular cross-sectional shape of the second corner 220 can guide the backing layer 180 toward a guide roller 146 positioned adjacent to the second compaction device 242. Figure 19 Orientation. Guide roller 146 can be redirected toward backing layer collecting roller 190. Figure 18 ) Guide backing layer 180.

[0078] Reference Figure 22 The distal end 206 of the second corner 220 may have a relatively small radius of curvature 214 and may be configured as any of the aforementioned configurations of the first corner 204. The small radius of curvature 214 of the distal end 206 of the second corner 220 allows the layup material 168 to separate from the backing layer 180 at the layup material separation point 170 on the distal end 206, similar to the configuration of the first corner 204. The close proximity of the second corner 220 to the second compaction device 242 results in a relatively short length of the unsupported segment 174 of the layup material between the layup material separation point 170 and the layup material compaction point 172 below the second compaction device 242, and this prevents undesirable stretching of the unsupported segment 174 of the layup material, thereby reducing or avoiding localized bunching or lifting of the layup material 174 of the composite laminate 196. Figure 5 ).

[0079] The movement of the laminating head 142 relative to the laminating surface 120 (e.g., laminating mandrel 124) can be controlled by a controller 112 that executes computer-readable program instructions (e.g., a numerical control program). Figure 1 ) control. In addition, the controller 112 can also control the operation of the cutter assembly 270. Figure 6 ), rotation of material supply roller 160 ( Figure 6), the rotation of the backing layer collecting roller 190 ( Figure 6 The extension and retraction of the first and second angular members 204 and 220 Figure 6 ), and the extension and retraction of the first and second compaction devices 240, 242 ( Figure 6 For example, controller 112 can be connected to collection drum drive motor 192. Figure 6 The operation synchronously translates the lamination mandrel 124 ( Figure 1 The backing layer collecting roller 190 (e.g., optionally coordinated with the rotational speed of the supply roller drive motor 162) is used to pull the backing material 166 through the laminating head 142, while maintaining a constant tensile load in the backing layer 180 during the dispensing of the layup material 168 from the laminating head 142. Further at this point, the controller 112 can control the movement of the laminating mandrel 124 and the rotational speed of the backing layer collecting roller 190 and / or the material supply roller 160, thereby allowing the unsupported section 174 of the layup material (e.g., ...) to... Figure 16 and 22 Any tensile load in the backing layer 180 is lower than the tensile load in the backing layer 180.

[0080] Reference Figure 23 A method 300 is shown for applying layup material 168 bidirectionally onto a substrate 122 using a laminator 142. Method 300 may include supporting a material supply roller 160, a backing layer collection roller 190, a backing layer separation assembly 200, a first compaction device 240, and a second compaction device 242 on a mounting frame 144. In the illustrated example, the mounting frame 144 may be supported by a laminator support structure 102 configured to suspend the laminator 142 above a movable lamination surface 120, such as a lamination mandrel 124. Alternatively, the mounting frame 144 may be supported on a mobile system, such as a gantry (not shown) or a robotic device (not shown), to move the laminator 142 on a fixed lamination surface (not shown) or a movable lamination surface 120.

[0081] Step 302 of method 300 includes feeding backing material 166 from material roll 164 to backing layer separation assembly 200 of laminating head 142. As described above, material roll 164 is mounted on material supply roller 160. Backing material 166 includes layup material 168 backed by backing layer 180. As described above, backing layer separation assembly 200 has a first separation device 202 and a second separation device 218, which respectively have a first corner 204 and a second corner 220.

[0082] Step 304 of method 300 includes moving the first corner 204 close to the laying material compaction point 172 associated with the first compaction device 240. Before performing step 304 of moving the first corner 204, method 300 may include retracting the second corner 220 away from the second compaction device 242 to a position that provides a clearance for the first corner 204 to move between a retracted position 224 and a protruding position 226 of the first corner 204. Step 304 may include actuating the first separation device actuator 216 to move the first corner 204 between the retracted position 224 and the protruding position 226 associated with the first corner 204. In the above example, the first corner 204 may be mounted on the end of a rod 232 extending from the cylinder 230 of the first separation device actuator 216. Movement of the first angle 204 can be performed by extending a rod 232 from the cylinder 230, wherein the rod 232 defines the actuator axis 234 of the first separation device actuator 216. In such an arrangement, step 304 may include moving the first angle 204 along the actuator axis 234, which may be oriented at an angle of less than 60 degrees relative to the first direction of travel 150. The relatively shallow orientation angle of the actuator axis 234 allows the first angle 204 to be positioned relatively close to the base 122 and the compaction device outer surface 246 of the first compaction device 240.

[0083] Step 304, moving the first corner 204 close to the layup compaction point 172 associated with the first compaction device 240, may include moving the distal end 206 of the first corner 204 within 0.5 inches of the base 122 and / or the compaction device outer surface 246 of the first compaction device 240. In some instances, method 300 may include moving the distal end 206 of the first corner 204 into a first cut area 256 defined by the base 122 and the compaction device outer surface 246. As described above and Figure 14 As shown, the first cut area 256 can be defined by the base 122, the outer surface 246 of the first compaction device 240, and the vertical tangent 254 of the outer surface 246 of the compaction device.

[0084] Step 306 of method 300 includes using a first angle 204 to separate the layup material 168 from the backing layer 180, and guiding the layup material 168 toward a layup material compaction point 172 associated with the first compaction device 240 while moving the laminator head 142 along a first travel direction 150. Step 306 of using the first angle 204 to separate the layup material 168 from the backing layer 180 may include pulling the backing layer 180 past the generally triangular cross-sectional shape of the first angle 204. As described above, the triangular cross-sectional shape of the first angle 204 can guide the layup material 168 generally toward the layup material compaction point 172 below the first compaction device 240, and can also orient the backing layer 180 generally aligned with the backing layer collection roller 190.

[0085] Step 306, which uses the first corner 204 to separate the layup material 168 from the backing layer 180, includes pulling the backing layer 180 with a relatively small radius of curvature 214 around the distal end 206 of the corner 204, thereby separating the leading edge 176 of the layup material from the backing layer 180 as the backing layer 180 moves around the distal end 206. As described above, the relatively small radius of curvature 214 of the distal end 206 causes the bending stiffness of the layup material 168 to result in a peel force exceeding the adhesive strength between the layup material 168 and the backing layer 180, and resulting in the separation of the layup material 168 from the backing layer 180. Step 306 may optionally include pulling the backing layer 180 with a sliding surface 208 around the distal end 206. As described above, the sliding surface 208 may have a static (i.e., immovable) outer surface, which may be a low-friction surface or a coated surface. Optionally, step 306 may include pulling the backing layer 180 around the roller 210, the roller 210 being configured to rotate freely about the roller axis 212 as the backing layer 180 moves on the roller 210.

[0086] Method 300 may include moving a first compaction device 240 to a compaction device extension position 262, in which the first compaction device 240 contacts the substrate 122, after the layup material 168 has separated from the backing layer 180 and before contacting the substrate 122. The first compaction device 240 may be moved to contact the substrate 122 before, during, or immediately after the first angle 204 is moved close to the first compaction device 240. The first compaction device 240 may be moved to the compaction device extension position 262 by extending a rod 232 from a cylinder 230 of a first separation device actuator 216 mounted to the laminator head 142. Method 300 may include using the first compaction device 240 to compact the layup material 168 onto the substrate 122 while dispensing the layup material 168 from the laminator head 142 along a first travel direction 150. The first compaction device 240 may be configured as a compaction roller 244, a compaction plate, a compaction ball, or another compaction device configuration.

[0087] When the laminating head 142 moves along the first travel direction 150 to the end of layer 194 of the layup material 168 being applied to the substrate 122, method 300 includes step 308 of retracting the first corner 204 away from the first compaction device 240. As described above, once the trailing edge 178 of the layup material is compacted onto the substrate 122 by the first compaction device 240, the relative movement of the laminating head 142 along the first travel direction 150 can be stopped.

[0088] Step 310 of method 300 includes moving the second angle 220 close to the laying material compaction point 172 associated with the second compaction device 242. The second angle 220 may extend to be close to the second compaction device 242 almost simultaneously with or immediately after the first angle 204 retracts away from the first compaction device 240. Step 310 of moving the second angle 220 may include actuating the second separation device actuator 222 to move the second angle 220 between a separation device retracted position 224 and a separation device extended position 226 associated with the second angle 220. For example, step 310 may include extending a rod 232 from the cylinder 230 of the second separation device actuator 222, wherein the second angle 220 may be mounted at the end of the rod. Similar to the arrangement of the first angle 204 described above, the actuator axis 234 of the second separation device actuator 222 may be oriented at an angle of less than 60 degrees relative to the second direction of travel 152.

[0089] As described above, the relatively shallow orientation angle of the actuator axis 234 of the second separation device actuator 222 allows the second angle 220 to be positioned close to the substrate 122 and the outer surface 246 of the compaction device 242. Before moving the second angle 220 to the separation device extended position 226, step 310 may include retracting the first angle 204 from the second compaction device 242 to a position that provides clearance for the movement of the second angle 220 between the separation device retracted position 224 and the separation device extended position 226 of the second angle 220.

[0090] Step 310, which involves moving the second corner 220 close to the layup compaction point 172 associated with the second compaction device 242, may include moving the distal end 206 of the second corner 220 into a second cut area 258 associated with the second compaction device 242. Similar to the first cut area 256 of the first compaction device 240, the second cut area 258 of the second compaction device 242 may be defined by the substrate 122, the compaction device outer surface 246 of the second compaction device 242, and a perpendicular tangent 254 to the compaction device outer surface 246 of the second compaction device 242. In some instances, step 310 may include moving the second corner 220 within 0.5 inches of the substrate 122 and / or the compaction device outer surface 246 of the second compaction device 242.

[0091] Step 312 of method 300 includes using a second angle 220 to separate the layup material 168 from the backing layer 180, and guiding the layup material 168 toward a layup material compaction point 172 associated with the second compaction device 242 while moving the laminator head 142 in a second travel direction 152 opposite to the first travel direction 150. Step 312 of using the second angle 220 to separate the layup material 168 from the backing layer 180 may include pulling the backing layer 180 past the generally triangular cross-sectional shape of the second angle 220. The triangular cross-sectional shape of the second angle 220 may guide the layup material 168 generally toward the layup material compaction point 172 below the second compaction device 242, and may also orient the backing layer 180 toward a guide roller 146, which may then guide the backing layer 180 toward a backing layer collection roller 190.

[0092] Step 312 may include pulling the backing layer 180 around the relatively small radius of curvature 214 of the distal end 206 of the second corner 220, causing the leading edge 176 of the layup material to separate from the backing layer 180, similar to the separation of the layup material 168 from the backing layer 180 that moves around the first corner 204 as described above. In step 312, the backing layer 180 may be pulled around a sliding surface 208 of the distal end 206 of the second corner 220, or the backing layer 180 may be pulled around a freely rotatable roller 210 mounted on the distal end 206 of the second corner 220.

[0093] Method 300 may include moving a second compaction device 242 to contact the substrate 122 before the layup material 168 contacts the substrate 122. The second compaction device 242 may be configured as a compaction roller 244, a compaction plate, a compaction ball, or other compaction device configuration. The second compaction device 242 may be moved to contact the substrate 122 before, during, or immediately after the second corner 220 is moved to a position immediately adjacent to the second compaction device 242. Similar to the operation of the first compaction device 240 described above, the second compaction device 242 may be moved to a compaction device extension position 262 by extending a rod 232 from the cylinder 230 of the second separation device actuator 222. Method 300 may include using the second compaction device 242 to compact the layup material 168 onto the substrate 122 while dispensing the layup material 168 from the laminating head 142 along a second travel direction 152.

[0094] As the backing material 166 moves through the laminating head 142, method 300 may include defining a path for the backing material 166 through the laminating head 142 using one or more guide rollers 146 and / or guide surfaces 148. Furthermore, the guide rollers 146 and / or guide surfaces 148 can help maintain tension in the backing layer 180. In this respect, method 300 may include using a backing layer collection roller 190 to pull the backing material 166 through the laminating head 142 while maintaining a constant tension load in the backing layer 180 during the application of the layup material 168 to the substrate 122. As described above, the laminating head 142 may include a collection roller drive motor 192 for rotating the backing layer collection roller 190. Method 300 may include controlling the rotational speed of the collection roller drive motor 192 in coordination with the movement speed of the lamination surface 120 (e.g., lamination mandrel 124) so ​​that the layup material 168 is distributed onto the substrate 122, wherein the tension load in the unsupported section 174 of the layup material ( Figure 16 and 22 The tension load is lower than that in the backing layer 180. As described above, reducing or eliminating the tension in the unsupported section 174 of the layup material can prevent undesirable stretching of the layup material 168, which can thereby improve the quality of the final composite laminate (not shown).

[0095] Furthermore, this disclosure includes examples as described in the following enumerated paragraphs:

[0096] A1. A laminating head (142) with bidirectional laying capability for laying composite laminates (196), the laminating head (142) comprising: a material supply roller (160) configured to support a material roll (164) of backing material (166), the backing material (166) comprising layup material (168) backed by a backing layer (180); a first separating device (202) and a second separating device (218), each having a first horn (204) and a second horn (220), respectively. The horn-shaped object is movable between the retracted position (224) and the extended position (226) of the separating device; a first compaction device (240) and a second compaction device (242) are configured to alternately apply compaction pressure to the laying material (168) at the compaction point (172) against the substrate (122); wherein: when the first separating device (202) is in the extended position (226) and the first horn-shaped object (204) is close to the first compaction device When the associated compaction point (172) of the layup material is set (240), the first corner (204) is configured to separate the layup material (168) from the backing layer (180) and guide the layup material (168) toward the substrate (122) and below the first compaction device (240) when the laminating head (142) moves along the first travel direction (150); and when the second separation device (218) is in the separation device extended position (226) and the second When the horn (220) is close to the compaction point (172) of the layup material associated with the second compaction device (242), the second horn (220) is configured to separate the layup material (168) from the backing layer (180) and guide the layup material (168) toward the substrate (122) and below the second compaction device (242) as the laminating head (142) moves along a second travel direction (152) opposite to the first travel direction (150).

[0097] A2. According to the laminating head (142) of A1, wherein: the first separating device (202) and the second separating device (218) respectively have a first separating device actuator (216) and a second separating device actuator (222) configured as linear actuators (228) to move the first separating device (202) and the second separating device (218) respectively between the retracted position (224) and the extended position (226) of the separating device.

[0098] A3. According to the laminating head (142) of A2, wherein: the first separation device actuator (216) and the second separation device actuator (222) each have an actuator axis (234), the actuator axis (234) being oriented at an angle of less than 60 degrees relative to the first travel direction (150) and the second travel direction (152), respectively.

[0099] A4. According to the laminating head (142) of A2 or A3, wherein: the first separating device actuator (216) and the second separating device actuator (222) each have an actuator axis (234); the actuator axis (234) of the first separating device actuator (216) is oriented to intersect with the actuator axis (234) of the second separating device actuator (222); when the first separating device (202) is in the retracted position (224), the first horn (204) is on one side of the actuator axis (234) of the second separating device actuator (222), in order to provide the second The horn (220) provides a position for movement of the second separation device actuator (222) between the separation device retracted position (224) and the separation device extended position (226); and when the second separation device (218) is in the separation device retracted position (224), the second horn (220) is positioned on one side of the actuator axis (234) of the first separation device actuator (216) to provide the first horn (204) with a gap for movement of the first separation device actuator (216) between the separation device retracted position (224) and the separation device extended position (226).

[0100] A5. A laminator (142) according to any one of A1 to A4, wherein: each of the first corner (204) and the second corner (220) has a distal end (206); and the distal end (206) has a radius of curvature (214) configured to separate the layup material (168) from the backing layer (180) as the backing layer (180) moves about the radius of curvature (214) of the distal end (206).

[0101] A6. According to the laminator (142) of A5, wherein the radius of curvature (214) is between 0.25 and 1.0 inches.

[0102] A7. According to the laminating head (142) of A5 or A6, wherein the distal end (206) of the corner comprises: one of a sliding surface (208) and a roller (210) at the distal end (206); the sliding surface (208) is a low-friction surface (208) configured to facilitate free sliding of the backing layer (180) on the distal end (206); and the roller (210) is configured to rotate freely about a roller axis (212) as the backing layer (180) moves on the distal end (206).

[0103] A8. A laminating head (142) according to A5, A6 or A7, wherein: the first separating device (202) and the second separating device (218) are configured such that when the first horn (204) and the second horn (220) are respectively in the extended position (226) of the separating device, the distal ends (206) of the first horn (204) and the second horn (220) are respectively located in a first cut region (256) and a second cut region (258), the first cut region (256) and the second cut region (258) being defined on the compaction device outer surfaces (246) of the first compaction device (240) and the second compaction device (242), respectively, the horizontal tangent (252) of the compaction device outer surface (246), and the vertical tangent (254) of the compaction device outer surface (246).

[0104] A9. A laminating head (142) according to any one of A1 to A8, wherein: the first compaction device (240) and the second compaction device (242) each include a first compaction device actuator (248) and a second compaction device actuator (250) configured as linear actuators (228) to alternately move the first compaction device (240) and the second compaction device (242) between a compaction device retracted position (260) and a compaction device extended position (262).

[0105] A10. The laminating head (142) according to any one of A1 to A9 further includes: a controller (112); a backing layer collecting roller (190) rotatably driven by a collecting roller drive motor (192); and the controller (112) is configured to control the rotational speed of the collecting roller drive motor (192) such that the backing layer collecting roller (190) pulls the backing material (166) through the laminating head (142) to distribute the layup material (168) onto the substrate (122), such that the tensile load of the unsupported section (174) of the layup material is lower than the tensile load in the backing layer (180), the unsupported section (174) of the layup material being located between the layup material compaction point (172) associated with the first layer or the second compaction device (240, 242) and the layup material separation point (170) of the first or second corner (204, 220), respectively.

[0106] B1. A laminator (142) with bidirectional layup capability, comprising: a material supply roller (160) configured to support a material roll (164) of backing material (166), the backing material (166) comprising layup material (168) backed by a backing layer (180); a first separation device (202) and a second separation device (218), each having a first horn (204) and a second horn (220), each horn being configurable in a retracted position. (224) and the separation device extended position (226) move between; the first compaction device (240) and the second compaction device (242), each of which moves between the compaction device retracted position (260) and the compaction device extended position (262), and is configured to apply compaction pressure to the laying material (168) at the compaction point (172) against the substrate (122); wherein: when the first separation device (202) is in the separation device extended position ( When the second separation device (226) and the second separation device (218) are in the retracted position (224), the first horn (204) is closely adjacent to the compaction point (172) of the layup material associated with the first compaction device (240) for separating the layup material (168) from the backing layer (180) when the laminating head (142) moves along the first travel direction (150); and when the second separation device (218) is in the retracted position (224), the first horn (204) is closely adjacent to the compaction point (172) of the layup material associated with the first compaction device (240) for separating the layup material (168) from the backing layer (180). When the extended position (226) and the first separation device (202) are in the retracted position (224), the second horn (220) is closely adjacent to the compaction point (172) of the layup material associated with the second compaction device (242) for separating the layup material (168) from the backing layer (180) when the laminating head (142) moves along the second travel direction (152) opposite to the first travel direction (150).

[0107] C1. A method (300) for bidirectionally applying layup material (168) to a substrate (122), the method comprising: feeding backing material (166) from a material roll (164) to a backing layer separation assembly (200) of a laminator (142), the material roll (164) being mounted on a material supply roller (160), the backing material (166) comprising layup material (168) backed by a backing layer (180), the backing layer separation assembly (200) having a first separation device (202) and a second separation device (218), each having a first angle (204) and a second angle (220); moving the first angle (204) close to a layup material compaction point (172) associated with a first compaction device (240); and using the first angle (204) to separate the layup material (168) from the backing layer (180). The laminating head (142) is moved along a first travel direction (150) and guided toward the lay material compaction point (172) associated with the first compaction device (240); the first corner (204) is retracted away from the first compaction device (240); the second corner (220) is moved close to the lay material compaction point (172) associated with the second compaction device (242); and the lay material (168) is separated from the backing layer (180) by the second corner (220), and the laminating head (142) is moved along a second travel direction (152) opposite to the first travel direction (150) and guided toward the lay material compaction point (172) associated with the second compaction device (242).

[0108] C2. According to the method (300) of C1, wherein moving the first horn (204) and moving the second horn (220) respectively comprises: actuating the first separation device actuator (216) and the second separation device actuator (222) to move the first horn (204) and the second horn (220) respectively between a separation device retracted position (224) and a separation device extended position (226) associated with the first horn (204) and the second horn (220).

[0109] C3. According to the method (300) of C1 or C2, wherein moving the first horn (204) and moving the second horn (220) respectively include: moving the first horn (204) and the second horn (220) along the actuator axis (234), the actuator axis (234) being oriented at an angle of less than 60 degrees relative to the first travel direction (150) and the second travel direction (152).

[0110] C4. The method (300) according to C1, C2 or C3, wherein before moving the first corner (204) and before moving the second corner (220), the method (300) respectively includes: retracting the second corner (220) from the second compaction device (242) to a position that provides a gap for the first corner (204) to move between a retracted separation device position (224) and a protruding separation device position (226); and retracting the first corner (204) away from the first compaction device (240) to a position that provides a gap for the second corner (220) to move between a retracted separation device position (224) and a protruding separation device position (226).

[0111] C5. The method (300) according to any one of C1 to C4, wherein using the first corner (204) and the second corner (220) respectively, separating the layup material (168) from the backing layer (180) comprises: pulling the backing layer (180) about a radius of curvature (214) around a distal end (206) of the corner, the distal end (206) of the corner being configured to separate the layup material (168) from the backing layer (180).

[0112] C6. According to the method (300) of C5, wherein using the first corner (204) and the second corner (220) respectively, separating the layup material (168) from the backing layer (180) includes: pulling the backing layer (180) with one of a sliding surface (208) around the distal end (206) of the corner and a roller (210).

[0113] C7. The method (300) according to any one of C1 to C6, wherein moving the first corner (204) and the second corner (220) to be close to the compaction point (172) of the paving material associated with the first compaction device (240) and the second compaction device (242) respectively comprises: moving the distal end (206) of the first corner (204) to the outer surface (246) of the compaction device of the first compaction device (240), the horizontal tangent (252) of the outer surface (246) of the compaction device of the first compaction device (240) and The first cut area (256) defined between the vertical tangent (254) of the outer surface (246) of the first compaction device (240); and the second cut area (258) defined between the outer surface (246) of the second compaction device (242), the horizontal tangent (252) of the outer surface (246) of the second compaction device (242), and the vertical tangent (254) of the outer surface (246) of the second compaction device (242).

[0114] C8. The method (300) according to any one of C1 to C7 further includes: moving the first compaction device (240) to contact the substrate (122) just before, during, or after moving the first corner (204) to be very close to the compaction point (172) of the lay material associated with the first compaction device (240); and moving the second compaction device (242) to contact the substrate (122) just before, during, or after moving the second corner (220) to be very close to the compaction point (172) of the lay material associated with the second compaction device (242) and moving the first compaction device (240) away from the substrate (122).

[0115] C9. A method (300) according to any one of C1 to C8, wherein the laminating head (142) includes a backing layer collecting roller (190), the backing layer collecting roller (190) being driven by a collecting roller drive motor (192), the method (300) further comprising: controlling the rotational speed of the collecting roller drive motor (192) in coordination with the linear velocity of the laminating head (142) along the first travel direction (150) and the second travel direction (152), thereby causing the backing layer collecting roller (190) to pull the backing material (166) through The laminating head (142) dispenses the layup material (168) onto the substrate (122), wherein the tensile load in the unsupported section (174) of the layup material is lower than the tensile load in the backing layer (180); wherein the unsupported section (174) of the layup material is located between a layup material compaction point (172) associated with the first compaction device (240) or the second compaction device (242), and a layup material separation point (170) on the distal end (206) of the first or second corner (204, 220).

[0116] Additional modifications and improvements to this disclosure will be apparent to those skilled in the art. Therefore, certain combinations of the portions described and illustrated herein are intended to represent only certain instances of this disclosure and are not intended to be limiting of alternative examples or apparatuses within the spirit and scope of this disclosure.

Claims

1. A laminating head (142) with bidirectional laying capability for laying composite laminates (196), said laminating head (142) comprising: A material supply roller (160) is configured to support a material roll (164) of a backing material (166), the backing material (166) comprising a layup material (168) backed by a backing layer (180); The first separating device (202) and the second separating device (218) have a first horn (204) and a second horn (220) respectively, each horn being movable between a retracted position (224) and an extended position (226); A first compaction device (240) and a second compaction device (242) are configured to alternately apply compaction pressure to the laying material (168) at the compaction point (172) against the substrate (122); in: When the first separating device (202) is in the extended position (226) and the first corner (204) is close to the layup compaction point (172) associated with the first compaction device (240), the first corner (204) is configured to separate the layup material (168) from the backing layer (180) and guide the layup material (168) toward the substrate (122) and below the first compaction device (240) as the laminating head (142) moves in the first travel direction (150); and When the second separating device (218) is in the extended position (226) and the second corner (220) is close to the compaction point (172) of the layup material associated with the second compaction device (242), the second corner (220) is configured to separate the layup material (168) from the backing layer (180) and guide the layup material (168) toward the substrate (122) and below the second compaction device (242) as the laminating head (142) moves along a second travel direction (152) opposite to the first travel direction (150).

2. The laminating head (142) according to claim 1, wherein: The first separation device (202) and the second separation device (218) each have a first separation device actuator (216) and a second separation device actuator (222) configured as linear actuators (228) to move the first separation device (202) and the second separation device (218) between the retracted position (224) and the extended position (226) of the separation device, respectively.

3. The laminating head (142) according to claim 2, wherein: The first separation device actuator (216) and the second separation device actuator (222) each have an actuator axis (234), which are oriented at an angle of less than 60 degrees relative to the first travel direction (150) and the second travel direction (152), respectively.

4. The laminating head (142) according to claim 3, wherein: The first separation device actuator (216) and the second separation device actuator (222) each have an actuator shaft (234); The actuator axis (234) of the first separation device actuator (216) is oriented to intersect with the actuator axis (234) of the second separation device actuator (222); When the first separating device (202) is in the separating device retracted position (224), the first horn (204) is on one side of the actuator axis (234) of the second separating device actuator (222), at a position that provides a gap for the second horn (220) to move between the separating device retracted position (224) and the separating device extended position (226) of the second separating device actuator (222); and When the second separating device (218) is in the separating device retracted position (224), the second horn (220) is on one side of the actuator axis (234) of the first separating device actuator (216), at a position that provides a gap for the first horn (204) to move between the separating device retracted position (224) and the separating device extended position (226) of the first separating device actuator (216).

5. The laminating head (142) according to claim 4, wherein: The first horn (204) and the second horn (220) each have a distal end (206); and The distal end (206) of the corner has a radius of curvature (214) configured to separate the layup material (168) from the backing layer (180) as the backing layer (180) moves about the radius of curvature (214) of the distal end (206) of the corner.

6. The laminating head (142) according to claim 5, wherein the distal end (206) of the horn comprises: One of the sliding surface (208) and roller (210) at the distal end (206) of the horn; The sliding surface (208) is a low-friction surface, configured to facilitate free sliding of the backing layer (180) on the distal end (206) of the corner; and The roller (210) is configured to rotate freely about the roller axis (212) as the backing layer (180) moves on the distal end (206) of the horn.

7. The laminating head (142) according to claim 6, wherein: The first compaction device (240) and the second compaction device (242) each include a first compaction device actuator (248) and a second compaction device actuator (250) configured as linear actuators (228) to alternately move the first compaction device (240) and the second compaction device (242) between a compaction device retracted position (260) and a compaction device extended position (262).

8. The laminator (142) according to any one of claims 1 to 7, comprising: Controller (112); A backing layer collecting roller (190) is rotatably driven by a collecting roller drive motor (192); and The controller (112) is configured to control the rotational speed of the collecting roller drive motor (192) so that the backing layer collecting roller (190) pulls the backing material (166) through the laminating head (142) to distribute the layup material (168) onto the substrate (122), such that the tensile load in the unsupported section (174) of the layup material is lower than the tensile load in the backing layer (180), the unsupported section (174) of the layup material being located between a layup material compaction point (172) associated with the first compaction device (240) or the second compaction device (242) and a layup material separation point (170) associated with the first corner (204) or the second corner (220) respectively.

9. A method (300) for bidirectionally applying a laying material (168) to a substrate (122), the method comprising: Backing material (166) is fed from a material roll (164) to a backing layer separation assembly (200) of a laminating head (142), the material roll (164) being mounted on a material supply roller (160), the backing material (166) comprising layup material (168) backed by a backing layer (180), the backing layer separation assembly (200) having a first separation device (202) and a second separation device (218), which respectively have a first corner (204) and a second corner (220); Move the first horn (204) close to the paving material compaction point (172) associated with the first compaction device (240); The first horn (204) is used to separate the lay material (168) from the backing layer (180), and the lay material (168) is guided toward the lay material compaction point (172) associated with the first compaction device (240) while the laminating head (142) is moved along the first travel direction (150). The first horn-shaped object (204) is retracted away from the first compaction device (240); Move the second horn (220) close to the compaction point (172) of the paving material associated with the second compaction device (242); and The second horn (220) is used to separate the lay material (168) from the backing layer (180), and the laminating head (142) is moved along a second travel direction (152) opposite to the first travel direction (150) while the lay material (168) is guided toward the lay material compaction point (172) associated with the second compaction device (242).

10. The method (300) according to claim 9, wherein moving the first horn (204) and moving the second horn (220) respectively comprise: Actuate the first separation device actuator (216) and the second separation device actuator (222) to move the first corner (204) and the second corner (220) between a retracted position (224) and a protruding position (226) associated with the first corner (204) and the second corner (220), respectively.

Images