Laminator with self-threading capability

Abstract

This invention relates to a laminator with self-threading capability. A self-threading laminator includes a material supply drum, a backing layer collection drum, and a material threading system. The material supply drum supports a roll of backing material, the roll comprising layup material backed by a backing layer. The material threading system includes at least one threading tape located on one side of the laminator. The threading tape is supported by a belt roller driven by a belt drive motor. A belt mounting layer engagement device is coupled to the threading tape for engaging a leading edge portion of the backing layer. As the laminator applies layup material onto a substrate, the backing layer collection drum collects the backing layer. The belt drive motor drives the threading tape on the belt roller and causes the belt mounting layer engagement device to pass the backing layer through the laminator and position the leading edge portion of the backing layer near the backing layer collection drum.

Description

Technical Field

[0001] This disclosure generally relates to manufacturing systems, and more specifically, to laminators for laying composite laminates and having self-threading capability. Background Technology

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

[0003] Because of 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 continuous strips of laminate material, such as prepreg tape, are dispensed from the laminator onto the laminating surface as the laminator moves relative to it. For example, the laminator can move on a stationary laminating surface. Alternatively, the laminator can be stationary, and the laminating surface can move beneath it. Each composite ply is formed by the laminator continuously laying rows or courses of tape in a parallel relationship relative to each other.

[0004] One drawback of traditional laminators is that layup material, such as prepreg tape, must be passed through the laminator before the tape is dispensed. Prepreg tape is typically supplied in rolls on a material supply drum, which is then mounted on the laminator. To prevent adhesion between adjacent prepreg tape rolls on the roll, the prepreg tape is backed by a backing layer. As the tape is dispensed from the roll and applied to the lamination surface, the backing layer is removed and wound onto a backing layer collection drum mounted on the laminator. When the roll runs out of tape, it needs to be replaced, and a new roll needs to be installed on the laminator. After each roll replacement, the tape on the new roll must pass through the laminator assembly and reach the backing layer collection drum.

[0005] In traditional laminators, the tape threading process is a time-consuming operation that can lead to significant downtime. Laminating a single composite laminate may require multiple roll changes, each necessitating manual tape threading, which increases laminator downtime and overall production time.

[0006] It can be seen that there is a need in the art for a laminator that allows the layup material to pass quickly through the laminator. Summary of the Invention

[0007] The aforementioned needs related to the manufacture of composite laminates are specifically addressed and mitigated by this disclosure, which provides a laminating head with self-threading capability. The laminating head includes a material supply drum configured to support a roll of backing material. The backing material includes a layup material backed by a backing layer. The laminating head further includes a material threading system having at least one belt track located on one side of the material path passing through the laminating head. The belt track includes a continuous loop threading belt supported on a plurality of belt rollers driven by a belt drive motor. The material threading system further includes at least one belt mounting layer bonding device coupled to the threading belt and configured to bond a leading edge portion of the backing layer. The laminating head further includes a backing layer collecting drum configured to wind at least a backing layer onto the drum when the laminating head applies layup material to a substrate. The belt drive motor is configured to drive the threaded belt on the belt roller, thereby causing the belt mounting layer bonding device to pull out at least the backing layer from the material supply roller and to pass the at least the backing layer along the material path through the laminating head, and to position the leading edge portion of the backing layer close to the backing layer collection drum for engagement with the backing layer collection drum.

[0008] A manufacturing system is also disclosed, comprising a series of laminating heads, each having self-threading capability and each including a material supply drum, a material threading system, and a backing layer collection drum. As described above, the material supply drum is configured to support a roll of backing material. The material threading system includes at least one belt track located on one side of the material path passing through the laminating head. The belt track includes a continuous loop threading belt supported on a plurality of belt rollers driven by a belt drive motor. The material threading system also includes at least one belt mounting layer bonding device coupled to the threading belt and configured to engage a leading edge portion of the backing layer. The laminating head further includes a backing layer collection drum configured to wind at least the backing layer onto the backing layer collection drum when the laminating head applies layup material onto a substrate. The belt drive motor is configured to drive the threading belt on the belt rollers, thereby causing the belt mounting layer bonding device to pull at least the backing layer from the material supply rollers and to pass at least the backing layer along the material path through the laminating head, and to position the leading edge portion of the backing layer against the backing layer collection drum. The manufacturing system further includes a reloading cylinder having a row of reloading mandrels movable along a circulation path to one of a plurality of storage locations. The reloading mandrels are configured to store stock rolls, including depleted stock rolls or replacement stock rolls. The reloading cylinder is configured to position an empty reloading mandrel to align with the material supply drum of one of the laminating heads, transfer a depleted stock roll from the laminating head to an empty reloading mandrel, circulate the reloading mandrels until a reloading mandrel supporting a replacement stock roll is aligned with the material supply drum, and transfer the replacement stock roll from the reloading mandrel to the material supply drum.

[0009] A method for passing layup material through a laminating head is also disclosed. As described above, the method includes supporting a roll of backing material on a material supply drum. The method also includes engaging a leading edge portion of the backing layer to a tape mounting layer engagement device coupled to at least one continuous loop threading tape located on one side of the material path through the laminating head. Furthermore, the method includes driving the threading tape on a tape roller using a tape drive motor, such that the tape mounting layer engagement device passes at least the backing layer through the laminating head along the material path and positions the leading edge portion of the backing layer near the backing layer collection drum.

[0010] The features, functions, and advantages already discussed may be implemented independently in various embodiments of this disclosure or may be combined in other embodiments, further details of which can be seen in the following description and accompanying drawings. Attached Figure Description

[0011] These and other features of this disclosure will become more apparent from the accompanying drawings, in which similar reference numerals refer to similar parts throughout the drawings, and wherein:

[0012] Figure 1 This is a top view of an example manufacturing system for laying composite laminates, which includes a series of laminating heads, each with self-threading capability.

[0013] Figure 2 yes Figure 1 A side view of the manufacturing system;

[0014] Figure 3 It is the manufacturing system by Figure 1 The figure shows an enlarged view of the portion identified by reference numeral 3, and shows the laminator supported by the laminator support structure, and further shows a reloading cylinder selectively positioned in front of each laminator for removing the exhausted roll from the laminator and replacing it with a replacement roll in the reloading cylinder;

[0015] Figure 4 It is the manufacturing system by Figure 2 The attached figure shows an enlarged view of the portion identified by reference numeral 4, and illustrates a laminating head supported above a laminating mandrel that is movable relative to a stationary laminating head.

[0016] Figure 5 This is a perspective view of an example of a series of laminating heads applying layup material onto a substrate (e.g., a laminating mandrel) that moves beneath the laminating heads;

[0017] Figure 6 It is by Figure 4The figure shows an enlarged view of the laminating head identified by reference numeral 6, and also shows a material supply drum supporting the roll of layup material backed by the backing layer, and further shows a backing layer separation assembly for separating the layup material from the backing layer.

[0018] Figure 7 It is a perspective view of an example of a laminator with self-threading capability, and includes a material threading system having a pair of rethreading tapes and at least one tape-mounted layer bonding device for spontaneously threading at least the layup material through the laminator.

[0019] Figure 8 It is by Figure 7 The attached figure shows an enlarged view of the portion of the laminating head identified by reference numeral 8, and shows a tape-mounted layer bonding device that is mounted on the pair of threaded tapes as a pair of tape mounting clips and configured to be clamped on the leading edge portion of the backing layer.

[0020] Figure 9 This is a view of the top portion of the laminator, wherein the mounting layer bonding device is configured as an electromagnetic transverse member or as a fastening transverse member that bonds the leading edge portion of the backing layer.

[0021] Figure 10 It is along Figure 3 The side view of the lamination station is taken from line 10-10 and shows the reloading cylinder located near the lamination head. The reloading cylinder is used to place the depleted roll from the lamination head onto the reloading mandrel on the empty reloading cylinder and transfer the replacement roll from the reloading cylinder to the lamination head.

[0022] Figure 11 It is along Figure 10 The front view of the reloading cylinder is taken from line 11-11, and shows multiple reloading mandrels, some of which are empty, some of which support replacement rolls, and some of which support depleted rolls taken out of the laminating head.

[0023] Figure 12 It is along Figure 11 A top view of the reloading cylinder taken from line 12-12, and the reloading mandrel occupied by the replaced roll and the exhausted roll;

[0024] Figure 13 It is a side view of the reloading cylinder located near the laminator head, and shows the free end of one of the reloading mandrels extending to lock into engagement with the free end of the material supply drum on the laminator head, and further shows the material transfer mechanism on the reloading mandrel prepared to transfer the depleted roll of material from the laminator head to the reloading cylinder.

[0025] Figure 14 The exhausted roll of material after it has been transferred to the reloading cylinder by the material transfer mechanism;

[0026] Figure 15 The telescopic reloading mandrel is shown retracting from the material supply drum.

[0027] Figure 16 This is a side view of the reloading cylinder, showing the reloading mandrel after the cycle, which moves the replacement roll to a position aligned with the material supply drum of the laminator.

[0028] Figure 17 This is a side view of the reloading cylinder, showing a pair of leading edge alignment rollers configured to extend and retract into a mounting layer bonding device close to the laminator head.

[0029] Figure 18 This is a side view of the reloading cylinder, showing the foremost edge of the backing layer after manual insertion between the leading edge alignment rollers;

[0030] Figure 19 It is by Figure 18 The attached figure shows an enlarged view of the portion of the reloading cylinder identified by reference numeral 19, and shows the leading edge of the leading edge portion of the backing layer pulled out between the counter-rotating leading edge alignment rollers;

[0031] Figure 20 This is a side view of the reloading cylinder, showing the free end of the alignment roller extending to the mounting layer bonding device close to the laminator head, while the material transfer mechanism of the replacement roll transfers it from the reloading mandrel to the material supply drum of the laminator head;

[0032] Figure 21 This is a front view of the laminator after the replacement roll has been mounted on the material supply drum, and further shows the leading edge portion of the backing layer captured between the leading edge alignment rollers;

[0033] Figure 22 It is by Figure 21 The attached figure shows an enlarged view of the portion of the laminating head identified by reference numeral 22, and shows the backing layer leading edge portion captured between the leading edge alignment rollers near the location of the leading edge mounting device.

[0034] Figure 23 The activation of the threading tape of the material threading system is shown, which is used to move the tape mounting layer bonding device, while the reverse rotation of the leading edge alignment roller is used to extend the leading edge portion of the backing layer toward the tape mounting layer bonding device.

[0035] Figure 24 The leading edge portion of the backing layer is shown in connection with the mounting layer bonding device;

[0036] Figure 25 It is by Figure 24The attached figure shows an enlarged view of a portion of the laminator head identified by reference numeral 25, and illustrates an example of a mounting layer bonding device configured as an electromagnetic transverse member that is magnetically coupled to a magnetically attracted element included together with the leading edge portion of the backing layer.

[0037] Figure 26 The diagram shows leading edge alignment rollers moving away from each other to release the leading edge portion of the backing layer, which engages with the mounting layer engagement device.

[0038] Figure 27 The diagram illustrates a backing layer assembly device that pulls the backing layer from the material supply roller and passes the backing layer through the laminating head;

[0039] Figure 28 This is a side view of the reloading cylinder, showing the retraction of the leading edge alignment roller and the reloading mandrel;

[0040] Figure 29 This is a side view of the laminator, showing the progress of the backing layer through the laminator via a material threading system;

[0041] Figure 30 The image shows the leading edge portion of the backing layer approaching the backing layer collection drum after the backing layer passes through the cutter assembly and the backing layer separation assembly of the laminator head;

[0042] Figure 31 The leading edge portion of the backing layer is shown positioned close to the drum mounting layer engagement device included together with the backing layer collection drum;

[0043] Figure 32 It is by Figure 31 The figure shows an enlarged view of a portion of the laminating head, identified by reference numeral 32, illustrating the positioning of the leading edge portion of the backing layer with the mounting layer engagement device for engagement with the drum mounting layer engagement portion.

[0044] Figure 33 A drum mounting layer joining device is shown, which is configured as a drum mounting clamping mechanism having a pair of jaws for clamping onto the leading edge of the leading edge portion of the backing layer;

[0045] Figure 34 The diagram shows a rotating backing layer collecting drum with the leading edge portion of the backing layer engaged with the drum mounting layer engagement device.

[0046] Figure 35 The diagram shows several windings of the backing layer on the drum;

[0047] Figure 36This is a side view of the laminator, showing the redirection rollers of the material threading system after the laminator has been moved away from the backing layer collection drum to provide clearance for winding the backing layer onto the backing layer collection drum in preparation for the laminator to dispense the layup material onto the substrate.

[0048] Figure 37 It is by Figure 36 An enlarged view of a portion of the laminating head, identified by reference numeral 37, is shown, and a first separating device and a first compacting device are shown, each in an extended position for separating the layup material from the backing layer and distributing the layup material onto the substrate as the laminating head moves along a first direction of travel.

[0049] Figure 38 A second separating device and a second compacting device are shown, each in an extended position for separating the layup material from the backing layer and distributing the layup material onto the substrate, while the laminating head moves along a second traveling direction opposite to the first traveling direction;

[0050] Figure 39 This is a side view of the laminating head, showing the depleted material supply drum and the backing layer collection drum filled with the backing layer;

[0051] Figure 40 The leading edge portion of the backing layer is shown during the release of the drum mounting layer engagement device that collects the drum from the backing layer;

[0052] Figure 41 The rotation of the material supply drum shows how the backing layer is pulled back through the laminating head;

[0053] Figure 42 The leading edge of the backing layer is shown near the material supply drum;

[0054] Figure 43 The backing layer is shown being rewound onto the material supply drum, and activation of the material threading system for moving the mounting layer bonding device from the backing layer collection drum to the material supply drum is further shown.

[0055] Figure 44 This is a side view of another example of a laminator head, wherein the material threading system includes a front edge coupling device for coupling the leading edge portion of the backing layer to a front edge coupling device with a mounting layer bonding device.

[0056] Figure 45 The leading edge portion of the backing layer is shown during engagement with the leading edge cup device;

[0057] Figure 46 It is by Figure 45The attached figure shows an enlarged view of a portion of the laminating head identified by reference numeral 46, and shows the leading edge portion of the backing layer captured between the reverse loading pairs of the leading edge alignment rollers, and the leading edge coupling device before being coupled to the belt mounting layer coupling device.

[0058] Figure 47 The diagram shows leading edge alignment rollers moving away from each other to release the leading edge portion of the backing layer, which engages with the leading edge cup device.

[0059] Figure 48 This is a side view of the laminator, showing the leading edge coupling device pulling the backing layer out of the material supply roller and passing the backing layer through the laminator;

[0060] Figure 49 The connecting device at the leading edge of the collection drum near the backing layer is shown;

[0061] Figure 50 The image shows the leading edge connecting device being pulled into the collection drum opening of the backing layer collection drum;

[0062] Figure 51 It is by Figure 50 The attached figure shows an enlarged view of a portion of the laminating head identified by reference numeral 51, and shows the leading edge coupling device during engagement with the drum mounting layer coupling device, while the leading edge coupling device is released from the belt mounting layer coupling device.

[0063] Figure 52 The leading edge coupling device that engages with the drum mounting layer coupling device is shown;

[0064] Figure 53 A backing layer collecting drum is shown rotating when the leading edge cup device is engaged with the drum mounting layer engagement device;

[0065] Figure 54 Several windings of the backing layer on the backing layer collection drum are shown;

[0066] Figure 55 This is a side view of the laminator, showing the redirection roller after it has been moved away from the backing layer collection drum to provide clearance for winding the backing layer onto the backing layer collection drum in preparation for the laminator to dispense the layup material onto the substrate.

[0067] Figure 56 The material supply drum that has been depleted is shown, as well as the backing layer collection drum filled with the backing layer;

[0068] Figure 57 A backing layer rewound onto a material supply drum is shown, and a redirection roller is further shown moving back toward the backing layer collection drum in preparation for releasing the leading edge coupling from the drum mounting layer engagement device.

[0069] Figure 58A front-edge coupling device is shown that is released from and engaged with a drum mounting layer engagement device;

[0070] Figure 59 The activation of the material threading system via the laminator rewinding the backing layer is shown;

[0071] Figure 60 This demonstrates further progress in rewinding the backing layer via a laminator head;

[0072] Figure 61 The leading edge coupling is shown in its initial position near the material supply drum;

[0073] Figure 62 The leading edge portion of the backing layer is shown after being released from the leading edge coupling device and wound around the material supply drum;

[0074] Figure 63 This is a flowchart of the method for passing the laying material through the laminating head. Detailed Implementation

[0075] Referring now to the accompanying drawings, which illustrate preferred and various examples of this disclosure, Figure 1 The diagram shown is a top view of an example manufacturing system 100 having an end-to-end series of laminating heads 200 (e.g., fiber placement heads) for laying uncured composite laminates 240. Figure 5 ) lamination station 136. Figure 2 This is a side view of the manufacturing system 100. As described in more detail below, each laminator 200 is configured to support the backing layer 230 ( Figure 4 ) Backing material 228 ( Figure 4 ) backing material 226 ( Figure 4 ) of the material roll 224 ( Figure 4 Each laminator head 200 is configured to dispense layup material 228 onto the lamination surface 120 or the substrate 122 during movement of the laminator head 200 relative to the substrate 122. Advantageously, each laminator head 200 has a self-threading capability for autonomously threading the layup material 228 through the laminator head 200 before dispensing it onto the substrate 122. The self-threading capability of the laminator head 200 reduces the downtime associated with the manual threading operation required by conventional laminators.

[0076] Figure 3 and Figure 4 These are top and side views of lamination station 136, showing a series of lamination heads 200, and also showing a reloading cylinder 400 located in front of the lamination heads 200. Figure 3As described below, the reloading cylinder 400 can be moved along the laminating station 136 to position the reloading cylinder 400 aligned with any of the laminating heads 200. The reloading cylinder 400 is configured to automatically remove depleted rolls 418 from the laminating heads 200. Figure 13-14 ), and use replacement roll 420 ( Figure 17 Replace the depleted roll 418 from the reloading cylinder 400.

[0077] Figure 5 This is a perspective view of an example of a series of laminating heads 200 applying a path 238 of layup material 228 to a substrate 122. In this disclosure, the substrate 122 may be described as the surface of a lamination mandrel 124, or the substrate 122 may be the path 238 of the most recently applied layup material 228. The lamination surface may include connections to a vacuum pressure source 128. Figure 4 Multiple apertures 126 are provided for vacuum bonding of the composite laminate 240 to the lamination surface 120. In some examples, a release film (not shown) may be applied (e.g., via lamination head 200) to the lamination surface (e.g., lamination mandrel 124). The release film may be perforated to allow vacuum pressure at the apertures 126 to vacuum couple to the composite laminate 240 laid on top of the release film.

[0078] In the example manufacturing system 100 shown in the figure, each laminator 200 may have a bidirectional layup capability for dispensing layup material 228 onto a substrate 122. For example, each laminator 200 may be configured to lay up material 228 in a first travel direction 208 relative to the substrate 122 (e.g., lamination mandrel 124). Figure 37 During the movement, the laying material 228 is distributed, and also relative to the substrate 122 along a second travel direction 210 opposite to the first travel direction 208. Figure 38 During movement, layup material 228 is distributed. However, the self-threading capability currently disclosed can be achieved on a laminator (not shown) configured to distribute layup material 228 along a single direction of travel, and is not limited to a laminator 200 having bidirectional layup capability.

[0079] exist Figure 1-4 In this system, manufacturing system 100 may include a base member 104 supported on a surface such as a factory floor. As described above, a laminated surface 120 (e.g., substrate 122) may be configured as a laminated mandrel 124. The laminated mandrel 124 may move or slide along a longitudinal guide rail 130 extending along the length of the base member 104. For example, manufacturing system 100 may include a mandrel translation mechanism (not shown), such as a screw driver coupled to a drive motor, for use in a controller 112 (… Figure 1The lamination mandrel 124 moves autonomously under the control of the lamination station 136. The mandrel translation mechanism can be initially positioned 132 on one side of the lamination surface of the lamination station 136. Figure 2 The rear part of the lamination surface on the opposite side of lamination station 136 is located at position 134. Figure 2 The lamination mandrel 124 moves between the two sides.

[0080] exist Figure 1-4 In the example manufacturing system 100, the laminator 200 may be supported by a laminator support structure 102. The laminator support structure 102 may include a longitudinal beam 110 to which the laminator 200 may 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 columns 106 extending upward from the factory floor. However, the laminator support structure 102 may be provided in any of a variety of alternative constructions and is not limited to these. Figure 1-4 The construction shown.

[0081] As an alternative to the movable laminating mandrel 124, the laminating surface 120 may be configured as a continuous annular laminating belt (not shown) supported by a series of internal laminating belt rollers (not shown) and rotatably driven by a laminating belt drive motor (not shown). The laminating belt may include an outer surface onto which the laminating head 200 may dispense layup material 228. In another example of the manufacturing system 100, the laminating surface 120 may be stationary, and the laminating head 200 may be movable above the laminating surface 120 to dispense laminating material 228 for laying the composite laminate 240. Figure 5 For example, the laminator 200 may be supported by a frame (not shown), a rail-mounted support structure (not shown), or a cantilever support structure (not shown) for use along the first travel direction 208. Figure 37 ) and along the second direction of travel 210 ( Figure 38The laminating head 200 is moved while dispensing layup material 228 onto the laminating surface 120. In another example, the manufacturing system 100 may include one or more robotic devices (not shown) for moving the laminating head 200 on the laminating surface 120. In any of the above examples, the manufacturing system 100 is not limited to a series of end-to-end laminating heads 200, but may include a single laminating head 200 having self-threading capability and being movable relative to the laminating surface 120. Furthermore, one or more of the currently disclosed laminating heads 200 may be supported in a manner that allows the dispensing of layup material 228 along first and second travel directions 208, 210 and along an additional travel direction (not shown), such as along a direction at 45 degrees to the first travel direction 208 and / or along a direction at 45 degrees to the second travel direction 210. Furthermore, the laminating surface 120 is not limited to a generally planar, elongated laminating surface 120, such as the currently disclosed laminating mandrel 124, but may include a laminating surface (not shown) with a non-planar profile. For example, the laminated surface 120 can be a movable laying tool, such as a rotatable laying mandrel (not shown).

[0082] refer to Figure 6-7 , Figure 6-7 Side and perspective views of an example of a laminator head 200 with self-threading capability are shown. The laminator head 200 includes a material supply drum 220, a material threading system 320, and a backing layer collection drum 300, each of which can be supported by a mounting frame 202. Furthermore, the laminator head 200 may include a cutter assembly 250, a backing layer separation assembly 260, and first and second compaction devices 284, 288, which are also supported by the mounting frame 202. The mounting frame 202 may be configured as a plate structure, a truss structure, or used to mechanically stabilize the laminator head 200 to the laminator head support structure 102. Figure 3-4 Any of the many other constructions of ).

[0083] As described above, the material supply drum 220 can be driven by the supply drum motor 222 and can support the roll 224 of backing material 226. The material threading system 320 is configured to at least allow the backing layer 230 to pass through the laminating head 200 and to position the leading edge portion 232 of the backing layer 230 to engage with the backing layer collection drum 300. The cutter assembly 250 is configured to be positioned near the laminating head 200 along the path 238 of the layup material 228 dispensed by the laminating head 200. Figure 5 The layup material 228 is cut at a specified start position and a specified end position. The backing layer separation assembly 260 is configured to separate the layup material 228 from the backing layer 230 and guide the layup material 228 toward the substrate 122. Figure 5The backing layer collection drum 300 is configured to roll up or wind the backing layer 230 onto the backing layer collection drum 300 when the layup material 228 is separated from the backing layer 230 (via the backing layer separation assembly 260) and applied to the substrate 122.

[0084] exist Figure 6-7 The image shows a laminator 200 before the backing material 226 passes through it. The backing material 226 comprises a continuous length or strip of layup material 228 backed by a continuous backing layer 230. In some examples, the layup material 228 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., glass fiber), carbon fibers, boron, aramid, metal fibers, ceramic fibers, or other fibrous materials. In one example, the composite material may be a carbon fiber epoxy prepreg tape. The composite material may be a unidirectional or multidirectional tape (e.g., braided or woven tape). The layup material 228 may have a width of up to 12 inches or more. In some examples of the laminator 200, the material supply drum 220 may be configured to support two or more rolls 224 in a side-by-side relationship relative to each other to dispense them onto the substrate 122 as parallel, side-by-side routes of the layup material 228. For example, the laminator 200 may be configured to support two or more rolls of prepreg tape (e.g., each 0.5 to 3 inches wide or wider) for dispensing onto the substrate 122 in a side-by-side relationship.

[0085] As an alternative to composite materials, layup material 228 can be a continuous strip of non-composite material backed by backing layer 230. For example, layup material 228 can be a metal foil or metal mesh backed by backing layer 230. In other examples, layup material 228 can be a processing material that facilitates the processing of composite laminate 240 (e.g., forming, bonding, curing, treatment, etc.). Examples of non-composite materials include release films, tackifier films, breathable layers, permeable layers, release cord layers, or any of a variety of other types of non-composite layers, films, or adhesives that can be laid on composite laminate 240. Figure 5 Dispensing is performed by laminator 200 before, during, or after the process.

[0086] Still referencing Figure 6-7The laminator head 200 may further include one or more guide rollers 204 and / or one or more guide surfaces 206 mounted to the mounting frame 202. The guide rollers 204 and / or guide surfaces 206 may define a material path 322 for the backing material 226 to pass through the laminator head 200. The guide surfaces 206 may have a larger radius of curvature than the guide rollers 204. The larger radius of curvature of the guide surfaces 206 may facilitate the initial passage of the backing material 226 through the laminator head 200 via the material threading system 320. In the example shown, the laminator head 200 includes two guide surfaces 206, each having an approximately quarter-circular shape. The guide rollers 204 and guide surfaces 206 may guide the backing material 226 through the cutter assembly 250 and the backing layer separation assembly 260 of the laminator head 200. For example, guide surfaces 206 located above and below the cutter assembly 250 can facilitate tensioning of the backing material 226 to achieve precise control over the cutting of the layup material 228 without cutting the backing layer 230.

[0087] like Figure 6 As shown, the cutter assembly 250 may include a cutter module 252 and a cutter clamping plate 254. The cutter clamping plate 254 may be fixedly mounted to the mounting frame 202. The cutter module 252 may have at least one cutter blade (not shown). To provide a gap for allowing backing material 226 (e.g., at least backing layer 230) to pass through the cutter assembly 250, the cutter module 252 may be configured to translate horizontally away from the cutter clamping plate 254 to an initial module position (not shown), wherein the cutter module 252 and the cutter clamping plate 254 are spaced apart from each other. When ready to cut the layup material 228, the cutter module 252 may translate horizontally toward the cutter clamping plate 254 back to a module engagement position, in which the backing material 226 is clamped between the cutter module 252 and the cutter clamping plate 254. The depth of the cutter blade can be precisely controlled to cut only the layup material 228 without cutting the backing layer 230. Controller 112 ( Figure 1 ) can be applied to each route 238 of the layup material 228 to be dispensed by the laminator 200. Figure 5 The cutter assembly 250 is controlled to cut the layup material 228 immediately before it begins, and the layup material 228 is also cut immediately before the laminating head 200 reaches the predetermined end of each route 238.

[0088] Still referencing Figure 6The backing layer separation assembly 260 is configured to receive backing material 226 after passing through the cutter assembly 250, as described above. The backing layer separation assembly 260 includes a first separation device 262 and a second separation device 272. The first separation device 262 includes a first guide angle 268, which is configurable via a first separation device actuator 264 (e.g., a linear actuator) in a separation device retracted position 278 and a separation device extended position 280 associated with the first separation device 262. Figure 37 The second separation device 272 includes a second guide bar angle 276, which is movable between a separation device retracted position 278 and a separation device extended position 280 associated with the second separation device 272 via a second separation device actuator 274 (e.g., a linear actuator). Figure 38 Move between ) . Figure 6 In the middle, the first guide bar angle 268 and the second guide bar angle 276 are both shown in their respective separation device retracted position 278 to provide a gap for the backing material 226 to pass through the laminator head 200. However, when the laminator head 200 is traveling in the first travel direction 208 ( Figure 37 When distributing the laying material 228, the first guide angle 268 can be in the extended position, while the second guide angle 276 can be in the retracted position. When the laminating head 200 travels along the second travel direction 210 (opposite to the first travel direction 208), Figure 38 When distributing the laying material 228, the second guide angle 276 can be in the extended position, while the first guide angle 268 can be in the retracted position, as described below.

[0089] exist Figure 6 In this process, the laminating head 200 may include a first compaction device 284 and a second compaction device 288, which are configured to apply compaction pressure to the layup material 228 abutting against the substrate 122 as the layup material 228 is dispensed by the laminating head 200. Figure 37 For example, the first compaction device 284 is configured such that when the laminating head 200 moves along the first travel direction 208 ( Figure 37 The compaction pressure is applied to the layup material 228 that abuts against the substrate 122. The second compaction device 288 is configured such that when the laminating head 200 moves along the second travel direction 210, ( Figure 38 The compaction pressure is applied to the laying material 228 that is against the substrate 122. Figure 38The first compaction device 284 may include a first compaction device actuator 286 (e.g., a linear actuator) for moving the first compaction device 284 between a compaction device retracted position 292 (e.g., an elevated position) where the first compaction device 284 is not in contact with the substrate 122 and a compaction device extended position 294 (e.g., a lowered position) where the first compaction device 284 is in contact with the substrate 122. Similarly, the second compaction device 288 may include a second compaction device actuator 290 (e.g., a linear actuator) for moving the second compaction device 288 between the compaction device retracted position 292 and the compaction device extended position 294.

[0090] As described below, when the laminating head 200 travels along the first travel direction 208 ( Figure 37 During movement, the second compaction device 288 can be raised from the substrate 122, and the first compaction device 284 can be lowered onto the substrate 122 to compact the layup material 228 after separation from the backing layer 230 via the first guide angle 268. When the laminating head 200 travels along the second direction of travel 210 (… Figure 38 During movement, the first compaction device 284 can be raised from the substrate 122, and the second compaction device 288 can be lowered onto the substrate 122 for compacting the layup material 228 after separation from the backing layer 230 via the second guide angle 276. Although shown as a compaction roller, the first and second compaction devices 284, 288 may each be provided with alternative constructions, such as compaction boots (not shown), or as elastically compressible compaction airbags (not shown) for sliding to form the layup material 228 on a molding lamination mandrel (not shown) having an outer surface with a non-planar cross-sectional shape.

[0091] refer to Figure 6-7 A material threading system 320 is shown, which is configured to pass at least a backing layer 230 through a laminating head 200 and engage with a backing layer collection drum 300. The backing layer collection drum 300 is rotatably driven by a collection drum motor 302, which is configured to pull at least the backing layer 230 through the laminating head 200 during the application of layup material 228 to the substrate 122. Figure 5 Furthermore, the backing layer 230 is configured to wrap at least the backing layer 230 onto the backing layer collection drum 300 when the laminating head 200 applies the layup material 228 onto the substrate 122.

[0092] The material threading system 320 includes one or more roller tracks 324 located along the material path 322 passing through the laminating head 200. Figure 5One side of the laminator 324. The belt roller 324 includes a continuous looping belt 326 supported on a plurality of belt rollers 328 driven by a belt drive motor 330. The belt roller 324 may be located on the inside of the material path 322 adjacent to the mounting frame 202. In the example shown in the figure, the laminator 200 includes a pair of belt rollers 324, each located on the material path 322 passing through the laminator 200. Figure 5 On the opposite side of ). For example, as Figure 5 As shown, one of the belt rollers 324 may be located inside the material path 322 adjacent to the mounting frame 202, while the other belt roller 324 may be located outside the material path 322. Each of the one or more belt rollers 324 includes a continuous loop of threaded belt 326 supported on a plurality of belt rollers 328. The belt rollers 328 may be driven by one or more belt drive motors 330. Each threaded belt 326 may be configured as a fiber-reinforced rubber block toothed belt supported on the belt rollers 328, and each belt roller may be configured as a block toothed pulley for engaging the block toothed belt 326. In an alternative example, each threaded belt 326 may be configured as a chain (not shown) consisting of a series of pivotally connected links supported on sprockets (not shown) having teeth configured to engage links. At least one of the belt rollers 328 may be rotatably driven by the belt drive motor 330 regardless of the specific construction of the threaded belt 326 and the guide rollers 204, and the belt drive motor 330 may be controlled by the controller 112. For example, a pair of cable ties 326 can be respectively controlled by a pair of controllers 112 ( Figure 1 Driven by a drive motor 330 (e.g., an electric motor) controlled by a controller.

[0093] Still referencing Figure 6-7 The material threading system 320 also includes at least one tape mounting layer engagement device 350 connected to the threading tape 326. The tape mounting layer engagement device 350 is configured to engage the leading edge portion 232 of the backing layer 230 before at least pulling the backing layer 230 through the laminating head 200. Figure 8 One or more belt drive motors 330 are configured to drive one or more threading tapes 326 (e.g., a pair of threading tapes 326) such that the tape mounting layer bonding device 350 pulls at least the backing layer 230 from the roll 224 and causes the backing layer 230 to move at least along the material path 322. Figure 5 The backing layer leading edge portion 232 is positioned through the laminating head 200 and engaged with the backing layer collecting drum 300. For example, as described below, when one or more belt drive motors 330 are activated by the controller 112, the belt mounting layer engagement device 350 can pull the backing layer leading edge portion 232 over the upper guide surface 206, over the lower guide surface 206, through the gap between the cutter module 252 and the cutter pressure plate 254 of the cutter assembly 250, and pull it close to the backing layer collecting drum 300.

[0094] refer to Figure 8 , Figure 8 An example of a mounting layer bonding device 350 is shown, which is configured as an electromagnetic member 355, coupled to at least one threaded tape 326 and configured to be magnetically coupled to a magnetic element 234, which may be included with the leading edge portion 232 of the backing layer, as described below. For example, the electromagnetic member 355 can be activated between a non-energized state and an energized state (e.g., via an electromagnetic power source – not shown). In the energized state, the electromagnetic member 355 can be magnetically coupled to the magnetic element of the leading edge portion 232 of the backing layer. Figure 8 In the example, the laminator 200 includes a pair of threaded strips 326, and the electromagnetic member 355 is configured as a generally rigid electromagnetic transverse member 356 extending between the pair of threaded strips 326, and is configured to be magnetically coupled to a magnetically attracted element 234 that may be included with the leading edge portion 232 of the backing layer.

[0095] In an alternative arrangement, the mounting layer engagement device 350 can be configured to be connected to a fastening member 355 of at least one threading tape 326. Figure 8 The fastening member 355 may include a ring element strip or a hook element strip (e.g., Velcro). TM (not shown), the strip is configured to releasably engage with a fastening element 236 that may be included on the leading edge portion 232 of the backing layer. Figure 24 The fastening element 236 may be a hook element strip or a loop element strip configured to engage with the loop element strip or the hook element strip of the fastening member 355, respectively. In the example shown, the fastening member 355 may be configured as a fastening transverse member 358 extending between a pair of threaded strips 326 and configured to releasably engage with the fastening element 236, which may be included on the leading edge portion 232 of the backing layer.

[0096] Figure 9 An example of a tape mounting layer engagement device 350 is shown, configured to be mounted to at least one tape mounting clip 352 of at least one threading tape 326 and configured to clamp onto a backing layer leading edge portion 232. In the illustrated example, the tape mounting layer engagement device 350 includes a pair of tape mounting clips 352 respectively mounted on the threading tape 326. Each tape mounting clip 352 may include a pair of jaws 354 pivotally connected to each other. The pair of jaws 354 of each tape mounting clip 352 may be actuated by a clamping actuator (not shown), such as an electromechanical actuator, for clamping onto the backing layer leading edge portion 232. The pair of tape mounting clips 352 may be oriented in a facing relationship to allow the tape mounting clips 352 to clamp onto opposite side edges of the backing layer leading edge portion 232.

[0097] For an example of a laminator 200 having a single threading tape 326 (i.e., located near the mounting frame 202), the backing layer 230, or at least the leading edge portion 232 of the backing layer, may have sufficiently high stiffness to allow the mounting layer engagement device 352 to pass the backing layer 230 through the laminator 200 as described below. In this respect, the relatively high bending stiffness of the leading edge portion 232 of the backing layer when engaged with the mounting layer engagement device 350 prevents the unsupported or unengaged side of the leading edge portion 232 of the backing layer from sagging, thereby allowing the mounting layer engagement device 352 to pass the backing layer 230 through the laminator 200 without causing the unengaged side of the leading edge portion 232 to become stuck on the laminator components. Furthermore, by limiting the laminator head 200 to a single threading tape 326 supported by a plurality of belt rollers 328 mounted close to the mounting frame 202 on the inner side of the laminator head 200, the redirection rollers 332 of the threading tape 326 can be fixedly mounted close to the backing layer collection drum 300 as described below.

[0098] Now for reference Figure 10-12 , Figure 10-12 An example of a reloading cylinder 400 that can be included with the manufacturing system 100 is shown. The reloading cylinder 400 is used to replace a depleted roll 418 from one or more laminating heads 200. Figure 10 This is an end view of laminating station 136, showing a reloading cylinder 400 located near laminating head 200, which is used to replace the depleted roll 418 on laminating head 200. Figure 11 This is a front view of the reloading cylinder 400, which shows multiple reloading mandrels 406, one of which is shown supporting a depleted roll 418, two of which are empty, and three of which are shown supporting a replacement roll 420. Figure 12 This is a top view of the reloading cylinder 400, showing the reloading mandrel 406, including the empty reloading mandrel 406, the reloading mandrel 406 supporting the replacement roll 420, and the reloading mandrel 406 supporting the depleted roll 418. Advantageously, the reloading cylinder 400 provides the ability to perform roll changes semi-autonomously and quickly with minimal impact on the production process, while avoiding the cost and complexity associated with replacing the entire laminator head 200 each time roll 224 is depleted.

[0099] As mentioned above and Figure 1 and Figure 3As shown, during operation of the laminator 200, the reloading cylinder 400 can be positioned outside the laminator station 136. The manufacturing system 100 may include a floor-mounted reloading cylinder track 402 extending generally parallel to a series of laminators 200. The reloading cylinder 400 may include a reloading cylinder drive motor (not shown) for moving the reloading cylinder 400 into and out of the laminator station 136 along the reloading cylinder track 402. During operation of the manufacturing system 100, the controller 112 may continuously receive input regarding the amount of layup material 228 retained on the rolls 224 of each laminator 200. When it is sensed that the rolls 224 of one or more laminators 200 are nearing depletion, the controller 112 may command the reloading cylinder 400 to move into the laminator station 136 and / or near one of the laminators 200 to facilitate the replacement of the roll 420. Figure 11 Replace the depleted roll 418 ( Figure 11 After the roll 224 on one or more laminators 200 is replaced, the reloading cylinder 400 can be moved back out of the laminator station 136. Although the reloading cylinder 400 is shown and described as movable via the reloading cylinder track 402, the reloading cylinder 400 can be supported by any of a variety of alternative mechanisms (not shown), such as overhead racks, robotic devices, or mechanisms for moving the reloading cylinder 400 into and out of the laminator station 136 and / or aligning it with each laminator head 200.

[0100] refer to Figure 10-14 The reloading cylinder 400 may include a material holder 404 and a material transfer mechanism 430. The material holder 404 may include a row of reloading mandrels 406. The reloading mandrels 406 may move along a circulation path 412 of the material holder 404 via a reloading mandrel circulation system 410. The reloading mandrel circulation system 410 may include components that can be controlled by a controller 112. Figure 1 A circulating path motor (not shown) is controlled by the controller 112. Upon command from the controller 112, the circulating path motor can move the reloading mandrel 406 along the circulating path 412 to any of a plurality of storage locations 414. Each reloading mandrel 406 may have an outer diameter complementary to the outer diameter of the material supply drum 220 on the laminator 200, thereby allowing a depleted roll 418 to slide (e.g., via material transfer mechanism 430) off the material supply drum 220 of the laminator 200 and onto an empty reloading mandrel 406, and also allowing a replacement roll 420 to slide from the reloading mandrel 406 onto an empty material supply drum 220 of the laminator 200.

[0101] like Figure 13-14 As shown, each reloading mandrel 406 may be configured to extend to engage with the material supply drum 220 of the laminating head 200, as described below. The free end of each reloading mandrel 406 may include a drum-mandrel alignment mechanism 408. Figure 11 The alignment mechanism is used to align with a corresponding drum-mandrel alignment mechanism 408 that may be included on the free end of the material supply drum 220 of each laminator 200. Figure 7 Locking alignment. In the example shown, the drum-mandrel alignment mechanism 408 at the end of each reloading mandrel 406 may be a raised boss with a cross shape, and the drum-mandrel alignment mechanism 408 at the end of each material supply drum 220 may be a cross-shaped recess of a corresponding size for receiving the cross-shaped boss of the reloading mandrel 406. However, the drum-mandrel alignment mechanism 408 may be provided in any of a variety of different sizes, shapes, and constructions, and is not limited to cross-shaped bosses and cross-shaped recesses.

[0102] Still referencing Figure 10-14 As described above, each reloading mandrel 406 can be configured to support rolls 224, such as depleted rolls 418 or replacement rolls 420. Depleted rolls 418 can consist primarily of a backing layer 230, which can be wound around the backing layer collection drum 300 of the laminator 200 during the application of layup material 228 to the substrate 122. Figure 7 After the laying material 228 is exhausted, the backing layer 230 on the backing layer collection drum 300 can be rewound onto the roll 224 to form an exhausted roll 418, which can then be transferred (via the material transfer mechanism 430) to the empty reloading mandrel 406 of the reloading drum 400, as shown. Figure 13-14 As shown. Replacement roll 420 may include layup material 228 backed by backing layer 230. As described above, the layup material 228 on replacement roll 420 may be a composite material (e.g., carbon fiber epoxy prepreg tape), or the layup material 228 may be a non-composite material, such as a processed material (e.g., release film, tackifier film, breathable layer, etc.), as described above. Although not shown, replacement roll 420 may be loaded onto reloading mandrel 406 manually or autonomously (e.g., via robotic device). Similarly, depleted roll 418 may be removed from reloading mandrel 406 manually or autonomously.

[0103] exist Figure 13-14 In this diagram, the material transfer mechanism 430 is shown transferring the depleted roll 418 from the laminator head 200 to the material holder 404. As described above, once the roll 224 on the laminator head 200 has exhausted the layup material 228, the backing layer 230 on the backing layer collection drum 300 can be rewound back onto the material supply drum 220. The reloading mandrel circulation system 410 (… Figure 11 This allows the reloading mandrel 406 to cycle until the empty reloading mandrel 406 is positioned at the center-top storage location 416 (e.g., Figure 11 And it is aligned with the exhausted roll 418 on the laminator 200. (As shown) Figure 13-14 As shown, the empty reloading mandrel 406 can extend and retract to engage with the material supply drum 220 of the laminating head 200. As described above, a drum-mandrel alignment mechanism 408 is located at the free end of the empty reloading mandrel 406. Figure 11 ) can be aligned with the corresponding drum-mandrel alignment mechanism 408 on the free end of the material supply drum 220. Figure 7 Join in a locked alignment manner.

[0104] The material transfer mechanism 430 may include a reloading actuator 432 configured to engage or grip a depleted roll 418 on the laminator head 200 and transfer the depleted roll 418 to an empty reloading mandrel 406. In the illustrated example, the reloading actuator 432 is configured as a reloading robot device 434 with a reloading robot arm 436. The reloading robot arm 436 may have an end effector (not shown), such as a vacuum pad, a clamping mechanism, or other mechanisms configured to engage or otherwise clamp onto the depleted roll 418 on the laminator head 200. The reloading robot arm 436 may be telescopic to extend into engagement with the depleted roll 418 on the laminator head 200. After the exhausted roll 418 is transferred from the laminating head 200 to the reloading cylinder 400, the drum-mandrel alignment mechanism 408 at the end of the reloading mandrel 406 can disengage from the drum-mandrel alignment mechanism 408 at the end of the material supply drum 220, as... Figure 15 As shown.

[0105] refer to Figure 16-19 The reloading cylinder 400 includes the aforementioned reloading mandrel circulation system 410, which allows the reloading mandrel 406 to be circulated to move the reloading mandrel 406 (supporting the replacement roll 420) to the center-top storage position 416 (e.g., Figure 16 This is for alignment with the empty material supply drum 220 on the laminator head 200. The reloading drum 400 may also include a pair of leading-edge alignment rollers 438 mounted on the material holder 404, one above the other near the center-top storage position 416. The leading-edge alignment rollers 438 may be vertically positioned relative to each other to define a roller interface 442 between the leading-edge alignment rollers 438. Figure 19 The leading edge alignment rollers 438 can move independently toward and away from each other to adjust the gap size at the roller interface 442 to accommodate backing layers 230 and / or backing materials 226 of varying thicknesses. For example, the gap at the roller interface 442 can be adjusted from zero gap (0.00 inch) to 0.005 inch or greater, depending on the thickness of the leading edge portion 232 of the backing layer to be captured or clamped between the leading edge alignment rollers 438 at the roller interface 442.

[0106] like Figure 19As shown, in preparation for transferring the replacement roll 420 from the reloading cylinder 400 to the laminating head 200 ( Figure 17 Empty material supply drum 220 ( Figure 17 When the backing layer leading edge alignment roller 438 is in operation, it can be driven by the alignment roller motor 440 to reverse the rotation of the leading edge alignment roller 438 to pull the leading edge portion 232 of the backing layer into the roller interface 442. The leading edge 242 of the backing layer leading edge portion 232 can be manually or automatically pulled off the replacement roll 420 on the reloading mandrel 406 at the center-top storage position 416 and positioned at the roller interface 442. The reverse rotation of the leading edge alignment roller 438 can pull the leading edge 242 of the backing layer leading edge portion 232 into the roller interface 442 until the leading edge portion 232 of the backing layer is clamped within the roller interface 442. As described below and Figure 20 As shown, the leading edge alignment roller 438 extends telescopically to position the leading edge portion 232 of the backing layer. Figure 20 ) with laminating head 200 ( Figure 20 ) material threading system 320 joint.

[0107] refer to Figure 18 In addition to the adjustability of the vertical position of the leading edge alignment rollers 438 relative to each other, the position of the leading edge alignment rollers 438 relative to the center-top storage position 416 can also be vertically adjusted to allow the roller interface 442 to be positioned at a height compatible with the height of the uppermost side of the outer diameter of the replacement roll 420 on the reloading mandrel 406 located at the center-top storage position 416. For example, the leading edge alignment rollers 438 can be vertically adjusted to position the roller interface 442 at approximately the same height as the horizontal tangent (not shown) of the uppermost side of the outer diameter of the replacement roll 420. The vertical adjustability of the leading edge alignment rollers 438 can accommodate replacement rolls 420 with different outer diameters. The difference in the outer diameter of the replacement rolls 420 may be due to the different thicknesses of the layup material 228 wound on different replacement rolls 420, and / or due to the difference in the total length of the continuous backing material 226 wound on different replacement rolls 420.

[0108] refer to Figure 20-21 Once the foremost edge 242 of the leading edge portion 232 of the backing layer ( Figure 19 The roller interface 442 between the leading edge alignment rollers 438 has been inserted. Figure 19 In this process, the horizontal position of the reloading cylinder 400 can be adjusted (e.g., via the reloading cylinder track 402-). Figure 3 The reloading mandrel 406 (i.e., at the center-top storage position 416) is positioned to align with the empty material supply drum 220 of the laminating head 200. The reloading mandrel 406 can extend telescopically to engage with the free end of the material supply drum 220. A drum-mandrel alignment mechanism 408 is located at the free end of the reloading mandrel 406. Figure 18) can be aligned with the corresponding drum-mandrel alignment mechanism 408 on the free end of the material supply drum 220. Figure 7 The material is engaged in a locking alignment manner. The material transfer mechanism 430 (e.g., reloading robot arm 436) can then transfer the replacement roll 420 from the reloading mandrel 406 to the empty material supply drum 220 on the laminating head 200. Simultaneously, the leading edge alignment roller 438 (which clamps the leading edge portion 232 of the backing layer) engages in a locking alignment manner. Figure 19 It can extend telescopically toward the laminator head 200 until the leading edge 242 of the backing layer leading edge portion 232. Figure 19 ) is positioned close to the mounting layer joint device 350 ( Figure 21 ).

[0109] refer to Figure 21-28 , Figure 21 The diagram shows the process of transferring replacement roll 420 from reloading mandrel 406 ( Figure 20 After being transferred to the material supply drum 220, the laminating head 200. Figure 22 The diagram shows the leading edge portion 232 of the backing layer captured between the retractable leading edge alignment rollers 438. An example of a tape mounting layer bonding device 350 supported on the threading tape 326 is also shown. Figure 23-24 As shown, the alignment roller motor 440 can be activated to reverse the rotation of the leading edge alignment roller 438 until the relatively short length of the backing layer leading edge portion 232 protrudes outward from the roller interface 442 along the direction toward one or more threaded tapes 326 of the laminator head 200. One or more belt drive motors 330 can be activated to drive one or more threaded tapes 326 on the belt roller 328, thereby moving (i.e., rotating) the belt mounting layer engagement device 350 to engage with the leading edge 242 of the backing layer leading edge portion 232, thereby transferring the backing layer leading edge portion 232 from the leading edge alignment roller 438 to the belt mounting layer engagement device 350.

[0110] refer to Figure 25 , Figure 25An example of a tape-mounted layer bonding device 350 configured as an electromagnetic member 355 is shown. As described above, the electromagnetic member 355 may be an electromagnetic lateral member 356, which may extend between a pair of threaded strips 326 and may be activated (e.g., via an electromagnetic power source - not shown) to be magnetically coupled to a magnetically attracting element 234 that may be included with the leading edge portion 232 of the backing layer. The magnetically attracting element 234 may comprise a relatively thin strip of metallic material or other magnetically attractable material, which may be mounted, adhesively bonded to, or otherwise included with the leading edge 242 of the leading edge portion 232 of the backing layer. The magnetically attracting element 234 may be located a short distance (e.g., less than 1 inch) upstream of the leading edge 242 of the leading edge portion 232 of the backing layer, such that the leading edge 242 protrudes downstream of the tape-mounted layer bonding device 350 and when the drum mounting layer bonding device 306 approaches the backing layer collection drum 300 ( Figure 31 The collection drum opening 304 ( Figure 31 This facilitates the insertion of the leading edge 242 of the backing layer leading edge portion 232 into the drum mounting layer engagement device 306. Figure 31 As described below.

[0111] As an alternative to the electromagnetic transverse member 356 coupled to the magnetic attraction element 234, the mounting layer bonding device 350 can be configured as one or more mounting clips 352, such as Figure 9 A pair of electromechanically actuated mounting clips 352 are shown for clamping onto the leading edge portion 232 of the backing layer. In yet another example, the mounting layer engagement device 350 may be configured as a fastener 357, such as the aforementioned fastening transverse member 358. Figure 8 The fastening transverse member 358 has a ring element strip (not shown) or a hook element strip (not shown) configured to releasably engage with the hook element strip or the ring element strip, respectively, which may be included on the backing layer leading edge portion 232. However, the tape mounting layer engagement device 350 may be provided in any of a variety of other arrangements for releasably engaging the backing layer leading edge portion 232 to the tape mounting layer engagement device 350.

[0112] refer to Figure 26-28 Once the leading edge portion 232 of the backing layer is engaged with the mounting layer engagement device 350, the leading edge alignment rollers 438 can move independently away from each other to release the leading edge portion 232 of the backing layer, as... Figure 26 As shown. Figure 28 As shown, the leading edge alignment roller 438 can retract telescopically toward the reloading cylinder 400. Furthermore, the reloading mandrel 406 can retract telescopically from the material supply drum 220, and the reloading cylinder 400 can be removed from the laminating station 136 (e.g., via the reloading cylinder track 402-). Figure 1 ).like Figure 27As shown, the belt drive motor 330 can then be activated to drive one or more threading belts 326 on the belt roller 328, thereby moving them along the material path 322 ( Figure 7 Pull the belt to install the lamination device 350 for passing at least the backing layer 230 through the laminator head 200.

[0113] refer to Figures 29-31 , Figures 29-31 The progress of the backing layer 230 through the laminating head 200 via the mounting layer bonding device 350 is shown. Figure 29 The initial stage of the threading process is shown, wherein the mounting layer bonding device 350 is shown pulling the leading edge 242 of the backing layer leading edge portion 232 over the guide surface 206 above the cutter assembly 250. Figure 30 A mounting layer bonding device 350 is shown after passing between cutter module 252 and cutter pressure plate 254, wherein cutter module 252 and cutter pressure plate 254 can be temporarily separated to provide a gap for the passage of mounting layer bonding device 350. Figure 31 The diagram shows the installation layer joining device 350 moving the leading edge 242 of the backing layer leading edge portion 232 into the drum installation layer joining device 306 included together with the backing layer collecting drum 300.

[0114] Figure 31 Also shown is a redirection roller 332, which may be included together with a plurality of belt rollers 328 supporting one or more threading tapes 326. As described above, for an example of a laminator head 200 having a single threading tape 326, the redirection roller 332 may be fixedly mounted to the mounting frame 202 at a redirection roller engagement position 338. However, for an example of a laminator head 200 having a pair of threading tapes 326 located on opposite sides of the material path 322, the belt rollers 328 supporting the pair of threading tapes 326 may include a pair of redirection rollers 332. The pair of redirection rollers 332 may be configured to translate along the redirection roller path 334 between a redirection roller initial position 336 and a redirection roller engagement position 338. The redirection roller 332 in the redirection roller initial position 336 may be located at a distance from the backing layer collection drum 300, a distance that provides a gap for the backing layer 230 when the layup material 228 has been completely wound onto the backing layer collection drum 300 after it has been exhausted from the roll 224. Figure 31As shown, in the redirection roller engagement position 338, the redirection roller 332 can be positioned close to the backing layer collection drum 300, and the tape mounting layer engagement device 350 can be oriented to align the leading edge 242 of the backing layer leading edge portion 232 with the drum mounting layer engagement device 306. The redirection roller path 334 can be an arcuate path, such that the redirection roller 332 maintains a constant tension in the threading tape 326 as it moves between the redirection roller initial position 336 and the redirection roller engagement position 338.

[0115] refer to Figure 32-35 , Figure 32-35 An example is shown of the engagement of the drum mounting layer engagement device 306 with the leading edge portion 232 of the backing layer. (See example...) Figure 32 As shown, the redirection roller 332 is in the redirection roller engagement position 338 for aligning the leading edge 242 of the backing layer leading edge portion 232 with the collection drum opening 304 (e.g., a slot) in the backing layer collection drum 300. Before the backing layer leading edge portion 232 reaches the backing layer collection drum 300, the collection drum motor 302 can orient the collection drum opening 304 toward the facing direction of the leading edge 242 of the backing layer leading edge portion 232. When the leading edge 242 of the backing layer leading edge portion 232 is positioned close to the drum mounting layer engagement device 306, the movement of the threading tape 326 can be paused to facilitate engagement with the drum mounting layer engagement device 306. As described below, the tape mounting layer engagement device 350 is configured to release the backing layer leading edge portion 232 after the drum mounting layer engagement device 306 engages with the backing layer leading edge portion 232, thereby transferring the backing layer 230 from the tape mounting layer engagement device 350 to the backing layer collection drum 300.

[0116] exist Figure 32-35 In the example, the drum mount layer engagement device 306 may include at least one drum mount clamping mechanism 308, which is contained within the backing layer collection drum 300. The drum mount clamping mechanism 308 may include a pair of jaws 310, which are pivotally coupled to each other and actuated by one or more clamping actuators (not shown) to clamp onto the leading edge 242 of the backing layer leading edge portion 232. Figure 32 As shown, the jaws 310 of the drum mounting clamping mechanism 308 can be oriented to open in a direction facing the leading edge 242 of the backing layer leading edge portion 232. The backing layer leading edge portion 232 can have a higher bending stiffness (e.g., in the axial direction) than the upstream portion of the backing layer 230. The relatively higher bending stiffness of the backing layer leading edge portion 232 prevents it from bending from side to side, instead maintaining a relatively straight shape to facilitate insertion of the leading edge 242 into the drum mounting layer engagement device 306. Furthermore, the relatively higher bending stiffness of the backing layer leading edge portion 232 facilitates the engagement with the aforementioned and Figure 22-24The shown is the engagement of the mounting layer engagement device 350.

[0117] Figure 33 The drum clamp 310 of the drum mounting clamping mechanism 308 is shown clamping onto the leading edge 242 of the backing layer leading edge portion 232. Once the backing layer leading edge portion 232 is engaged with the drum mounting layer engagement device 306 (e.g., drum mounting clamping mechanism 308), the redirecting roller 332 can be moved from the redirecting roller engagement position 338 (…). Figure 36 Move to the initial position 336 of the redirection roller. Figure 31 This provides a gap for the backing layer 230 to be wound onto the backing layer collection drum 300. With the redirection roller 332 in the redirection roller initial position 336, the material threading system 320 can guide the laying material 228 ( Figure 5 ) applied to substrate 122 ( Figure 5 The period above is static. Figure 34 The initial rotation of the backing layer collecting drum 300 is shown, wherein the leading edge portion 232 of the backing layer engages with the drum mounting layer engagement device 306. Figure 35 The leading edge portion 232 of the backing layer is shown to be wound several times around the backing layer collection drum 300.

[0118] As an alternative to the drum mounting clamping mechanism 308, the drum mounting layer engagement device 306 can be configured as a drum mounting electromagnetic engagement device (not shown), which is configured to be magnetically coupled to a magnetically attracted element 234 that can be mounted to the leading edge portion 232 of the backing layer. Figure 25 In another alternative to the drum mount clamping mechanism 308, the drum mount layer engagement device 306 can be configured as a drum mount vacuum engagement device (not shown), which is configured to vacuum couple to the leading edge portion 232 of the backing layer. It is understood that the drum mount layer engagement device 306 can be provided in any of a variety of configurations for engagement with the leading edge portion 232 of the backing layer, and is not limited thereto. Figure 32-35 The drum mounting clamping mechanism 308 shown is illustrated.

[0119] Figure 36The redirection roller 332 is shown in its initial position 336. A collection drum motor 302 is also shown rotating a backing layer collection drum 300 to pull the backing layer 230 through the laminator head 200. The outermost circumference of the roll 224 typically consists only of the backing layer 230, without any layup material 228. For example, the roll 224 may have only a few feet (e.g., up to 15 feet) of backing layer 230 at its starting point. Once the leading edge portion 232 of the backing layer is engaged with the backing layer collection drum 300, the collection drum motor 302 can rotate the backing layer collection drum 300 to pull out enough backing layer 230 until the backing material 226 (i.e., the layup material 228 backed by the backing layer 230) begins to move off the roll 224, at which point the cutter assembly 250 and the backing layer separation assembly 260 can be activated to begin removing the layup material 228 ( Figures 37-38 ) applied to substrate 122 ( Figure 5 The process on the substrate 122. For example, as described above, the cutter module 252 and the cutter platen 254 can be positioned near the laminator head 200 at the route 238 where the layup material 228 is to be applied to the substrate 122. Figure 5 The cut in the pavement 228 at the starting point of the pavement is used to cut the pavement material 228. The cut in the pavement material 228 creates a leading edge of the pavement material (not shown) and a trailing edge of the pavement material adjacent to the leading edge of the pavement material (not shown).

[0120] refer to Figures 37-38 , Figures 37-38 An example of a laminator 200 applying layup material 228 to a substrate 122 is shown. As described above, the laminator 200 includes a backing layer separation assembly 260. Furthermore, the laminator 200 may include at least one compaction device. The backing layer separation assembly 260 may include at least one separation device configured to separate the leading edge of the layup material from the backing layer 230 and, as the laminator 200 moves in the travel direction, guide the layup material 228 toward the substrate 122 and below the compaction device for compaction onto the substrate 122.

[0121] Figures 37-38 The lower portion of the laminating head 200 is shown, which has a design for travel along a first direction of travel 208 ( Figure 37 ) and along the first segment of the journey 208 ( Figure 37 ) The opposite second direction of travel 210 ( Figure 37 Apply the laying material 228 to the substrate 122. Figure 38The backing layer separation assembly 260 may include a first separation device 262 and a second separation device 272 having a first guide angle 268 and a second guide angle 276, respectively, each guide angle being movable between a separation device retracted position 278 and a separation device extended position 280. Furthermore, the laminating head 200 may include a first compaction device 284 and a second compaction device 288 configured to apply compaction pressure to the layup material 228 abutting against the substrate 122. The first compaction device 284 may include a first compaction device actuator 286 configured as a linear actuator to alternately move the first compaction device 284 between its compaction device retracted position 292 (e.g., an elevated position) and its compaction device extended position 294 (i.e., a lower position). Similarly, the second compaction device 288 may include a second compaction device actuator 290, which is configured as a linear actuator to alternately move the second compaction device 288 between its compaction device retracted position 292 and its compaction device extended position 294.

[0122] refer to Figure 37 When the first separating device 262 is in its extended separating device position 280, the first guide angle 268 is close to the first compaction device 284. Furthermore, the first compaction device 284 descends onto the substrate 122, and the second guide angle 276 and the second compaction device 288 retract. The first guide angle 268, in its extended separating device position 280, is configured to separate the layup material 228 from the backing layer 230 and guide the layup material 228 towards the substrate 122 and below the first compaction device 284 as the laminating head 200 moves along the first travel direction 208.

[0123] refer to Figure 38 When the second separating device 272 is in its extended position 280, the second guide angle 276 is close to the second compaction device 288. Furthermore, the second compaction device 288 descends onto the substrate 122, and both the first guide angle 268 and the first compaction device 284 retract. The second guide angle 276 is configured to separate the layup material 228 from the backing layer 230, and as the laminating head 200 moves along the second travel direction 210, it guides the layup material 228 towards the substrate 122 and below the second compaction device 288. The first guide angle 268 and the second guide angle 276 each have a distal guide angle 270 with a small radius of curvature, which causes the leading edge of the layup material to separate from the backing layer 230 as the backing layer 230 moves about the distal guide angle 270 toward the backing layer collection drum 300. Figure 36 ).

[0124] Still referencing Figures 37-38The first separating device 262 may have a first separating device actuator 264, which is configured as a linear actuator to alternately move the first guide angle 268 between its retracted position 278 and its extended position 280. Similarly, the second separating device 272 may have a second separating device actuator 274, which is also configured as a linear actuator to move the second guide angle 276 between its retracted position 278 and its extended position 280. Advantageously, the actuator axes (not shown) of the first separating device 262 and the second separating device 272 may be oriented intersectingly, which allows the first guide angle 268 to be positioned close to the first compaction device 284 and the second guide angle 276 to be positioned close to the second compaction device 288. The ability to position the first guide angle 268 and the second guide angle 276 abutting the first compaction device 284 and the second compaction device 288, respectively, results in reduced tension and stretching of the unsupported section (i.e., without backing layer) of the layup material between the distal end 270 of each guide angle 268, 276 and the substrate 122. This reduction or elimination of stretching in the unsupported section of the layup material can reduce or eliminate warping that would otherwise occur in the composite laminate 240 in which the layup material is stretched during installation.

[0125] refer to Figure 39 , Figure 39 A laminating head 200 is shown, in which roll 224 has exhausted layup material 228, and a backing layer 230 wound on a backing layer collection drum 300 is also shown. When preparing to rewind the backing layer 230 onto roll 224, the first separating device 262 and the second separating device 272 are in their respective retracted positions, as are the first compacting device 284 and the second compacting device 288. The supply drum motor 222 can be commanded to rotate the material supply drum 220 in the opposite direction to unwind the backing layer 230 from the backing layer collection drum 300 and rewind the backing layer 230 onto the material supply drum 220, resulting in an exhausted roll 418. Figure 40 It mainly includes the backing layer 230.

[0126] refer to Figures 40-43 , Figure 40 The image shows a depleted roll 418 containing primarily the backing layer 230 during the final stage of rewinding the backing layer 230 via the laminator 200. During the final length of rewinding of the backing layer 230, rotation of the backing layer collection drum 300 can be stopped, causing the collection drum opening 304 to be oriented towards the backing layer separation assembly 260. The drum mount layer engagement device 306 can release the leading edge portion 232 of the backing layer, thereby allowing the leading edge 242 of the leading edge portion 232 to separate from the drum mount layer engagement device 306 and allowing the leading edge 242 of the leading edge portion 232 to exit the collection drum opening 304, as shown. Figures 40-41 As shown. Figure 42 The leading edge portion 232 of the backing layer is shown after it has been pulled past the cutter assembly 250 by the rotation of the material supply drum 220. Figure 43 In the middle, the redirection roller 332 can move from the redirection roller initial position 336 to the redirection roller engagement position 338 to prepare for the insertion of a new or replacement roll 420. Figure 28 The backing layer 230 passes through the laminating head 200. Additionally, the belt drive motor 330 can be activated to reverse the movement of the threading belt 326, thereby moving the belt mounting layer bonding device 350 from the backing layer collection drum 300 back to its proximity to... Figure 6 The initial position of the material supply drum 220 is shown. As described above, for the example of a laminator head 200 with a single redirecting roller 332 supporting a single threading tape 326, the redirecting roller 332 can be fixedly mounted in the redirecting roller engagement position 338 and close to the mounting frame 202 to prevent the redirecting roller 332 from interfering with the backing layer 230 winding onto the backing layer collection drum 300. (Using material from the reloading cylinder 400...) Figure 3 The process described above, in which replacement roll 420 replaces the depleted roll 418 on laminating head 200, can be performed on composite laminate 240. Figure 5 The laying process can be repeated an arbitrary number of times.

[0127] Now for reference Figure 44-62 , Figure 44-62 An example of a laminating head 200 is shown, which is essentially similar to Figure 6-7 The aforementioned laminating head 200 is shown. However, Figure 44-62 The laminator head further includes a leading edge coupling device 360 ​​to facilitate the passage of the backing layer 230 through the laminator head 200. Before the backing layer 230 of a new or replacement roll 420 initially passes through the laminator head 200, the leading edge coupling device 360 ​​is configured to engage the leading edge portion 232 of the backing layer to the tape mounting layer coupling device 350 when positioned near the material supply drum 220. As described above, the laminator head 200 may be provided with a single threading tape 326 supporting the tape mounting layer coupling device 350, or the laminator head 200 may be provided with a pair of threading tapes 326 that collectively support the tape mounting layer coupling device 350. A belt drive motor 330 of one or more threading tapes 326 may be activated to pass the leading edge portion 232 of the backing layer through the laminator head 200 and toward the backing layer collection drum 300. Upon reaching the backing layer collection drum 300, the leading edge coupling device 360 ​​is configured to release from the belt mounting layer coupling device 350 and engage with the drum mounting layer coupling device 306. Figure 51 This transfers the leading edge portion 232 of the backing layer from the threading tape 326 to the backing layer collection drum 300, as described in more detail below.

[0128] After most of the laying material 228 has been applied to the substrate 122 ( Figure 5After the backing layer 230 on the backing layer collection drum 300 has been rewound onto the material supply drum 220, the leading edge coupling device 360 ​​provides a means for securing the leading edge 242 of the backing layer leading edge portion 232 to the threading tape 326 while threading the leading edge 242 back through the laminator head 200. In this respect, the leading edge coupling device 360 ​​is configured to release from the drum mounting layer engagement device 306 and re-engage with the tape mounting layer engagement device 350. The tape drive motor 330 can then be activated to drive the threading tape 326 in the opposite direction to move the leading edge coupling device 360 ​​(e.g., when engaged with the tape mounting layer engagement device 350 and the leading edge 242) through the laminator head 200 and back to its initial position near the material supply drum 220. The leading edge 242 can then be released from the leading edge coupling device 360 ​​to allow the leading edge 242 of the backing layer leading edge portion 232 to be wound onto the depleted roll 418. Figures 58-61 ), and then it can be replaced with replacement roll 420 ( Figure 25 ), as described below.

[0129] refer to Figure 44 and 46 , Figure 44 and 46 The process for attaching the leading edge portion 232 of the backing layer to the leading edge coupling device 360 ​​is illustrated. The leading edge coupling device 360 ​​can be attached to the mounting layer coupling device 350. (In conjunction with the above...) Figure 18-19 In a process similar to that shown, when the replacement roll 420 is on the reloading drum 400, before engaging the leading edge portion 232 of the backing layer of the leading edge coupling device 360, the foremost edge 242 of the backing layer leading edge portion 232 of the replacement roll 420 may be initially inserted (e.g., manually) into the roll interface 442 between the leading edge alignment rollers 438. Figure 46 Similar to Figure 20-22 The process shown, Figure 44 The leading edge alignment roller 438 is shown extending telescoping toward the laminator 200 after the replacement roll 420 has been transferred from the reloading cylinder 400 to the material supply drum 220.

[0130] exist Figure 44 and 46 In this configuration, the leading edge alignment roller 438 can rotate in the opposite direction to extend the leading edge 242 of the backing layer leading edge portion 232 to engage with the leading edge coupling device 360, similar to the above. Figure 23-24 The process shown is as follows. Figure 46An example of a leading-edge coupling device 360 ​​configured as an electromagnetic device 364 is shown. A mounting layer coupling device 350 is shown configured as a magnetic element 234. Similarly, the backing layer leading-edge portion 232 may include at least one magnetic element 234, as described above. The electromagnetic device 364 can be activated (e.g., via an electromagnetic power source – not shown) to magnetically couple to the magnetic element 234 on the threading tape 326 (i.e., the mounting layer coupling device 350). As the electromagnetic device 364 is coupled to the threading tape 326, the electromagnetic device 364 can be activated to couple to the magnetic element 234 of the backing layer leading-edge portion 232 when the counter-rotating leading-edge alignment roller 438 extends the leading edge 242 of the backing layer leading-edge portion 232 abuts against the electromagnetic device 364. In the example shown, the electromagnetic device 364 (e.g., leading edge coupling device 360) may include a device slot 362, which is sized and configured to receive and magnetically couple with the leading edge portion 242 of the backing layer 232.

[0131] Figure 45 and 47 This illustrates how leading edge alignment rollers 438 move independently of each other to release the leading edge portion 232 of the backing layer. Similar to... Figure 28 The arrangement shown above, with leading edge aligned roller 438 (e.g., in...) Figure 45 and 47 (middle) and reloading spindle 406 ( Figure 28 It can retract telescopically toward the reloading cylinder 400. (Example) Figure 48 As shown, the drive motor 330 can be activated to drive one or more threading tapes 326 on the belt roller 328, thereby causing the leading edge coupling device 360 ​​to begin pulling the backing layer 230 off the roll 224 and passing the backing layer 230 through the laminator head 200.

[0132] although Figure 44-47 The leading edge coupling device 360 ​​is shown as an electromagnetic device 364, but the leading edge coupling device 360 ​​can be provided in any of a variety of alternative configurations. For example, the leading edge coupling device 360 ​​can be configured as one or more electromechanically actuated clips (not shown) similar to the aforementioned mounting clip 352. Figure 9 The 352 with mounting clips Figure 9 The lead edge coupling device 360 ​​is configured to clamp onto the leading edge portion 232 of the backing layer and is also releasably engaged with the threading tape 326. In another alternative example, the leading edge coupling device 360 ​​may be configured as one or more fastening elements 236. Figure 8 ), such as hook element strips and / or loop element strips (e.g., Velcro). TM(not shown), the hook element strip and / or ring element strip are configured to be releasably fastened to the leading edge portion 232 of the backing layer, to the threading strip 326, and to the collecting drum 300 of the backing layer, respectively.

[0133] Figures 48-50 Progress has been made in a leading edge connection device 360 ​​(e.g., electromagnetic device 364) that allows the leading edge portion 232 of the backing layer to pass through the laminator head 200. Figure 48 It is also shown that the leading edge connection device 360 ​​pulls the leading edge 242 of the backing layer leading edge portion 232 over the guide surface 206 located above the cutter assembly 250. Figure 49 The leading edge connection device 360 ​​is shown after passing between the cutter module 252 and the cutter pressure plate 254. Figure 50 The leading edge coupling device 360 ​​is shown after moving past the backing layer separation assembly 260 and reaching the backing layer collection drum 300.

[0134] refer to Figures 51-54 , Figures 51-54 An electromagnetic device 364 (i.e., leading edge coupling device 360) at the backing layer collection drum 300 is shown. The redirection roller 332 is shown in the redirection roller engagement position 338. As described above, for an example of a laminator head 200 having a belt-mounted layer coupling device 350 mounted to a single threading tape 326, the redirection roller 332 can be fixedly mounted in the redirection roller engagement position 338. Figure 51 In this configuration, the movement of one or more threading tapes 326 has stopped to position the electromagnetic device 364 aligned with the collection drum opening 304 of the backing layer collection drum 300. The leading edge coupling device 360 ​​can be configured to at least partially protrude into the collection drum opening 304 when the movement of the threading tape 326 has stopped. The collection drum opening 304 may include a magnetic element 234. The electromagnetic device 364 can be electrically manipulated to release the magnetic coupling between the electromagnetic device 364 (i.e., the leading edge coupling device 360) and the magnetic element 234 on the threading tape 326 (e.g., the tape mounting layer bonding device 350), and to magnetically couple the electromagnetic device 364 to the magnetic element 234 of the backing layer collection drum 300, thereby pulling the electromagnetic device 364 into the collection drum opening 304, as... Figure 52 As shown. Figure 53 The initial rotation of the backing layer collecting drum 300 is shown, with the leading edge coupling device 360 ​​engaged with the backing layer collecting drum 300. Figure 54 The leading edge portion 232 of the backing layer is shown to be wound several times around the backing layer collection drum 300.

[0135] Figure 55The diagram shows the redirection roller 332 moving to its initial position 336 to provide a gap for the backing layer 230 to be fully wound onto the backing layer collection drum 300 after the layup material 228 has been exhausted from the roll 224. Layup material 228 is then applied to the substrate 122. Figure 5 The process can be similar to Figures 37-38 The bidirectional laying process is shown above. However, as mentioned above, the leading edge connection device 360 ​​can be implemented on the laminating head 200 (not shown), which is limited to applying the laying material 228 in a single direction of travel.

[0136] refer to Figures 56-62 , Figure 56 The image shows a laminating head 200, in which roll 224 has exhausted the layup material 228. Figure 55 The backing layer 230 is wound onto the backing layer collecting drum 300. The first separating device 262, the second separating device 272, the first compacting device 284, and the second compacting device 288 are in their respective retracted positions. The supply drum motor 222 can rotate in the opposite direction to unwind the backing layer 230 from the backing layer collecting drum 300 and rewind the backing layer 230 onto the roll 224.

[0137] Figure 57 This illustrates the final stage of rewinding the backing layer 230 onto the roll 224. Similar to... Figures 40-43 The process described above, Figure 57 The backing layer collecting drum 300 can be rotated until the collecting drum opening 304 is oriented in a direction facing the backing layer separating assembly 260. The redirecting roller 332 can be moved from the redirecting roller initial position 336 to a redirecting roller engagement position 338 near the backing layer collecting drum 300. The power supply to the electromagnetic device 364 (i.e., the leading edge coupling device 360) can be actuated to release the electromagnetic device 364 from the backing layer collecting drum 300, while simultaneously magnetically coupling the electromagnetic device 364 to the tape mounting layer engagement device 350 (i.e., the magnetic element 234) on the threading tape 326, such as... Figure 58 As shown.

[0138] Figure 59 The movement of one or more threading tapes 326 is shown to move the electromagnetic device 364 (i.e., the leading edge coupling device 360) away from the backing layer collection drum 300, while the material supply drum 220 is rotated to wind the backing layer 230 back onto the roll 224. Figure 60 This illustrates the movement of the electromagnetic device 364 toward the cutter assembly 250 as the backing layer 230 continues to be wound onto the roll 224. Figure 61 The electromagnetic device 364 is shown returning to its initial position near the material supply drum 220 and still coupled to the leading edge portion 232 of the backing layer. Figure 62The remaining portion of the leading edge portion 232 of the backing layer is shown wound onto the roll 224, thereby forming a depleted roll 418.

[0139] Now for reference Figure 63 , Figure 63 A method 500 for passing layup material 228 through a laminator head 200 is illustrated. Step 502 of method 500 includes supporting a roll 224 of backing material 226 on a material supply drum 220. As described above, the backing material 226 comprises layup material 228 backed by a backing layer 230. As described above, layup material 228 may be a composite material, such as a continuous strip of fiber-reinforced polymer matrix material (e.g., prepreg tape), or layup material 228 may be a non-composite material, such as metal foil, metal mesh, release film, tackifier film, breathable layer, venting layer, release layer, or any of a variety of other types of non-composite materials that may be dispensed by the laminator head 200 before, during, or after the dispensing of a composite material.

[0140] Step 504 of method 500 includes engaging the leading edge portion 232 of the backing layer 230 to a mounting layer engagement device 350, which is coupled to a continuous loop threading tape 326 located on one side of the material path 322 passing through the laminator head 200. As described above, the threading tape 326 may be supported on a plurality of tape rollers 328. For an example of a laminator head 200 having a pair of tape raceways 324, step 504 includes engaging the leading edge portion 232 of the backing layer to the mounting layer engagement device 350, which is coupled to a pair of threading tapes 326 arranged in a parallel and spaced-apart relationship on opposite sides of the material path 322 passing through the laminator head 200. In some examples, step 504 of engaging the backing layer leading edge portion 232 to the tape mounting layer engagement device 350 may include clamping it onto the backing layer leading edge portion 232 using at least one tape mounting clip 352 mounted on the threading tape 326. In the illustrated example, the method may include using a pair of tape mounting clips 352 respectively mounted on a pair of threading tapes 326. Figure 9 ) sandwiched on the front edge portion 232 of the backing layer, such as Figure 8 As shown. As described above, the jaws 354 with mounting clips 352 can be oriented to open in a face-to-face relationship to allow the jaws 354 to clamp onto the leading edge portion 232 of the backing layer.

[0141] In another example, step 504 of attaching the leading edge portion 232 of the backing layer to the mounting layer attachment device 350 may include using an electromagnetic member 355 coupled to the threaded strap 326 to a magnetically coupled magnetic element 234 of the leading edge portion 232 of the backing layer. For a pair of threaded straps 326 ( Figure 8Example of a laminating head 200, step 504 may include magnetically coupling a magnetic element 234 of the leading edge portion 232 of the backing layer to an electromagnetic lateral member 356 (i.e., a strip mounting layer bonding device 350) extending between a pair of threaded tapes 326. Figure 25 As shown and described above, the electromagnetic transverse member 356 can be activated by an electromagnetic power source (not shown) such that the electromagnetic transverse member 356 is magnetically coupled to a magnetically attracting element 234 included together with the leading edge portion 232 of the backing layer. As described above, the magnetically attracting element 234 can be configured as one or more relatively thin strips of metal material attached to the leading edge portion 232 of the backing layer.

[0142] In yet another example, step 504 of engaging the backing layer leading edge portion 232 to the mounting layer engagement device 350 may include fastening one of the hook element strips or loop element strips of the backing layer leading edge portion 232 to one of the loop element strips or hook element strips of the fastening member 355 coupled to one or more threading straps 326. For example, step 504 may include engaging the fastening transverse member 358 (i.e., the mounting layer engagement device 350) to the fastening element 236 included together with the backing layer leading edge portion 232. As described above, the fastening transverse member 358 may be a relatively rigid material extending between a pair of threading straps 326, and it may have loop element strips or hook element strips coupled to the fastening transverse member 358. The fastening element 236 on the backing layer leading edge portion 232 may be a hook element strip or loop element strip for engaging with the loop element strip or hook element strip of the fastening transverse member 358, respectively.

[0143] In yet another example, step 504 of attaching the leading edge portion 232 of the backing layer to the mounting layer attachment device 350 may include attaching the leading edge connection device 360 ​​to the mounting layer attachment device 350, and attaching the leading edge portion 232 of the backing layer to the leading edge connection device 360. In the above... Figures 46-47 In the example shown, the leading edge coupling device 360 ​​may include an electromagnetic device 364 that can be activated to magnetically couple to a magnetically attracting element 234 that may be included with the leading edge portion 232 of the backing layer. Figures 46-47 As shown, the leading edge connection device 360 ​​may optionally include a device slot 362, which is sized and configured to receive the leading edge 242 of the backing layer leading edge portion 232. In addition to magnetic coupling with the magnetic element 234 on the backing layer leading edge portion 232, the electromagnetic device 364 can be activated to magnetically couple to the magnetic element 234 mounted to the threading tape 326.

[0144] When the leading edge portion 232 of the backing layer is engaged with the tape mounting layer engagement device 350, the method may include step 506 of driving the threading tape 326 on the tape roller 328 using a tape drive motor 330, thereby causing the tape mounting layer engagement device 350 to pull at least the backing layer 230 out of the material supply roller and to pass at least the backing layer 230 along the material path 322 through the laminating head 200 and into a position near the backing layer collection drum 300, as described above. Figures 29-30 As shown in Figures 48-49. As described below, when the laminating head 200 applies the layup material 228 onto the substrate 122, the backing layer collection drum 300 is configured to wind at least the backing layer 230 onto the backing layer collection drum 300.

[0145] Before the leading edge portion 232 of the backing layer reaches the backing layer collecting drum 300, the method may include positioning the redirecting roller 332 at a redirecting roller engagement position 338 adjacent to the backing layer collecting drum 300, as described above. Figure 31 and 50 As shown. However, as mentioned above for a laminator head 200 with a single threading tape 326 positioned close to 202, the redirection roller 332 can be fixedly mounted to the mounting frame 202 at the redirection roller engagement position 338. For the example of a laminator head 200 with a pair of threading tapes 326, the corresponding redirection roller 332 can initially be in the redirection roller initial position 336 and can move to the redirection roller engagement position 338 before or approximately at the time when the drum mounting layer engagement device 306 (i.e., and the backing layer leading edge portion 232) reaches the backing layer collection drum 300. As described above, the redirection roller 332 is part of the guide roller 204 that supports the threading tape 326. Figure 32 and 51 As shown, when the redirecting roller 332 is in the redirecting roller engagement position 338, the mounting layer engagement device 350 can orient the leading edge portion 232 of the backing layer to engage with the backing layer collection drum 300. In addition to moving the redirecting roller 332 to the redirecting roller engagement position 338 before the leading edge portion 232 of the backing layer reaches the backing layer collection drum 300, the collection drum motor 302 can rotate the backing layer collection drum 300 to orient the collection drum opening 304 towards the facing direction of the leading edge 242 of the leading edge portion 232 of the backing layer.

[0146] When the leading edge coupling device 360 ​​reaches the backing layer collecting drum 300, the method may include engaging the leading edge portion 232 of the backing layer to the drum mounting layer coupling device 306 of the backing layer collecting drum 300. The step of engaging the leading edge portion 232 of the backing layer to the drum mounting layer coupling device 306 may include receiving, from the mounting layer coupling device 350, the leading edge 242 of the leading edge portion 232 of the backing layer in the collecting drum opening 304 formed in the backing layer collecting drum 300, such as... Figures 32-33As shown. The method may further include disengaging the backing layer leading edge portion 232 from the mounting layer engagement device 350 after the backing layer leading edge portion 232 has been engaged with the drum mounting layer engagement device. Disengagement of the backing layer leading edge portion 232 from the mounting layer engagement device 350 may include disabling the electromagnetic transverse member 356 by deactivating an electromagnetic power supply (not shown) that can power the electromagnetic transverse member 356. Figure 8 The magnetic element 234 of the leading edge portion 232 of the backing layer is magnetically separated from the backing layer leading edge portion 232. In another example, the separation of the backing layer leading edge portion 232 from the mounting layer bonding device 350 may include a loop element strip or hook element strip (e.g., Velcro) mounted on the backing layer leading edge portion 232. TM ) and fastening transverse member 358 with corresponding hook element strip or ring element strip. Figure 8 Disengagement. In another example, disengagement of the backing layer leading edge portion 232 from the tape mounting layer engagement device 350 may include releasing a pair of tape mounting clips 352 from the backing layer leading edge portion 232. Figure 9 ).

[0147] The step of engaging the leading edge 242 of the backing layer leading edge portion 232 to the drum mount layer engagement device 306 may include clamping it onto the leading edge 242 of the backing layer leading edge portion 232 using a drum mount clamping mechanism 308. As described above, the drum mount clamping mechanism 308 may include a pair of jaws 310 pivotally coupled to each other and actuated by one or more clamping actuators (not shown). In the illustrated example, the drum mount clamping mechanism 308 may be included within the backing layer collection drum 300.

[0148] As an alternative to the drum mounting clamping mechanism 308, the drum mounting layer joining device 306 may be a drum mounting electromagnetic joining device (not shown), configured to be magnetically coupled to a magnetically attracted element 234 (e.g., a thin metal strip) mounted on the leading edge portion 232 of the backing layer. In yet another alternative to the drum mounting clamping mechanism 308, the drum mounting layer joining device 306 may be a drum mounting vacuum joining device (not shown), configured to be vacuum-coupled to the leading edge portion 232 of the backing layer.

[0149] refer to Figures 51-52As an alternative to engaging the backing layer leading edge portion 232 to the drum mounting clamping mechanism 308, the step of engaging the backing layer leading edge portion 232 to the drum mounting layer engagement device 306 may include receiving a leading edge coupling device 360 ​​from the mounting layer engagement device 350, which can be coupled to the backing layer leading edge portion 232. As described above, in one example, the leading edge coupling device 360 ​​may be an electromagnetic device 364 for magnetic coupling to the drum mounting layer engagement device 306, and the electromagnetic device 364 may be a magnetic element 234. For example, the magnetic element 234 may include a metal element located inside the backing layer collecting drum 300 opposite to the collecting drum opening 304. As described above, while the electromagnetic device 364 (e.g., leading edge coupling device 360) is magnetically coupled to the magnetic element 234 in the backing layer collection drum 300, the electromagnetic device 364 can be separated from the magnetic element 234 mounted to one or more threading tapes 326 (i.e., tape mounting layer bonding device 350), thereby transferring the leading edge portion 232 of the backing layer from the threading tape 326 to the backing layer collection drum 300.

[0150] Once the leading edge portion 232 of the backing layer is engaged with the backing layer collecting drum 300, the method may include translating the redirecting roller 332 along the redirecting roller path 334 from the redirecting roller engagement position 338 to the redirecting roller initial position 336, as follows: Figure 36 and 55 As shown. Figure 39 and 56 As shown, when the layup material 228 is dispensed onto the substrate 122, moving the redirection roller 332 to the redirection roller initial position 336 can provide clearance for the backing layer 230 to be wound onto the backing layer collection drum 300. To this end, the method may include rotating the backing layer collection drum 300 to pull the backing material 226 over the laminating head 200 to initiate the process of applying the layup material 228 onto the substrate 122.

[0151] As part of the process of applying the layup material 228, the method may include cutting the layup material 228 using a cutter assembly 250 when the laminator head 200 approaches the start or end point of the route 238 of the layup material 228 on the substrate 122. The cutting of the layup material 228 can be performed using a cutter module 252 and a cutter platen 254, which can be operated to cut the layup material 228 while keeping the backing layer 230 intact. The cutting of the layup material 228 may create a leading edge of the layup material and a trailing edge of the layup material adjacent to the leading edge.

[0152] refer to Figures 37-38The method may include separating the layup material 228 from the backing layer 230 using at least one separation device of the backing layer separation assembly 260, and guiding the layup material 228 toward the substrate 122. For an example of a laminator head 200 with a compaction device, the method may include guiding the layup material 228 toward the substrate 122 and toward below the compaction device as the laminator head 200 moves along the travel direction. The method may additionally include supplying backing material 226 to the backing layer separation assembly 260. In the currently disclosed example, the laminator head 200 has bidirectional layup capability, and the backing layer separation assembly 260 has a first separation device 262 with a first guide angle 268 and a second separation device 272 with a second guide angle 276. Furthermore, Figures 37-38 An example of the laminating head 200 has a first compaction device 284 and a second compaction device 288.

[0153] refer to Figure 37 The method may include moving a first guide angle 268 from its retracted position 278 to its extended position 280 via a first separation device actuator 264, in which the first guide angle 268 is abutted against the first compaction device 284. Before moving the first guide angle 268 abutting against the first compaction device 284, a second guide angle 276 may be moved to its retracted position 278 via a second separation device actuator 274 to provide clearance for the movement of the first guide angle 268. Furthermore, before, during, or after moving the first guide angle 268 abutting against the first compaction device 284, the first compaction device 284 may be moved from its retracted position 292 to its extended position 294 where it can contact the substrate 122. However, as described above, the first and second compaction devices 284, 288 may optionally be included together with the laminating head 200.

[0154] As described above, both the first separating device actuator 264 and the second separating device actuator 274 can be configured as linear actuators with rods extending from cylinders. The first guide angle 268 and the second guide angle 276 can be mounted on the ends of the rods of their respective linear actuators. Similarly, the first compaction device 284 and the second compaction device 288 can each include a first compaction device actuator 286 and a second compaction device actuator 290, each of which can be configured as a linear actuator with a rod extending from a cylinder. In this respect, movement of the first and second guide angles 276 can be achieved by extending and retracting rods from the cylinders of the first and second separating device actuators 264 and 274, respectively. Likewise, movement of the first and second compaction devices 284 and 288 can be achieved by extending and retracting rods from the cylinders of the first and second compaction device actuators 286 and 290, respectively.

[0155] As the first guide angle 268 is positioned near the first compaction device 284, the method may include using the first guide angle 268 to separate the layup material 228 from the backing layer 230 and guiding the layup material 228 toward the substrate 122, while the laminating head 200 moves along a first travel direction 208. Separation of the layup material 228 from the backing layer 230 can be performed by pulling the backing layer 230 past the typically small radius of curvature of the distal end 270 of the first guide angle 268, thereby causing the leading edge of the layup material to separate from the backing layer 230 as the backing layer 230 moves about the distal end 270 of the guide angle. The relatively small radius of curvature of the distal end 270 of the guide angle allows the bending stiffness of the layup material 228 to result in a peel force exceeding the adhesive strength between the layup material 228 and the backing layer 230, thus causing the layup material 228 to separate from the backing layer 230. The method may optionally include compacting the layup material 228 onto the substrate 122 using a first compaction device 284 as the layup material 228 is dispensed from the laminating head 200 while moving along the first travel direction 208. The first compaction device 284 may be configured as a compaction roller, compaction shoe, compaction bladder, or other compaction device configuration.

[0156] When the laminating head 200, moving along the first travel direction 208, reaches the end of the path 238 of the layup material 228 applied to the substrate 122, the method may include retracting the first guide angle 268 away from the first compaction device 284. Once the trailing edge of the layup material has been compacted onto the substrate 122 by the first compaction device 284, the relative movement of the laminating head 200 along the first travel direction 208 may be paused. The first compaction device 284 may be retracted from the substrate 122, and a second compaction device 288 may extend to contact the substrate 122.

[0157] refer to Figure 38The method may include moving a second guide angle 276 from its retracted separation position 278 to its extended separation position 280 to position the second guide angle 276 against the second compaction device 288. After the first guide angle 268 retracts from the first compaction device 284, the second guide angle 276 may move approximately simultaneously or immediately against the second compaction device 288. The method may include using the second guide angle 276 to separate the layup material 228 from the backing layer 230, and guiding the layup material 228 toward the substrate 122 and the second compaction device 288 while moving the laminator head 200 along the second travel direction 210. Separating the layup material 228 from the backing layer 230 may include pulling the backing layer 230 with a relatively small radius of curvature about the distal end 270 of the second guide angle 276, so that the leading edge of the layup material separates from the backing layer 230, similar to the process described above for separating the layup material 228 from the backing layer 230 moving about the first guide angle 268. The method may optionally include using a second compaction device 288 to compact the layup material 228 onto the substrate 122 during relative movement along the second travel direction 210 when the layup material 228 is dispensed from the laminator head 200. The second compaction device 288 may be configured as a compaction roller, compaction shoe, compaction bladder, or other compaction device configuration.

[0158] As the laminating head 200 moves relative to the laminating surface 120, the method may include pulling backing material 226 through the laminating head 200 via rotation of the backing layer collection drum 300, while dispensing layup material 228 onto the substrate 122, and the backing layer 230 being wound around the backing layer collection drum 300. The method may include controlling the rotational speed of the backing layer collection drum 300 in coordination with the speed of movement of the laminating head 200 relative to the laminating surface 120. As described above, the manufacturing system 100 may be provided in one example where the laminating head 200 is stationary and the laminating surface 120 moves below the laminating head 200 as the layup material 228 is dispensed onto the laminating surface 120 (e.g., laminating mandrel 124). Alternatively, the manufacturing system 100 may be provided in one example where the laminating surface 120 is stationary and the laminating head 200 moves on the laminating surface 120 while dispensing the layup material 228. Although the above-described process of distributing the lay-up material 228 is described in the context of a laminate head 200 with bidirectional lay-up capability, the process of distributing the lay-up material 228 can also be performed using a laminate with lay-up capability in a single direction.

[0159] The dispensing of layup material 228 from laminator 200 can continue until roll 224 is depleted of layup material 228. At this point, backing layer collection drum 300 can be filled with backing layer 230, such as... Figure 39 and 56As shown. The method may include reversing the rotational direction of the material supply drum 220 to wind the backing layer 230 from the backing layer collection drum 300 onto a depleted roll 418 on the material supply drum 220. As... Figures 39-40 As shown in Figures 56-57, the rewinding of the backing layer 230 can be performed by rotating the material supply drum 220 in a direction opposite to the direction of rotation used to dispense the layup material 228 from the laminator head 200.

[0160] After most of the backing layer 230 has been rewound onto the depleted roll 418, the method may include releasing the leading edge portion 232 of the backing layer from the drum mounting layer engagement device 306. The process of releasing the leading edge portion 232 may include rotating the material supply drum 220 and the backing layer collection drum 300 in opposite directions until the collection drum opening 304 is substantially facing the threading tape 326, as shown. Figure 40 As shown. Then, the drum mounting layer joining device 306 can release the leading edge portion 232 of the backing layer while causing the material supply drum 220 to rotate so as to pull the leading edge portion 232 of the backing layer away from the backing layer collecting drum 300 via the laminating head 200, and onto the depleted roll 418, as shown. Figures 41-43 As shown. Figure 43 As shown, the belt drive motor 330 of the material threading system 320 can be activated to reverse drive one or more threading belts 326 to move the belt mounting layer bonding device 350 back to its initial position near the material supply drum 220. Figure 21 Furthermore, the redirection roller 332 can move from the initial position 336 to the engagement position 338. Figure 43 ), to prepare to pass the backing layer 230 of the replacement roll 420 through the laminator 200.

[0161] For those with such Figure 44-62 The example laminator head 200 of the illustrated leading edge coupling device 360 ​​may further include coupling the leading edge coupling device 360 ​​to the tape mounting layer coupling device 350 during the process of releasing the leading edge portion 232 of the backing layer from the drum mounting layer coupling device 306. The process of releasing the leading edge coupling device 360 ​​from the drum mounting layer coupling device 306 may be performed in the reverse order of the process of coupling the leading edge coupling device 360 ​​to the drum mounting layer coupling device 306, as shown below. Figures 51-54 As shown. For example, it can be done according to... Figures 53-54 The backing layer collecting drum 300 is rotated in the reverse order of the above process shown, such that the collecting drum opening 304 faces one or more threading tapes 326. The leading edge coupling device 360 ​​(e.g., electromagnetic device 364) can be released from the magnetic element 234 of the backing layer collecting drum 300 (i.e., drum mounting layer engagement device 306), and the leading edge coupling device 360 ​​can be coupled with… Figures 51-52 The process described above is performed in reverse order with the mounting layer engagement device 350.

[0162] Once the leading edge coupling device 360 ​​engages with the mounting layer coupling device 350, the method may include using a belt drive motor 330 to drive one or more threading belts 326 across the belt roller 328 in the opposite direction, thereby allowing the leading edge coupling device 360 ​​and the backing layer leading edge portion 232 to pass back through the laminator head 200, as... Figures 59-60 As shown. When the mounting layer bonding device 350 reaches its initial position near the material supply drum 220 (e.g. Figure 61 (As shown), movement of one or more threading tapes 326 can be stopped. The method may then include releasing the backing layer leading edge portion 232 from the leading edge coupling device 360 ​​and winding the backing layer leading edge portion 232 onto the material supply drum 220, thereby producing a depleted roll 418, which can be replaced by a replacement role using the reloading drum 400, such as... Figure 62 As shown.

[0163] like Figure 43 and 62 As shown, after rewinding the backing layer 230 onto the depleted roll 418, the method may include transferring the depleted roll 418 from the material supply drum 220 to an empty reloading mandrel 406 positioned near the reloading cylinder 400 of the laminator head 200, as... Figure 13-15 As shown, the replacement roll 420 is transferred from the reloading cylinder 400 to the empty material supply drum 220 on the laminating head 200, as... Figure 16-20 As shown. Before transferring the depleted roll 418 from the material supply drum 220 to an empty reload mandrel 406, the method may include unloading (e.g., manually) any depleted roll 418 recently transferred to a previous roll 224 replacement operation onto a reload mandrel 406, such that there is at least one empty reload mandrel 406 on the reload cylinder 400, and at least one reload mandrel 406 contains a replacement roll 420. The replacement roll 420 may be loaded onto the reload mandrel 406 before positioning the reload cylinder 400 near the laminator head 200. For example, the reload cylinder 400 may be initially positioned outside the laminator station 136 to allow access to the reload mandrel 406 to unload the depleted roll 418 and install the replacement roll 420.

[0164] The reloading cylinder 400 can then be moved into the laminating station 136 (e.g., along the reloading cylinder track 402) and positioned close to the laminating head 200, where the depleted roll 418 will be replaced. The method can then include positioning an empty reloading mandrel 406 at a storage location 414 configured to align with the material supply drum 220 supporting the depleted roll 418 to be replaced. For example, the empty reloading mandrel 406 can be positioned at… Figure 11The center-top storage location is shown at position 416. (As shown) Figure 13 As shown, the method may further include retractably extending the free end of the empty reloading mandrel 406 to engage with the free end of the material supply drum 220. Additionally, the method may include a drum-mandrel alignment mechanism 408 on the free end of the empty reloading mandrel 406. Figure 11 The corresponding drum-mandrel alignment mechanism 408 is connected to the free end of the material supply drum 220. Figure 7 Alignment locking. As described above, alignment of the empty reloading mandrel 406 with the material supply drum 220 facilitates the sliding transfer of the depleted roll 418 from the material supply drum 220 onto the empty reloading mandrel 406. With the empty reloading mandrel 406 aligned with the material supply drum 220, the method may include manipulating the reloader actuator 432 (e.g., the reloader robotic arm 436) to engage or clamp onto the depleted roll 418, and causing the depleted roll 418 to slide away from the material supply drum 220 and slide onto the empty reloading mandrel 406 of the reloading cylinder 400, as... Figure 14 As shown.

[0165] The replacement roll 420 can be transferred from the reloading cylinder 400 to the material supply drum 220, including, for example, Figure 15 The reloading mandrel 406 is retracted telescopically away from the free end of the material supply drum 220, as shown. Figure 16 As shown, the method may further include circulating the reloading mandrel 406 along the circulation path 412 of the reloading cylinder 400 until the reloading mandrel 406 supporting the replacement roll 420 is positioned at a storage location 414 (e.g., a center-top storage location 416), which is configured to align with the material supply drum 220 from which depleted material is removed. As described below, the reloading cylinder 400 may be temporarily removed from the laminating station 136 to provide access to the reloading cylinder 400 for preparation of the replacement roll 420 for transfer onto the laminating head 200.

[0166] like Figure 18-19 As shown, the method may include (e.g., manually) inserting the leading edge 242 of the backing leading edge portion 232 of the replacement roll 224 (i.e., at the center-top storage position 416) into the roll interface 442 between a pair of leading edge alignment rolls 438 mounted on the reloading cylinder 400. Figure 19 As shown, the method may include reversing the rotation of the leading edge alignment roller 438 to pull and clamp the leading edge 242 of the backing layer leading edge portion 232 into the roller interface 442. With the leading edge 242 clamped in the roller interface 442, the reloading cylinder 400 can be moved back into the laminating station 136 near the laminating head 200 to be reloaded. Figure 20As shown, the method may then include, while the leading edge alignment roller 438 extends telescopically toward the laminator head 200, the reloading mandrel 406 extends telescopically to engage the free end of the material supply drum 220. Figure 21-22 As shown, the leading edge alignment roller 438 extends telescopically to the leading edge 242 of the backing layer leading edge portion 232, positioned abutting against the tape mounting layer engagement device 350. As described above, the method may include engaging a drum-mandrel alignment mechanism 408 on the free end of the reloading mandrel 406 with a drum-mandrel alignment mechanism 408 on the free end of the material supply drum 220 to facilitate the sliding transfer of the replacement roll 420 from the reloading mandrel 406 to the material supply drum 220. The transfer of the replacement roll 420 from the reloading mandrel 406 to the material supply drum 220 may be performed by a reloader actuator 432 (e.g., a reloader robotic arm 436) that can engage the replacement roll 420 and slide the replacement roll 420 off the reloading mandrel 406 and onto the material supply drum 220, as... Figure 20 As shown.

[0167] The method may include reversing the rotation of the leading edge alignment roller 438 to further extend the leading edge 242 of the backing layer leading edge portion 232 away from the roller interface 442 and extend it to engage with the mounting layer engagement device 350. Figure 23-24 ) engagement, or connection with the leading edge coupling device 360 ​​( Figures 46-47 The method may then include moving the leading edge alignment rollers 438 away from each other to release the leading edge portion 232 of the backing layer from between the leading edge alignment rollers 438, as shown in the figure. Figure 26 and 47 As shown. The method may include, for example... Figure 28 The leading edge alignment roller 438 is telescopically retracted away from the laminator head 200 and returns toward the reloading cylinder 400, while the reloading mandrel 406 is telescopically retracted away from the free end of the material supply drum 220. As the replacement roll 420 is mounted on the laminator head 200 and the backing layer leading edge portion 232 engages with the drum mount layer engagement device 306, the reloading cylinder 400 can be removed from the laminator head 200 and removed from the lamination station 136.

[0168] Furthermore, this disclosure includes examples described in the following listed paragraphs:

[0169] A1. A laminator (200) with self-threading capability, comprising: a material supply drum (220) configured to support a roll (224) of backing material (226), the backing material (226) comprising layup material (228) backed by a backing layer (230); a material threading system (320) comprising: at least one belt roller (324) located on one side of a material path (322) passing through the laminator (200) and having a continuous loop threading belt (326) supported on a plurality of belt rollers (328) driven by a belt drive motor (330); at least one belt mounting layer joining device (350) coupled to the threading belt (326) and configured to join the leading edge portion (232) of the backing layer; and a backing layer collection. The drum (300), the backing layer collecting drum being configured to wind at least the backing layer (230) onto the backing layer collecting drum (300) when the laminating head (200) applies the layup material (228) onto the substrate (122); and the belt drive motor (330), the belt drive motor being configured to drive the threading belt (326) on the belt roller (328), such that the belt mounting layer bonding device (350) pulls at least the backing layer (230) out of the roll (224), and at least causes the backing layer (230) to pass through the laminating head (200) along the material path (322), and positions the leading edge portion (232) of the backing layer close to the backing layer collecting drum (300) for engagement with the backing layer collecting drum (300).

[0170] A2. The laminating head (200) according to A1, wherein the tape mounting layer bonding device (350) comprises one of the following: at least one tape mounting clip (352) mounted on the threading tape (326) and configured to clamp on the leading edge portion (232) of the backing layer; an electromagnetic member (355) coupled to the threading tape (326) and configured to be magnetically coupled to a magnetically attracted element (234) included together with the leading edge portion (232) of the backing layer; and a fastener (355) coupled to the threading tape (326) and having one of a loop element strip or a hook element strip, the loop element strip or the hook element strip being configured to releasably engage with one of the hook element strip or the loop element strip included together with the leading edge portion (232) of the backing layer, respectively.

[0171] A3. The laminating head (200) according to A1 or A2, wherein: the backing layer collecting drum (300) includes a drum mounting layer engagement device (306) configured to engage the leading edge portion (232) of the backing layer; and a strip mounting layer engagement device (350) configured to release the leading edge portion (232) of the backing layer after it has engaged with the drum mounting layer engagement device (306).

[0172] A4. The laminating head (200) according to A3, wherein: the drum-mounted lamination device (306) includes at least one drum-mounted clamping mechanism (308) having a pair of jaws (310) pivotally connected to each other to clamp on the leading edge (242) of the leading edge portion (232) of the backing layer.

[0173] A5. The laminating head (200) according to A3 or A4 further includes: a leading edge coupling device (360) configured to be releasably coupled to the leading edge portion (232) of the backing layer, the leading edge portion of the backing layer being releasably coupled to the tape mounting layer connection device (350), and releasably coupled to the drum mounting layer connection device (306); wherein: when the leading edge coupling device (360) is positioned near the material supply drum (220), the leading edge coupling device (360) is configured to be coupled to the leading edge portion (232) of the backing layer and to the tape mounting layer connection device (350) for passing at least the backing layer (230) through the laminating head (200); when the leading edge coupling device (360) is located near the backing layer collection drum (300), the leading edge coupling device (360) is configured to be connected from the tape mounting layer connection device (350) The leading edge coupling device (360) is released from and coupled to the drum mounting layer coupling device (306) for winding at least the backing layer (230) onto the backing layer collection drum (300) when the laminating head (200) applies the layup material (228) onto the substrate (122). The leading edge portion (232) of the backing layer passes through the laminating head (200) for rewinding onto the material supply drum (220); and when the leading edge coupling device (360) returns to the material supply drum (220) after passing the leading edge portion (232) of the backing layer through the laminating head (200), the leading edge coupling device (360) is configured to release the leading edge portion (232) of the backing layer for rewinding onto the material supply drum (220).

[0174] A6. The laminating head (200) according to A1 to A5, wherein the plurality of belt rollers (328) supporting the threading tape (326) includes: a redirection roller (332), the redirection roller being positioned close to the backing layer collecting drum (300) and configured to translate along a redirection roller path (334) between the redirection roller initial position (336) and the redirection roller engagement position (338); the redirection roller (332) located at the redirection roller initial position (336) of the redirection roller (332) 32) Distanced from the backing layer collecting drum (300) to provide a gap for the backing layer (230) when the backing layer is wound onto the backing layer collecting drum (300); and the redirecting roller (332) in the redirecting roller engagement position (338) is positioned close to the backing layer collecting drum (300) and configured to orient the threading tape (326) to facilitate engagement of the leading edge portion (232) of the backing layer with the backing layer collecting drum (300).

[0175] A7. The laminating head (200) according to A6, wherein: the redirection roller path (334) is configured such that a constant tension is maintained in the backing layer (230) when the redirection roller (332) moves between the initial position (336) and the engagement position (338) of the redirection roller.

[0176] A8. The laminating head (200) according to A1 to A7, wherein: the material supply drum (220) is configured to reverse the direction of rotation and pull the backing layer (230) from the backing layer collection drum (300) and, after the layup material (228) on the roll (224) is at least partially exhausted, rewind the backing layer (230) onto the material supply drum (220).

[0177] A9. The laminator (200) according to A1 to A8 further includes a backing layer separation assembly (260), the assembly including: at least one separation device (262, 264) configured to separate the layup material (228) from the backing layer (230), and to guide the layup material (228) toward the substrate (122) as the laminator (200) moves in the travel direction (208, 210).

[0178] A10. The laminating head (200) according to A9 further includes: at least one compaction device configured to compact the layup material (228) onto the substrate (122) as the laminating head (200) moves along the travel direction (208, 210).

[0179] B1. A manufacturing system (100) comprising: a series of laminating heads (200), each laminating head (200) having self-threading capability, and each laminating head comprising: a material supply drum (220) configured to support a roll (224) of backing material (226), the backing material (226) comprising layup material (228) backed by a backing layer (230); and a material threading system (320) comprising: at least one belt roller (324) located on one side of a material path (322) passing through the laminating head (200) and having supports on a plurality of belt drive motors (330). A continuous loop threading tape (326) on a belt roller (328); at least one belt mounting layer joining device (350), which is coupled to the threading tape (326) and configured to join the leading edge portion (232) of the backing layer; a backing layer collecting drum (300), which is configured to wind at least the backing layer (230) onto the backing layer collecting drum (300) when the laminating head (200) applies the layup material (228) onto the substrate (122); a belt drive motor (330), which is configured to drive the threading tape (326) above the belt roller (328) from... The mounting layer bonding device (350) pulls at least the backing layer (230) from the roll (224) and at least the backing layer (230) passes through the laminating head (200) along the material path (322) and positions the leading edge portion (232) of the backing layer close to the backing layer collection drum (300); a reloading cylinder (400) having a row of reloading mandrels (406) movable along a circulation path (412) to one of a plurality of storage locations (414), and each reloading mandrel being configured to store either a depleted roll (418) or a replacement roll (42). The depleted roll (418) is loaded with a material reel (224); and a reloading cylinder (400) configured to position an empty reloading mandrel (406) aligned with a material supply drum (220) of one of the laminating heads (200), to transfer the depleted roll (418) from the laminating head (200) onto the empty reloading mandrel (406), to circulate the reloading mandrel (406) until the reloading mandrel (406) supporting a replacement roll (420) is aligned with the material supply drum (220), and to transfer the replacement roll (420) from the reloading mandrel (406) to the material supply drum (220).

[0180] B2. The manufacturing system (100) according to B1, wherein the reloading cylinder (400) further comprises: a pair of leading edge alignment rollers (438), one of which is mounted on the reloading cylinder (400) above the other near one of the storage locations (414) along the circulation path (412); the leading edge alignment rollers (438) are rotatable in the opposite direction for pulling in and clamping the leading edge (242) of the backing layer leading edge portion (232); and the leading edge alignment rollers (438) extend and retract to position the leading edge (242) of the backing layer leading edge portion (232) against the material supply drum (220) of the laminating head (200) during the transfer of the replacement roll (420) from the reloading mandrel (406) to the material supply drum (220) of the laminating head (200).

[0181] B3. The manufacturing system (100) according to B1 or B2, wherein: each reloading mandrel (406) is configured to be retractable to engage with the free end of the material supply drum (220) to facilitate the transfer of the roll (224) between the material supply drum (220) and the reloading mandrel (406) of the reloading cylinder (400).

[0182] C1. A method (500) for passing layup material (228) through a laminator (200), comprising: supporting a roll (224) of backing material (226) on a material supply drum (220), the backing material (226) comprising layup material (228) backed by a backing layer (230); and engaging a leading edge portion (232) of the backing layer to a mounting layer engagement device (350) connected to a material path (32) passing through the laminator (200). 2) A continuous loop threading belt (326) on one side, the threading belt (326) being supported on a plurality of belt rollers (328); and the threading belt (326) on the belt rollers (328) being driven by a belt drive motor (330), such that the belt mounting layer bonding device (350) passes at least the backing layer (230) through the laminating head (200) along the material path (322) and positions the leading edge portion (232) of the backing layer close to the backing layer collection drum (300).

[0183] C2. The method (500) according to C1, wherein joining the leading edge portion (232) of the backing layer to the tape mounting layer joining device (350) includes one of the following: clamping the tape mounting clip (352) mounted on the threading tape (326) onto the leading edge portion (232); magnetically coupling the magnetic attraction element (234) of the leading edge portion (232) of the backing layer using an electromagnetic member (355) coupled to the threading tape (326); and fastening one of the hook element strips or loop element strips of the leading edge portion (232) of the backing layer to one of the loop element strips or hook element strips of the fastener (355) connected to the threading tape (326).

[0184] C3. The method (500) according to C1 or C2 further includes: when the tape mounting layer joining device (350) positions the leading edge (242) of the backing layer leading edge portion (232) close to the backing layer collecting drum (300), engaging the leading edge (242) of the backing layer leading edge portion (232) to the drum mounting layer joining device (306) of the backing layer collecting drum (300); and after the leading edge (232) of the backing layer is engaged to the drum mounting layer joining device (306), releasing the leading edge (232) of the backing layer from the tape mounting layer joining device (350).

[0185] C4. The method (500) according to C3, wherein engaging the leading edge (242) of the backing layer leading edge portion (232) to the drum mounting layer engaging device (306) comprises: clamping the leading edge (242) of the backing layer leading edge portion (232) onto the leading edge (242) using at least one drum mounting clamping mechanism (308), the clamping mechanism (308) having a pair of pivotally interconnected jaws (310).

[0186] C5. The method (500) according to C1 to C4, wherein the plurality of belt rollers (328) includes a redirection roller (332), the method (500) further comprising: positioning the redirection roller (332) at a redirection roller engagement position (338) adjacent to the backing layer collection drum (300) before passing at least the backing layer (230) through the laminating head (200) via the belt mounting layer engagement device (350).

[0187] C6. The method (500) according to C5 further includes: after the leading edge portion (232) of the backing layer engages with the backing layer collecting drum (300), translating the redirecting roller (332) along the redirecting roller path (334) from the redirecting roller engagement position (338) to the redirecting roller initial position (336), thereby providing a gap for the backing layer (230) to be wound onto the backing layer collecting drum (300).

[0188] C7. The method (500) according to C1 to C6 further includes: using at least one separating device (262, 264) to separate the layup material (228) from the backing layer (230), and guiding the layup material (228) toward the substrate (122) as the laminating head (200) moves along the travel direction (208, 210).

[0189] C8. The method (500) according to C7 further includes: pressing the layup material (228) onto the substrate (122) as the laminating head (200) moves along the travel direction (208, 210).

[0190] C9. The method (500) according to C1 to C8 further includes: reversing the rotation directions of the material supply drum (220) and the backing layer collection drum (300) to pull the backing layer (230) off the backing layer collection drum (300) and rewinding the backing layer (230) onto the material supply drum (220) after the roll (224) has at least partially exhausted the layup material (228).

[0191] Other modifications and improvements to this disclosure will likely be apparent to those skilled in the art. Therefore, the specific combinations of parts described and illustrated herein are intended only to represent certain embodiments of this disclosure and are not intended to be used as alternative embodiments or limitations of the spirit and scope of this disclosure.

Claims

1. A laminating head (200) with self-threading capability, comprising: Material supply drum (220) configured as a roll (224) supporting backing material (226), the backing material (226) comprising layup material (228) backed by backing layer (230); Material threading system (320), comprising: At least one belt roller (324) is located on one side of the material path (322) passing through the laminator (200) and has a continuous looped wire belt (326) supported on a plurality of belt rollers (328) driven by a belt drive motor (330); At least one mounting layer bonding device (350) is attached to the threaded tape (326) and configured to bond the leading edge portion (232) of the backing layer; A backing layer collection drum (300) is configured to wind at least the backing layer (230) onto the backing layer collection drum (300) when the laminating head (200) applies the layup material (228) onto the substrate (122); as well as The belt drive motor (330) is configured to drive the threading belt (326) on the belt roller (328), thereby causing the belt mounting layer bonding device (350) to at least pull the backing layer (230) from the roll (224), and at least cause the backing layer (230) to pass through the laminator (200) along the material path (322), and position the leading edge portion (232) of the backing layer close to the backing layer collecting drum (300) for engagement with the backing layer collecting drum (300).

2. The laminating head (200) according to claim 1, wherein, The mounting layer bonding device (350) includes one of the following: At least one mounting clip (352) is mounted on the threading tape (326) and configured to clamp onto the leading edge portion (232) of the backing layer; An electromagnetic component (355) is coupled to the threading tape (326) and configured to be magnetically coupled to a magnetically attracted element (234) included together with the leading edge portion (232) of the backing layer; Fastener (357), which is connected to the threaded tape (326) and has one of a loop element strip or a hook element strip, the loop element strip or the hook element strip being configured to releasably engage with one of the hook element strips or loop element strips included together with the leading edge portion (232) of the backing layer.

3. The laminating head (200) according to claim 2, wherein: The backing layer collecting drum (300) includes a drum mounting layer engagement device (306) configured to engage the leading edge portion (232) of the backing layer; and The mounting layer engagement device (350) is configured to release the backing layer leading edge portion (232) after it is engaged with the drum mounting layer engagement device (306).

4. The laminating head (200) according to claim 3, wherein, The plurality of belt rollers (328) supporting the threading belt (326) include: A redirection roller (332) is positioned close to the backing layer collection drum (300) and is configured to translate along the redirection roller path (334) between the redirection roller initial position (336) and the redirection roller engagement position (338). The redirecting roller (332), located at the initial position (336) of the redirecting roller, is spaced a certain distance from the backing layer collecting drum (300) to provide a gap for the backing layer (230) when wound onto the backing layer collecting drum (300); and The redirecting roller (332) located at the redirecting roller engagement position (338) is positioned close to the backing layer collection drum (300) and configured to orient the threading tape (326) to facilitate engagement of the leading edge portion (232) of the backing layer with the backing layer collection drum (300).

5. The laminating head (200) according to claim 4, wherein: The redirection roller path (334) is configured such that a constant tension is maintained in the backing layer (230) as the redirection roller (332) moves between the initial position (336) and the engagement position (338) of the redirection roller.

6. The laminating head (200) according to claim 5, wherein: The material supply drum (220) is configured to reverse the direction of rotation and pull the backing layer (230) from the backing layer collection drum (300) and rewind the backing layer (230) onto the material supply drum (220) after the laying material (228) on the roll (224) has been at least partially exhausted.

7. The laminator (200) according to any one of claims 1 to 6, further comprising a backing layer separation assembly (260), the backing layer separation assembly comprising: At least one separation device (262, 264) is configured to separate the layup material (228) from the backing layer (230) and to guide the layup material (228) toward the substrate (122) as the laminating head (200) moves in the travel direction (208, 210).

8. The laminating head (200) according to claim 7, further comprising: At least one compaction device is configured to compact the layup material (228) onto the substrate (122) as the laminating head (200) moves along the direction of travel (208, 210).

9. A method (500) for passing layup material (228) through a laminating head (200) according to claim 1, the method comprising: A roll (224) of backing material (226) is supported on a material supply drum (220), the backing material (226) comprising layup material (228) backed by a backing layer (230); The leading edge portion (232) of the backing layer is joined to a mounting layer joining device (350), which is connected to a continuous loop threading tape (326) located on one side of the material path (322) passing through the laminator (200), the threading tape (326) being supported on a plurality of belt rollers (328). as well as The threading tape (326) on the belt roller (328) is driven by a belt drive motor (330), thereby causing the belt mounting layer bonding device (350) to pass at least the backing layer (230) through the laminating head (200) along the material path (322) and to position the leading edge portion (232) of the backing layer close to the backing layer collection drum (300).

10. The method (500) according to claim 9, wherein, Joining the leading edge portion (232) of the backing layer to the mounting layer joining device (350) includes one of the following: Use the strap mounting clip (352) mounted on the threading tape (326) to clamp onto the front edge portion (232) of the backing layer; The magnetic element (234) of the leading edge portion (232) of the backing layer is magnetically coupled using an electromagnetic component (355) coupled to the threading tape (326); One of the hook element strips or loop element strips of the leading edge portion (232) of the backing layer is fastened to one of the loop element strips or hook element strips of the fastener (357) connected to the threading tape (326).

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