Laminator waste collection components

Abstract

A scrap collection assembly for a tape lamination head for applying a plurality of composite tape segments includes a disengagement assembly having a scrap disengagement reorientation roller configured to engage one or more composite tape segments and one or more scrap portions, a second disengagement roller configured to engage one or more composite tape segments and one or more scrap portions, a pivot connecting the disengagement assembly to the tape lamination head, wherein the second disengagement roller is selectively moved about the pivot to change a direction of motion of the composite tape, and a conveyor receiving the scrap portions from the second disengagement roller.

Description

[0001] Cross-referencing of related patent applications

[0002] This application is an International Patent Cooperation Treaty (IPC) patent application and claims priority to U.S. Provisional Patent Application No. 62 / 971032, filed February 6, 2020, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This application relates to tape lamination machines, and more specifically to a waste collection assembly included in a tape lamination head. Background Technology

[0004] A belt laminator is used to manufacture composite workpieces. A composite material in the form of resin-impregnated fibrous material is applied by the machine at precise positions and lengths to collectively form the composite workpiece. The belt laminator moves a belt laminator head to precisely apply the composite belt according to the final shape of the composite workpiece. As the belt laminator head moves, it leaves behind multiple composite belt segments (hereinafter also referred to as layers). The automated application of these composite belt segments involves the cooperation of a set of mechanisms for fixing, moving, and ultimately cutting the composite belt.

[0005] Each composite tape segment may include a head and a tail at both ends of the segment. The head and tail are shaped by a cutting blade used to cut the composite tape, thus forming the tail of one composite tape segment and the head of a subsequent composite tape segment. Some composite tape segments have relatively simple shapes, such as a butt cut, which separates the tail of one composite tape segment from the head of another. However, other composite tape segments may be generated by a cut in the supplied composite tape that leaves unwanted waste on the backing paper to be processed. Summary of the Invention

[0006] In one embodiment, a waste collection assembly for a belt laminator that applies multiple composite belt segments includes a crack-off assembly having a waste crack-off reorientation roller configured to engage with one or more composite belt segments and one or more waste portions; a second crack-off roller configured to engage with one or more composite belt segments and one or more waste portions; a pivot connecting the crack-off assembly to the belt laminator, wherein the second crack-off roller selectively moves about the pivot to change the direction of movement of the composite belt; and a conveyor for receiving one or more waste portions from the second crack-off roller.

[0007] In another embodiment, a belt laminator for applying multiple composite belt segments includes: a frame carrying a composite belt supply reel and multiple reorientation rollers; a release assembly including: a waste release reorientation roller configured to engage with one or more composite belt segments and one or more waste portions; a second release roller configured to engage with one or more composite belt segments and one or more waste portions; a pivot connecting the release assembly to the belt laminator, wherein the second release roller selectively moves about the pivot to change the direction of movement of the composite belt; and a conveyor receiving one or more waste portions from the second release roller. Attached Figure Description

[0008] Figure 1 It is a perspective view depicting an implementation method with a laminator;

[0009] Figure 2 It is a perspective view depicting an embodiment with a laminating head; and

[0010] Figure 3 This is a perspective view depicting another embodiment with a portion of the laminating head;

[0011] Figure 4 It is a top view depicting the pattern of the applied composite strip portion and the schematic implementation of the composite strip portion on the backing paper together with the waste material;

[0012] Figure 5 It is a perspective view depicting a portion of a waste collection assembly in a laying pattern or positioning.

[0013] Figure 6 It is a perspective view depicting a portion of a waste collection component in a waste collection mode or location;

[0014] Figure 7 It is a cross-sectional view depicting an embodiment of a portion of the waste collection assembly; and

[0015] Figure 8 This is a cross-sectional view depicting another embodiment of the laminated head. Detailed Implementation

[0016] A belt laminator includes a laminating head with a waste collection assembly for removing waste composite belt from the backing paper and storing waste portions at the laminator. As mentioned above, generating composite belt segments sometimes involves generating waste composite belt segments that are ultimately discarded. For example, the tail of a composite belt segment may be cut at a different angle than the head of a subsequent composite belt segment. Waste portions of the composite belt can be formed between or within consecutive or composite belt segments cut in this manner. Conventionally, the belt laminator may have moved from the worktable base to the waste removal position, where the machine operator removes the waste portions from the backing paper. However, this slows down the application speed of the composite belt segments, thus slowing down the formation of composite parts. Instead, the belt laminator can collect waste portions in situ using its carried waste collection assembly. As the composite belt passes through the belt laminator and the cutting assembly cuts the belt to generate one or more waste portions, the waste collection assembly can be activated to remove the waste portions from the backing paper and collect them in a collection tray. The waste collection assembly may include a release assembly, a conveyor, and a collection tray, which will be discussed in detail below.

[0017] After the cutting assembly cuts through the composite belt with the laminating head and generates a waste portion, the waste portion eventually reaches its designated waste location, and the second release roller can move to engage with the backing paper attached to the composite belt, thereby moving towards the compaction assembly. The engaged secondary roller can form a backward bend in the composite belt path and guide the waste portion to a conveyor section, which pulls the waste portion out of the backing paper and conveys it to a collection tray. The waste collection assembly can remove the waste portion without operator assistance and without moving the laminating head to the waste removal position.

[0018] The implementation method with laminator 10 is as follows: Figure 1As shown. The belt laminator 10 includes a frame 12 that movably carries a belt laminator head 14 on a worktable base 16, on which composite parts are formed from multiple composite belt segments. The frame 12 may include a vertical support 18 connected via a horizontal support 20 or a beam attached to the upper end of the vertical support 18. The frame 12 may be implemented as a multi-axis belt laminator 10, such as a Cincinnati CHARGER ATL or GEMINI. In one embodiment, the belt laminator 10 may allow six-axis movement of the belt laminator head 14. The bottom of the vertical support 18 may be linearly movable relative to the worktable base 16 along the X-axis. The bottom of the vertical support 18 may be movable on a track 22 or wheels to allow the frame 12 to move along the X-axis. In one embodiment, the track 22 may be included on the worktable base 16 such that the vertical support 18 rests against the worktable. In other embodiments, the track 22 may be formed on the floor where the belt laminator 10 is mounted. The ram 24 can carry the laminator head 14, allowing the head 14 to be raised and lowered relative to the worktable base 16 along the Z-axis. The laminator head 14 can be slidably connected to a horizontal support 20 at one end of the ram 24 away from the laminator head. A slidable coupling allows the frame to move along the Y-axis on the worktable base 16. A releasable coupling 26 between the laminator head 14 and the ram 24 allows for the removal and replacement of the laminator head. The vertical support 18 and the ram 24 can move along the X, Y, and Z axes to position the laminator head 14 relative to the change station 28. Another laminator head 14 can then be coupled to the ram 24 and moved by the frame 12 to its position on the worktable base 16.

[0019] The movement of rack 12 (including vertical support 18 and ram 24) can be controlled by operator station 30. Operator station 30 includes one or more microprocessors (not shown) that communicate with a computer-readable storage medium having executable instructions, and can control the movement of hydraulic ram, electric motor, or other drive elements, thereby controlling the movement and positioning of rack 12 and the operation of laminating head 14. The one or more microprocessors can be any type of device capable of processing electronic instructions, including microcontrollers, main processors, controllers, and application-specific integrated circuits (ASICs). It can be a dedicated processor used only for controlling rack 12, or it can share functions with other machines. The microprocessor executes various types of digitally stored instructions, such as software or firmware programs stored in memory. Communication between the mechanisms that move rack 12 and laminating head 14 (e.g., hydraulic ram or electric motor) and the one or more microprocessors can be made via a communication bus.

[0020] Turning Figure 2 and Figure 3The tape laminator 14 includes a frame 32 connected to a releasable coupling 26 that releasably attaches the head to a slide 24. The frame 32 can support a supply reel 34 carrying a composite tape 36, which is ultimately supplied to a compaction assembly 38, applying the tape 36 onto a workbench base 16. The composite tape 36 can travel along this path through a supply regulator 40, a first reorientation roller 42, a second reorientation roller 44, and a waste removal reorientation roller 46, which together guide the tape 36 adjacent to the cutting assembly 48. The composite tape 36 can be wound on the supply reel 34 at one of a variety of widths. For example, a composite tape 36 with a width of 1.5 inches to 12 inches can be wound on the supply reel 34 for subsequent unwinding as the composite tape 36 passes through the tape laminator 14. The composition of the composite tape 36 is known and may include carbon fiber as an example of a composite tape. The liner 50 can be applied to one side of the composite belt 36 such that the surface of the composite belt 36 does not contact the subsequently wound layers of the belt 36. The supply regulator 40, the first reorientation roller 42, and the second reorientation roller 44 can be attached to a dancing mechanism 52, which controls the tension applied to the composite belt 36 as it is pulled from the supply reel 34 and transmitted to the compaction assembly 38. The dancing mechanism 52 can allow the rollers to move linearly under the control of a spring or a hydraulically controlled ram. One or more electric motors can be used to apply rotational force to the supply reel 34, the supply regulator 40, the first reorientation roller 42, or the second reorientation roller 44. The liner reel 54 is included in the belt laminator 14 and can receive the liner 50 removed from the composite belt 36 before the belt 36 is applied to the worktable base 16. In one embodiment, a servo motor powered by a servo drive is used to control the movement of the composite belt 36 along the supply reel 34, the supply regulator 40, or the liner reel 54.

[0021] The compaction assembly 38 applies a portion of the composite belt onto the worktable base 16. The compaction assembly 38 may include a compaction roller 84 that presses the composite belt segment onto the worktable base 16 and a tail-separation assembly. In some embodiments, the compaction assembly 38 includes a compaction slider.

[0022] The cutting assembly 48 is included in the laminating head 14 and moves along a linear path in the direction of movement of the composite belt via a cutting bracket 56. This linear path can be a track 58 or a groove on which the cutting assembly 48 moves linearly, adjacent to the path on which the composite belt moves toward the compaction assembly 38. In this embodiment, the cutting assembly 48 moves vertically from the top 60 of the laminating head 14 to the bottom 62 of the head 14. A linear motor 64 can cause the cutting assembly 48 to move along the track 58 in the same direction or plane as the composite belt 36 moves toward the compaction assembly 38. When the cutting assembly 48 approaches its endpoint, a bumper 66 can help stop the downward movement of the assembly 48.

[0023] The cutting assembly 48 may include a cutting blade 68 that cuts a portion of the composite tape 36 against the cutting anvil 70 as the tape 36 travels toward the compaction assembly 38. The cutting assembly 48 can move in coordination with the tape 36 such that the cutting blade 68 moves at the same speed as the tape 36 without halting the movement of the composite tape 36 through the tape laminator 14. Thus, when the blade 68 is moved to cut the tape 36, only relative movement occurs between the composite tape 36 and the cutting blade 68.

[0024] like Figure 4 As shown, the composite tape 36 can be cut into various shapes. The cross-section of the composite tape is shown as having a composite tape segment 86 and a waste portion 88, which is applied to the workbench base 16. After cutting and before removing the composite tape segment 86 and waste portion 88 from the backing paper 50, the composite tape segment 86 is shown as being included in the waste portion 88. A pattern showing the composite tape segment 86 applied to the workbench base 16 is also shown. After the composite tape 36 is cut into the composite tape segment 86 and waste portion 88, the composite tape 36 (including the composite tape segment 86 and waste portion 88 attached to the backing paper 50) moves toward the waste collection assembly 90.

[0025] like Figure 5-6As shown, the waste collection assembly 90 may include a release assembly 92, a conveyor 94, and a collection tray 96, which work together to remove waste portions 88 from the backing paper 50 before passing the composite belt segment 86 to the compaction assembly 38 that applies the composite belt segment 86 to the worktable base 16. The composite belt segment 86 and the waste portions 88 travel along a belt path that includes a second reorientation roller 44 and a waste release reorientation roller 46. The second reorientation roller 46 may be a passive roller fixedly mounted on a frame for changing the direction of the belt path as the composite belt travels toward the compaction assembly. The waste release reorientation roller 46 may also passively change the direction of the belt path as the composite belt 36 travels toward the compaction assembly 38. However, the waste release reorientation roller 44 may be included in the release assembly 92 together with the second release roller 98, which may selectively change the direction of the composite belt travel or the shape of the belt path while being positioned in a waste collection mode. The separation assembly 92 includes a waste separation reorientation roller 46, a second separation roller 98, a pivot 100, and a piston 102 or similar mechanical or electromechanical actuator (allowing the separation assembly 92 to selectively move between a tape laying mode and a waste collection mode). In some embodiments, the waste separation reorientation roller 46 may rotate or pivot about a pivot axis of the pivot 100. The separation assembly 92 may include a roller carrier 104 that carries the conveying waste separation reorientation roller 46 and the second separation roller 98. The pivot 100 may rotatably connect the separation assembly 92 to a frame 32 of the tape laminator 14. The piston 102 (e.g., a hydraulically controlled ram or linear motor) may extend or retract, thereby moving the separation assembly 92 about the pivot 100. In other embodiments, different mechanical actuators may be used. The second separation roller 98 is positioned relative to the waste separation reorientation roller 46 such that the second separation roller 98 can contact the backing paper 50, and the waste separation reorientation roller 46 can contact the composite tape 36.

[0026] In the belt laying mode, the release assembly 92 can be positioned such that, as the composite belt 36 is transferred to the compaction assembly 38, the belt path is influenced by the second reorientation roller 44 and the scrap release reorientation roller 46. The positioning of the release assembly 92 in the belt laying mode or positioning is as follows: Figure 5 As shown. When the composite belt segment 86 is cut and waste portion 88 is generated as part of the cutting, the detachment component 92 can be moved to a waste collection mode or positioned, wherein the detachment component 92 changes the belt path or direction of the composite belt 36 toward the conveyor 94 that transfers the waste portion 88 to the collection tray 96. Figure 6The positioning of the disengagement assembly 92 in the waste collection mode is shown. In this embodiment, the disengagement assembly 92 rotates about the pivot 100, causing the second disengagement roller 98 to engage with the backing paper 50 of the composite belt 36, and changing the belt path or direction so that the conveyor 94 can receive the waste portion 88. Once the conveyor 94 receives the waste portion 88, the disengagement assembly 92 moves back to the belt laying mode positioning, and the composite belt segment 86 can proceed to the compaction assembly 38.

[0027] Figure 7 The conveyor 94, shown in more detail, receives waste portion 88 and transfers it to collection tray 96. The conveyor 94 may include two opposing conveyor belts 106, 108 that rotate in opposite directions to pull waste portion 88 from the backing paper 50 and convey it to collection tray 96. One end of conveyor belts 106, 108 is positioned adjacent to a second reorienting roller 44 such that waste portion 88 passes between the second reorienting roller 44 and a waste removal reorienting roller 46. When the first conveyor belt 106 and the second conveyor belt 108 engage, the first conveyor belt 106 can rotate counterclockwise, and the second conveyor belt 108 can rotate clockwise. The combined movement of the first conveyor belt 106 and the second conveyor belt 108 causes waste portion 88 to move from the second reorienting roller 44 along waste path 110 to the other end of conveyor belts 106, 108, where collection tray 96 receives waste portion 88. The first conveyor belt 106 and the second conveyor belt 108 can be made of a rubber-like material that is flexible but also has a sufficient coefficient of friction to pull the waste portion 88 off the liner 50 and secure it between the conveyor belts 106 and 108 as the waste portion 88 is transferred to the collection tray 96. The collection tray 96 can be a container sized to accept a specific length and quantity of waste portions 88. The collection tray 96 can also be detached from the belt laminator 14 so that the waste portion 88 can be processed. In another embodiment, the collection tray 96 can be replaced by a waste reel 112 that receives the waste portion 88 from the conveyor 94 and winds the waste portion onto the waste reel 112, as shown below. Figure 8 As shown. The waste reel 112 can be configured to handle a longer portion of waste 88 as it leaves the conveyor section 94. The waste portion 88 can be wound onto the waste reel 112 on a waste winding medium (e.g., a conveyor belt).

[0028] It should be understood that the foregoing description is of one or more embodiments of the present invention. The present invention is not limited to the specific embodiments disclosed herein, but is defined solely by the following claims. Furthermore, the statements contained in the foregoing description relate to specific embodiments and should not be construed as limiting the scope of the invention or the definitions of terms used in the claims, unless the term or phrase is expressly defined above. Various other embodiments and various changes and modifications to the disclosed embodiments will be apparent to those skilled in the art. All such other embodiments, changes, and modifications are intended to fall within the scope of the appended claims.

[0029] As used in this specification and claims, the terms “for example,” “e.g.,” “such as,” “like,” and “etc.,” as well as the verbs “comprising,” “having,” “including,” and other verb forms thereof, when used with an enumeration of one or more parts or other articles, shall be interpreted as open-ended, meaning that the enumeration shall not be construed as excluding other, additional parts or articles. Other terms shall be interpreted in their broadest reasonable sense unless they are used in a context that requires a different interpretation.

Claims

1. A scrap collection assembly for a tape laminator head that applies a plurality of composite tape segments, the scrap collection assembly comprising: a disengagement assembly comprising: a scrap disengagement reorientation roller configured to engage one or more composite tape segments and one or more scrap portions; a second disengagement roller configured to engage one or more composite tape segments and one or more scrap portions; a pivot connecting the disengagement assembly to the tape laminator head, wherein the disengagement assembly and the second disengagement roller are configured to selectively move about the pivot to shift an axis of rotation of the second disengagement roller to change a direction of motion of the composite tape; and a conveyor that receives the one or more scrap portions from the second disengagement roller, wherein a mechanical or electromechanical actuator moves the disengagement assembly about the pivot.

2. The scrap collection assembly of claim 1, further comprising a collection tray configured to receive the one or more scrap portions from the conveyor.

3. The scrap collection assembly of claim 2, wherein the collection tray is configured to be detachable from the scrap collection assembly.

4. The scrap collection assembly of claim 1, further comprising a scrap spool that receives the one or more scrap portions from the conveyor.

5. The scrap collection assembly of claim 1, further comprising a piston attached to a frame of the tape laminator head and the scrap collection assembly, the piston rotating the disengagement assembly about the pivot.

6. The scrap collection assembly of claim 1, wherein the second disengagement roller is in contact with backing paper of a composite tape.

7. The scrap collection assembly of claim 1, wherein the scrap disengagement reorientation roller rotates about a pivot rotation axis of the pivot.

8. A tape laminator head for applying a plurality of composite tape segments, comprising: a frame carrying a composite tape supply reel and a plurality of reorientation rollers; a disengagement assembly comprising: a scrap disengagement reorientation roller configured to engage one or more composite tape segments and one or more scrap portions; a second disengagement roller configured to engage one or more composite tape segments and one or more scrap portions; a pivot connecting the disengagement assembly to the tape laminator head, wherein the disengagement assembly and the second disengagement roller are configured to selectively move about the pivot to shift an axis of rotation of the second disengagement roller to change a direction of motion of the composite tape; and a conveyor that receives the one or more scrap portions from the second disengagement roller, wherein a mechanical or electromechanical actuator moves the disengagement assembly about the pivot.

9. The tape laminator head of claim 8, further comprising a collection tray configured to receive the one or more scrap portions from the conveyor.

10. The tape laminator head of claim 9, wherein the collection tray is configured to be detachable from the scrap collection assembly.

11. The tape laminator head of claim 8, further comprising a scrap spool that receives the one or more scrap portions from the conveyor.

12. The tape lamination head of claim 8, further comprising a piston attached with a frame of the tape lamination head and the waste collection assembly, the piston rotating the disengagement assembly about the pivot axis.

13. The tape lamination head of claim 8, wherein the waste disengagement reorientation roller rotates about a pivot rotation axis of the pivot axis.

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