Carbon fiber compression molded part with finished coated surface

Abstract

A part forming system includes: a mobile robot; a first material feeding device configured to feed the carbon fiber prepreg material layer by layer at a time onto the mobile robot to form a stack of carbon fiber prepreg layers on the mobile robot; a second material feeding device configured to feed a coating film onto the stack of carbon fiber prepreg layers to provide a resulting stack of layers; and a hot press configured to form and cure the resultant stack of layers by heating and compressing the resultant stack of layers to provide a resultant coated part.

Description

Technical Field

[0001] introduction

[0002] The information provided in this section is for the purpose of generally presenting the background of the present disclosure. The work of the presently named inventors, to the extent it is described in this section and in all aspects of this description that may not otherwise be considered prior art at the time of filing, is neither explicitly nor implicitly admitted to be prior art against the present disclosure.

[0003] The present disclosure relates to vehicle body panels and other painted parts, and more particularly to part forming and coating systems. Background Art

[0004] Vehicles typically include multiple exterior body panels, such as side panels, fenders, roof panels, door panels, etc., which have complex shapes and finished coated surfaces. The panels typically include multiple paint layers, including basecoats and clearcoats. The paint layers provide a smooth and shiny finished exterior surface that is attractive to customers. The systems and processes used to coat vehicle parts to provide a final product that meets stringent quality requirements are complex, tortuous, and expensive. Summary of the invention

[0005] A part forming system is disclosed, and the part forming system includes: a mobile robot; a first material feeding device, which is configured to feed carbon fiber prepreg material one layer at a time to the mobile robot to form a stack of carbon fiber prepreg layers on the mobile robot; a second material feeding device, which is configured to feed a coating film onto the stack of carbon fiber prepreg layers to provide a resulting stack of layers; and a hot press, which is configured to form and cure the resulting stack of layers by heating and compressing the resulting stack of layers to provide a resulting coated part.

[0006] In other features, the mobile robot is configured to rotate and adjust the orientation of the carbon fiber prepreg layers during layup so that the carbon fiber prepreg layers are in different orientations relative to a material feeding direction of the first material feeding device.

[0007] In other features, the mobile robot includes a work table configured to rotate and adjust the orientation of the stack of carbon fiber prepreg layers before each application of the carbon fiber prepreg material so that the carbon fiber prepreg layers in the stack of carbon fiber prepreg layers are laid in different orientations relative to the material feeding direction of the first material feeding device.

[0008] In other features, at least one of the mobile robot and the worktable of the mobile robot is configured to rotate so that at least one of the carbon fiber prepreg layers is in each of 0°, 45°, 90°, and -45° orientations.

[0009] In other features, the part forming system further includes a laser cutter configured to cut the carbon fiber prepreg plies as they are laid up and before another ply is stacked on each of the carbon fiber prepreg plies.

[0010] In other features, the part forming system also includes: one or more overhead cameras, the overhead cameras being configured to detect the perimeter of one of the carbon fiber prepreg layers; a laser cutter; and a control module configured to control the laser cutter to cut another of the carbon fiber prepreg layers or the coating film based on the detected perimeter.

[0011] In other features, the mobile robot is configured to adjust a height of a work table of the mobile robot prior to stacking each of the carbon fiber prepreg layers.

[0012] In other features, the part forming system further includes a gripper robot configured to pull at least one of the carbon fiber prepreg material and the coating film onto the mobile robot.

[0013] In other features, the part forming system further includes at least one of a punch and a press configured to apply pressure to flatten and remove air under a corresponding one of the carbon fiber prepreg layers each time the corresponding one of the carbon fiber prepreg layers is stacked.

[0014] In other features, the part forming system also includes a roller configured to roll and apply pressure on a corresponding one of the carbon fiber prepreg layers each time the corresponding one of the carbon fiber prepreg layers is stacked, and to remove air from under the corresponding one of the carbon fiber prepreg layers.

[0015] In other features, the coating film includes a tie layer that helps bond the coating film to the stack of carbon fiber prepreg plies when heated and compressed in a hot press.

[0016] In other features, a method of forming a part is disclosed. The method includes: stacking a plurality of carbon fiber prepreg layers to form a first stack on a mobile robot; disposing a coating film on the first stack to provide a resulting stack; moving the resulting stack into a hot press; and heating and compression molding the resulting stack to provide a part having a coated surface due to heating and compressing the coating film and the carbon fiber prepreg layers.

[0017] In other features, the method also includes: feeding the carbon fiber prepreg layers one layer at a time to the mobile robot via a first material feeding device in a first station to form a first stack on the mobile robot; moving the mobile robot from the first station to a second station; and feeding the coating film onto the first stack via a second material feeding device in the second station to provide the resulting stack.

[0018] In other features, the method further includes rotating at least one of the mobile robot or the worktable of the mobile robot to orient the carbon fiber prepreg layers in a different orientation relative to a material feed direction of the carbon fiber prepreg material used to form the carbon fiber prepreg layers.

[0019] In other features, the method further includes: pre-treating the coating substrate of the coating film to provide a pre-treated surface; applying one or more precursors to the pre-treated surface of the coating film to deposit the tie layer; and disposing the coating film including the tie layer on the first stack before placing the resulting stack in a hot press.

[0020] In other features, the method further includes applying an epoxy-based thermoset layer on the tie layer; and disposing a coating film including the tie layer and the epoxy-based thermoset layer on the first stack before placing the resulting stack in a heat press.

[0021] In other features, at least one of pretreating and applying one or more precursors is performed using atmospheric pressure plasma enhanced deposition.

[0022] In other features, the method further includes cutting the carbon fiber prepreg layers while being laid up and before another layer is stacked on each of the carbon fiber prepreg layers.

[0023] In other features, the method further includes detecting a perimeter of one of the carbon fiber prepreg layers via one or more overhead cameras; and cutting another of the carbon fiber prepreg layers or the coating film based on the detected perimeter.

[0024] In other features, the method also includes at least one of the following items: each time a corresponding one of the carbon fiber prepreg layers is stacked, applying pressure to flatten and remove air under the corresponding one of the carbon fiber prepreg layers; and each time a corresponding one of the carbon fiber prepreg layers is stacked, rolling and applying pressure on the corresponding one of the carbon fiber prepreg layers, and removing air under the corresponding one of the carbon fiber prepreg layers.

[0025] The present disclosure also provides the following technical solutions:

[0026] 1. A part forming system, comprising:

[0027] Mobile robots;

[0028] a first material feeding device configured to feed carbon fiber prepreg material onto the mobile robot one layer at a time to form a stack of carbon fiber prepreg layers on the mobile robot;

[0029] a second material feed device configured to feed a coating film onto the stack of carbon fiber prepreg plies to provide a resulting stack of plies; and

[0030] A hot press is configured to form and cure the resulting stack of layers by heating and compressing the resulting stack of layers to provide a resulting coated part.

[0031] 2. A part forming system according to technical solution 1, wherein the mobile robot is configured to rotate and adjust the orientation of the carbon fiber prepreg layer during laying, so that the carbon fiber prepreg layer is in a different orientation relative to the material feeding direction of the first material feeding device.

[0032] 3. The part forming system according to technical solution 1, wherein:

[0033] The mobile robot comprises a workbench; and

[0034] The workbench is configured to rotate and adjust the orientation of the stack of current carbon fiber prepreg layers before each application of the carbon fiber prepreg material, so that the carbon fiber prepreg layers in the stack of carbon fiber prepreg layers are laid in different orientations relative to the material feeding direction of the first material feeding device.

[0035] 4. A part forming system according to technical solution 1, wherein the mobile robot and at least one of the worktable of the mobile robot are configured to rotate so that at least one of the carbon fiber prepreg layers is in each of the 0°, 45°, 90°, and -45° orientations.

[0036] 5. The part forming system according to technical solution 1 also includes a laser cutting machine, which is configured to cut the carbon fiber prepreg layers during laying and before another layer is stacked on each of the carbon fiber prepreg layers.

[0037] 6. The part forming system according to technical solution 1 further comprises:

[0038] one or more overhead cameras configured to detect a perimeter of one of the carbon fiber prepreg layers;

[0039] Laser cutting machines; and

[0040] A control module is configured to control the laser cutting machine to cut the other one of the carbon fiber prepreg layers or the coating film based on the detected perimeter.

[0041] 7. A part forming system according to technical solution 1, wherein the mobile robot is configured to adjust the height of a worktable of the mobile robot before stacking each of the carbon fiber prepreg layers.

[0042] 8. The part forming system according to technical solution 1 further includes a gripper robot configured to pull at least one of the carbon fiber prepreg material and the coating film onto the mobile robot.

[0043] 9. The part forming system according to Technical Solution 1 also includes at least one of a punch and a press, which is configured to apply pressure to flatten and remove air under the corresponding one of the carbon fiber prepreg layers each time the corresponding one of the carbon fiber prepreg layers is stacked.

[0044] 10. The part forming system according to Technical Solution 1 also includes a roller, which is configured to roll and apply pressure on the corresponding one of the carbon fiber prepreg layers each time the corresponding one of the carbon fiber prepreg layers is stacked, and to remove air under the corresponding one of the carbon fiber prepreg layers.

[0045] 11. A part forming system according to technical solution 1, wherein the coating film includes a bonding layer, which helps to bond the coating film to the stack of carbon fiber prepreg layers when heated and compressed in the hot press.

[0046] 12. A method of forming a part, the method comprising:

[0047] stacking a plurality of carbon fiber prepreg layers to form a first stack on the mobile robot;

[0048] disposing a coating film on the first stack to provide a resulting stack;

[0049] transferring the resulting stack into a hot press; and

[0050] The resulting stack is heated and compression molded to provide a part having a coated surface due to heating and compressing the coating film and the carbon fiber prepreg layer.

[0051] 13. The method according to technical solution 12 further includes:

[0052] feeding carbon fiber prepreg layers one layer at a time onto the mobile robot via a first material feeding device in a first station to form the first stack on the mobile robot;

[0053] moving the mobile robot from the first station to a second station; and

[0054] The coating film is fed onto the first stack via a second material feeding device in the second station to provide the resulting stack.

[0055] 14. The method according to technical solution 13 also includes rotating the mobile robot or at least one of the workbenches of the mobile robot to orient the carbon fiber prepreg layer in a different orientation relative to the material feeding direction of the carbon fiber prepreg material used to form the carbon fiber prepreg layer.

[0056] 15. The method according to technical solution 12 further includes:

[0057] pretreating a coating substrate of the coating film to provide a pretreated surface;

[0058] applying one or more precursors to the pretreated surface of the coating film to deposit a tie layer; and

[0059] The coating film including the tie layer is disposed on the first stack before placing the resulting stack in the heat press.

[0060] 16. The method according to technical solution 15 further includes:

[0061] applying an epoxy-based thermosetting layer over the tie layer; and

[0062] The coating film including the tie layer and the epoxy-based thermosetting layer is disposed on the first stack before placing the resulting stack in the heat press.

[0063] 17. A method according to technical solution 15, wherein the pretreatment and applying at least one of the one or more precursors are implemented using atmospheric pressure plasma enhanced deposition.

[0064] 18. The method according to technical solution 12 also includes cutting the carbon fiber prepreg layers during laying and before stacking another layer on each of the carbon fiber prepreg layers.

[0065] 19. The method according to technical solution 12 further includes:

[0066] detecting a perimeter of one of the carbon fiber prepreg layers via one or more overhead cameras; and

[0067] Another one of the carbon fiber prepreg layers or the coating film is cut based on the detected perimeter.

[0068] 20. The method according to technical solution 12 further comprises at least one of the following items:

[0069] applying pressure to flatten and remove air under the corresponding one of the carbon fiber prepreg layers each time the corresponding one of the carbon fiber prepreg layers is stacked; and

[0070] Each time a corresponding one of the carbon fiber prepreg layers is stacked, rolling and applying pressure on the corresponding one of the carbon fiber prepreg layers, and removing air under the corresponding one of the carbon fiber prepreg layers.

[0071] Further areas of applicability of the present disclosure will become apparent from the detailed description, the claims and the accompanying drawings.The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0072] The present disclosure will become more fully understood from the detailed description and accompanying drawings, in which:

[0073] Figure 1 is a side view of an example carbon fiber prepreg stacking station and an example coating film application station including a mobile robot according to the present disclosure;

[0074] Figure 2 is a side view of a mobile robot including a stack of layers and a heat press according to the present disclosure;

[0075] Figure 3 yes Figure 1 to Figure 2 A side view of a mobile robot;

[0076] Figure 4 yes Figure 1 to Figure 2 Front view of a mobile robot;

[0077] Figures 5 to 7 yes Figure 1 to Figure 2 A top view of a mobile robot in different rotational orientations;

[0078] Fig. 8A shows a side view of another example stacking station illustrating a laser cutting machine and an overhead camera according to the present disclosure;

[0079] Figure 8B yes Fig. 8A A top view of a rack of a stacking station;

[0080] Fig. 9 is a side view of an example layer stacking station illustrating an example of a stamping robot, a layer pulling robot, and a mobile robot including a vacuum pump according to the present disclosure;

[0081] Fig.10 is a side view of another example layer stacking station illustrating an example roller pressing robot according to the present disclosure;

[0082] Fig.11 is a side view of an example carbon fiber prepreg stacking station and an example coating film application station including another example mobile robot on tracks according to the present disclosure;

[0083] Fig.12 yes Fig.11 A side view of a mobile robot comprising a stack of layers according to the present disclosure and a heat press;

[0084] Figures 13 to 15 yes Figure 11 to Figure 12 A top view of a mobile robot with different rotational orientations of its worktable;

[0085] Fig.16 is used Figure 20 to Figure 21 Example stacks of layers of parts formed by methods;

[0086] Fig.17 is an example of two injectors used to introduce a pretreatment gas and a precursor plasma into a coating substrate according to the present disclosure;

[0087] Fig.18 is a side cross-sectional view of an example injector that may be used to introduce one or more gases and / or plasma according to the present disclosure;

[0088] Fig.19 is a functional block diagram of a portion of an example part forming system according to the present disclosure;

[0089] Fig. 20 is an example coated part forming method according to the present disclosure; and

[0090] Fig.21 is an exemplary coating film forming method according to the present disclosure.

[0091] In the drawings, reference numerals may be repeated to identify similar and / or identical elements. DETAILED DESCRIPTION

[0092] The exterior body panels of the vehicle may be formed of composite materials. Composite body panels do not suffer from corrosion like steel and aluminum body panels. However, composite body panels may have a long cycle time. The cycle time of the body panel includes: the time to arrange, cut and stack the layers (or laminated sheets) of the panel on a fixed workbench; the time to heat, press and cure the panel, and the time to coat the panel. Each layer may be a carbon fiber epoxy resin (or prepreg) layer (referred to herein as a "carbon fiber prepreg layer"). These layers may be laid and oriented manually. Each layer may be laid in a different orientation (e.g., 0°, 45°, 45°, 90°, etc.) relative to the previously laid layer. These layers are laid in different orientations to increase the strength of the body panel. The stack of layers is placed in an oven or autoclave and heated to cure the stack. Pressure is applied to the stack during curing. The curing process may take 1 to 8 hours. Once cured, the body panel is coated. The coating process may be time-consuming and include the application of multiple layers, which include a base coat and a clear coat.

[0093] The examples disclosed herein include automatic stacking, orientation and cutting of carbon fiber prepreg layers, tie layers and coating film layers, and simultaneously heating, pressing and forming the resulting stacks of carbon fiber prepreg layers, tie layers and coating film layers to form parts. The stacking, orientation and cutting of layers are faster than the manual laying process described above. In addition, the coating film layer includes a coating material and provides a finished product coated surface when heated, pressed and formed, without the need for a traditional coating chamber (which has a coating system including a paint spraying robot). The coating film layer is a fast curing layer that cures together with the prepreg layer in less than 20 minutes. In an embodiment, curing occurs within 3 to 5 minutes.

[0094] Each example describes a manufacturing process and corresponding equipment and tools for producing high-strength, carbon fiber-based body panels and other parts, which include finished paint surfaces that meet the stringent exterior paint surface requirements of the vehicle. The finished coated surface may be free of scratches, blemishes, dents, etc. and meet gloss and orange peel requirements. For example, the orange peel (or R value) may be greater than 8.5. As an example, a paint finish of this quality may be referred to as a Class A paint surface. The process for forming a part includes stacking a plurality of carbon fiber plies pre-impregnated with a fast-curing epoxy resin and a fast-curing compatible paint film layer. These layers may also include a tie layer disposed between a carbon fiber ply (or carbon fiber prepreg) layer and a paint layer. The tie layer helps adhere the paint layer to the carbon fiber prepreg layer. An epoxy-based thermosetting layer may be applied to the tie layer and / or disposed between the tie layer and the carbon fiber prepreg layer. An epoxy-based thermosetting layer may be included to further improve the bonding between the tie layer and the carbon fiber prepreg layer. The resulting stack of layers is compression molded to form and cure the stack, thereby providing a resulting part having a predetermined geometry and a finished coating (e.g., a coated surface having a predetermined color, texture, and gloss). The disclosed method provides high-strength parts having a three-dimensional shape that can be assembled onto a vehicle without the need for subsequent coating.

[0095] The coating film and process conditions used are selected to be compatible with carbon fiber and epoxy resin based layers, which are arranged to provide quasi-isotropic reinforced parts. As used herein, a "quasi-isotropic" part refers to a part having the same tensile modulus and tensile strength in multiple predetermined directions of interest. In one embodiment, the quasi-isotropic part formed has the same physical properties in two or more different directions, such as the same tensile modulus and tensile strength. In another embodiment, the quasi-isotropic part formed has the same physical properties in 3 to 10 different directions, such as the same tensile modulus and tensile strength. In another embodiment, the quasi-isotropic part formed has the same physical properties in any direction tested, such as the same tensile modulus and tensile strength.

[0096] Figure 1 A carbon fiber prepreg stacking station 100 and a coating film application station 102 are shown that include a mobile robot 104. The mobile robot 104 is capable of moving from one station to another, rotating about the robot's Z axis and relative to the feed direction of the material (e.g., carbon fiber prepreg material or coating film), and rotating relative to the laser cutter. The Z axis is a vertical axis. The mobile robot 104 can be an automatic or partially automatic robot and / or can be controlled by an onboard control module and / or a remote control module. Examples of these control modules are shown in FIG. Fig.19 Shown in.

[0097] The carbon fiber prepreg stacking station 100 includes a material feeding device 106 for feeding a layer of carbon fiber prepreg material 108 to the mobile robot 104. The material feeding device 106 may include a roller and a motor for feeding the material 108. The carbon fiber prepreg stacking station 100 also includes an overhead laser cutter 110 and an overhead camera 112. The laser cutter 110 and the camera 112 can be mounted on a frame 114. The frame 114 may include tracks and / or actuators for moving the laser cutter 110 and the camera 112. The head of the overhead laser cutter 110 can move in the X, Y and Z directions. Any number of layers can be stacked at this station. For example, 17 to 31 layers can be cut and stacked at this station. Each layer can be cut after the layer is laid on the stack 113.

[0098] The coating film application station 102 includes a material feeding device 120 for feeding a coating film 121, which may include multiple coating film layers on the stack 113 of layers on the mobile robot 104. The coating film is not a protective film for wrapping the coated body panel, but a film with a colored coating layer, which is heated and cured simultaneously with the carbon fiber prepreg layer to provide the coating layer of the resulting finished part. The material feeding device 120 may include a roller and a motor for feeding the coating film 121. The coating film application station 102 also includes an overhead laser cutter 122 and an overhead camera 124. The laser cutter 122 and the camera 124 can be mounted on a frame 126. The frame 126 may include tracks and / or actuators for moving the laser cutter 122 and the camera 124. The head of the overhead laser cutter 122 can move in the X, Y and Z directions. The coating film can be cut after the coating film is placed on the stack. In an embodiment, each material feed device 106, 120 is in the same station, and the coating film 121 is applied at the same station as the carbon fiber prepreg layer.

[0099] The mobile robot 104 has a table 130 that can move vertically relative to a base 132 via a column 134. This allows the top of the table 130 to move vertically relative to the material feed device 106, 120. As an example, after each material layer is laid on the stack 113, the table 130 can be moved down by the thickness of the material being laid. The mobile robot 104 can rotate to any angle relative to the material feed direction (referred to as the 0° position). The mobile robot 104 can be an omnidirectional drive robot. Figure 3 A side view of the mobile robot 104 is shown, and Figure 4 A front view of the mobile robot 104 is shown.

[0100] Figure 2A mobile robot 104 is shown including a stack 113. The stack 113 includes a carbon fiber prepreg layer and a coating film. The mobile robot 104 can travel from the last station (e.g., the coating film application station 102) to the hot press 200. The stack 113 is then removed from the mobile robot 104 and placed in the hot press 200. This can be done manually via another robot (not shown), or via the mobile robot 104 if the mobile robot 104 is equipped with a robotic arm for lifting and moving the stack from the mobile robot 104 into the hot press 200.

[0101] The hot press 200 includes a top portion (or mold) 202 and a bottom portion (or mold) 204, which may include respective heaters. The stack 113 is placed between the portions 202 and 204 and is heated and compression molded to take the shape of the inner surface of the portions 202 and 204. The process cures the stack 113, and the coating film has a finished product outer surface that meets the coated surface requirements for the part when cured. As an example, the stack 113 may be heated to 175°C ± 10°C and compressed under a pressure of 800-900 pounds per square inch (psi). In an embodiment, the stack 113 is heated to 175°C. The process may take less than 20 minutes. In one embodiment, the process is 3 to 5 minutes. In another embodiment, the process is 3 minutes.

[0102] Figures 5 to 7 A top view of different rotational orientations of the mobile robot 104 is shown. As an example, the stack 500 is shown as being cut into a "D" shape. The stack 500 and the mobile robot 104 are shown at 0 °, 45 ° and 90 ° positions, but can be rotated to any angular position. The mobile robot 104 can have any number of reference points 502, which can be detected by an overhead camera (e.g., the camera mentioned herein). Relative to the reference point 502, the position of the stack 500 is known and / or determined. This enables each of the layers of the stack 500 to be accurately cut when laid.

[0103] The mobile robot 104 rotates around the Z axis of the mobile robot 104 via the omnidirectional drive motor of the mobile robot 104 to align the stack 500 on the workbench of the mobile robot 104 clockwise or counterclockwise in a predefined orientation. This is done to form a carbon fiber grid stacked at different angles to increase strength. In an embodiment, the mobile robot 104 is positioned at two different angles (0° and 90° or 45° and -45°). For the first layer (or part matrix), the material layer is set on the workbench of the mobile robot 104 and cut using the laser cutting machine mentioned in this article. This is based on the shape of the material layer (or part matrix) to be cut (or part), the size of the material layer (or part) and the known position of the reference point 502 relative to the material layer (or part). The material layer can be a first carbon fiber prepreg layer.

[0104] When there are one or more layers (or stacks) on the workbench of the mobile robot 104, the vision camera is used to detect the position and orientation of the stack on the mobile robot 104. The vision camera is used to detect the perimeter including the borders and / or edges of the stack to understand the cutting path of the laser cutter. When cutting subsequent layers, the laser cutter can follow the perimeter of the first and / or previously applied layer. These operations can be performed by Fig.19 Each layer in the stack can be pulled over and laid on a workbench and / or an existing stack using a pulling tool, device and / or robot. Fig. 9 An example of a layer pulling robot is shown in .

[0105] FIG. 8A to FIG. 8B A view of another example stacking station 800 is shown, which illustrates a laser cutter 802 and an overhead camera 804 mounted on a rack 805. The laser cutter 802 can move in the X and Y directions. The laser cutter 802 can move in the Y direction on a first track 806. The first track 806 can move in the X direction on a pair of tracks 808, which enables the laser cutter 802 to move in the X direction. The laser cutter 802 can move relative to the mobile robot 104 so as to cut the layer on the mobile robot 104. The camera 804 can move in the X and Y directions along the beam 809 relative to the mobile robot 104, and / or be angled to observe the layer and its parts on the mobile robot 104. The beam 809 can move laterally in the Y direction on the pair of tracks 811. In one embodiment, the camera 804 can observe the layer and its parts without being moved. Any number of cameras can be included.

[0106] The laser cutter 802 is capable of moving in the X, Y, and Z directions. In the example shown, a roll of thermoset carbon fiber material or coating film is fed to the mobile robot 104 in a unidirectional direction and cut using the laser cutter 802. The mobile robot 104 rotates between each applied layer to reorient the stack being formed before the next layer is applied. The height of the table is also moved (or indexed) between successive layer applications.

[0107] Fig. 9 A layer stacking station 900 is shown, which includes a punching robot 902, a layer pulling robot 904, and a mobile robot 906 including a vacuum pump 908. After each layer is applied to a stack 910, the punching robot 902 presses down on the stack 910 on the mobile robot 906 to remove air between the layers and flatten the stack 910. The pressure applied to the stack 910 by the press arm plate 912 is low, for example 25-50 psi.

[0108] To prevent the stack 910 and / or any of its layers from sticking to the press arm plate 912, the press arm plate 912 may be formed of a non-stick material such as polytetrafluoroethylene (PTFE), and / or the mobile robot 906 may include a vacuum pump 908 that draws air through holes 913 in a table 914 of the mobile robot 906. This allows the stack 910 to be held on the table 914. The holes 913 may be distributed on a top plate 915 of the table 914 and be part of a manifold 916 connected to the vacuum pump 908. As another example and to prevent sticking, the bottom surface of the press arm plate 912 may be sprayed (or coated) with a release material, such as calcium carbonate.

[0109] The stamping robot 902 may include an arm 917 extending from a base 918 to a top plate assembly 919 and configured to rotate (or move) the top plate 915 onto and away from the stack 910. This allows the laser cutter to cut the applied layers without the top plate 915 getting in the way. Fig. 9 910. Although not shown, an overhead laser cutter and an overhead camera may be included in the layer stacking station 900. The arm 917, the top plate assembly 919, and the top plate 915 are capable of vertical movement. The stamping robot 902 includes a robot for vertically moving the top plate and for rotating the top plate to and away from the stack 910.

[0110] The layer pulling robot 904 includes a gripper 920 that extends in a direction opposite to the material feed direction, grabs material 922, and pulls the material onto the stack 910. The material 922 is in a roll 924 of a material feed device 926. The material 922 is delivered to the top of the mobile robot 906 via rollers 928. The rollers 928 can roll freely or be attached to a motor and moved via Fig.19 The mobile robot 906 can be similar to Figure 1 Mobile robot 104.

[0111] The material (e.g., composite material) is pulled onto the stack 910 by the gripper 920. In an embodiment, the roller 928 captures the cut edge of the material after the material has been cut, and then presents the cut edge of the material to the gripper 920. The workbench 914 is raised or lowered depending on whether another layer is added to the current stack or a new stack is being formed. The workbench 914 is raised to an initial height when a new stack is to be formed, and the workbench 914 is lowered for each layer being applied. After the layer is applied, the layer is pressed with the press arm plate 912. The press arm plate 912 is then removed, and the layer is cut using, for example, a laser cutter as mentioned herein. The laser cutter cuts off the excess material. The workbench 914 can be rotated between the application of each layer so that the carbon fiber and / or carbon fiber array of each layer is at a different angle. Two or more layers can be arranged at the same angle. In one embodiment, a predetermined orientation pattern is provided by the layer of the first group, and then the pattern is repeated for the layer of the next group in the stack of the same layer.

[0112] Fig.10 A layer stacking station 1000 is shown, which includes a layer pulling robot 904, a mobile robot 906, and a roller robot 1002. The roller robot 1002 applies pressure on the top surface of the stack 1004 on the mobile robot 906 and rolls across it. This can occur after each layer is applied to the stack 1004 to remove air between the layers and flatten the stack 1004. The pressure applied to the stack 1004 is low, such as 25-50psi. The roller robot 1002 includes a roller 1010 and an arm 1012. As shown, the arm 1012 can rotate, or can move vertically to apply pressure on the stack 1004 via the roller 1010. The roller robot 1002 can move in the X and Y directions via an overhead track 1020 on a frame 1022. The roller robot 1002 can be used instead of Fig.10 The stamping robot 902.

[0113] Fig.11A carbon fiber prepreg stacking station 1100 and an example paint film application station 1102 are shown, which include another example mobile robot 1104 on a track 1106. The stations 1100, 1102 may include laser cutters 1110, 1112 and cameras 1114, 1116 mounted and / or suspended on frames 1118, 1120. Material feeders 1122, 1124 feed carbon fiber prepreg material 1126 and paint film 1128 to be applied to a stack 1130.

[0114] The mobile robot 1104 includes a base 1140 and a worktable 1142 that moves vertically via a column 1139 and rotates relative to the base 1140. The worktable 1142 rotates around the Z axis of the mobile robot 1104. The base moves along a track 1106. Although not shown, the mobile robot 1104 can move from one station to another along the track 1106 and from one station to a heat press. Fig.12 An example heat press is shown. As an example, the mobile robot 1104 can move from one station to another in the X direction and from one station to the heat press. The mobile robot 1104 can be an automatic or semi-automatic robot.

[0115] Fig.12 Shows Fig.11 The mobile robot 1104 includes a stacker 1130 and a heat press 1200. The mobile robot 1104 moves along a track 1106 from a previous station (eg, a coating film application station 1102) to the heat press 1200.

[0116] The hot press 1200 includes a top portion (or mold) 1202 and a bottom portion (or mold) 1204, which may include respective heaters. The stack 1130 is placed between the portions 1202 and 1204 and is heated and compression molded to take the shape of the inner surface of the portions 1202 and 1204. The process solidifies the stack 1130. The coating film has a finished product outer surface that meets the coated surface requirements for the part when solidified. As an example, the stack 1130 may be heated to 175°C ± 10°C and compressed under a pressure of 800-900psi. In an embodiment, the stack 1130 is heated to 175°C. The process may take less than 20 minutes. In an embodiment, the process is 3 to 5 minutes. In another embodiment, the process is 3 minutes.

[0117] Figures 13 to 15Different rotational orientations of the workbench 1142 of the mobile robot 1104 are shown. As an example, the stack 1300 is shown as being cut into a "D" shape. The stack 1300 and the workbench 1142 are shown at 0 °, 45 ° and 90 ° positions, but can be rotated to any angular position relative to the base 1140. The workbench 1142 can have any number of reference points 1302, which can be detected by an overhead camera (e.g., a camera mentioned herein). Relative to the reference points 1302, the position of the stack 1300 is known and / or determined. This enables each of the layers of the stack 1300 to be accurately cut when laid.

[0118] The workbench 1142 is rotated about the Z axis via the motor of the mobile robot 1104 to align the stack 1300 on the workbench 1142 clockwise or counterclockwise in a predefined orientation. This is done to form a carbon fiber grid stacked at different angles to increase strength. In an embodiment, the workbench 1142 is positioned at two different angles (0° and 90° or 45° and -45°). For the first layer (or part matrix), the material layer is set on the workbench 1142, and based on the shape of the material layer (or part matrix) being cut, the size of the material layer, and the known position of the reference point 1302 relative to the material layer, the laser cutting machine mentioned in this article is used for cutting. The material layer can be a first carbon fiber prepreg layer.

[0119] When there are one or more layers (or stacks) on the work table 1142, the vision camera is used to detect the position and orientation of the stack on the mobile robot 1104. The vision camera is used to detect the perimeter including the borders and / or edges of the stack to understand the cutting path of the laser cutter. When cutting layers other than the first layer, the laser cutter can follow the perimeter of the first and / or previously applied layer. These operations can be performed by Fig.19 Each layer in the stack can be pulled over and laid on a workbench and / or an existing stack using a pulling tool, device and / or robot. Fig. 9 An example of a layer pulling robot is shown in .

[0120] Fig.16 Shows the use of Figure 20 to Figure 21The stack 1600 of example layers of a part formed by the method of the present invention. The stack 1600 includes a base support layer 1602, a bonding layer 1604, an epoxy-based thermosetting layer 1605, and a coating film layer 1606 of a coating film. The base support layer 1602 may include a part matrix 1610 and one or more carbon fiber prepreg layers 1612. The part matrix 1610 may be a carbon fiber prepreg layer or other matrix support layer. As an example, the carbon fiber prepreg layers 1610, 1612 may have a tensile modulus of 30-70 gigapascals (GPA). The resin and carbon fiber of the carbon fiber prepreg layers 1610, 1612 are selected, and the orientation of the carbon fiber prepreg layers 1610, 1612 is selected to provide a target tensile modulus. In an embodiment, at least some of the carbon fiber prepreg layers 1610, 1612 may be oriented around the corresponding Z axis (or vertical axis) at 0°, 90°, 45°, -45°. In an embodiment, 17 to 31 carbon fiber prepreg layers are stacked up to a total panel thickness of 2-3 mm to provide a corresponding target panel strength. The carbon fiber prepreg layers 1610, 1612 may include a material having an epoxy-based chemistry.

[0121] The bottom portion of coating matrix 1620 is pre-treated before forming tie layer 1604, which is a thin film having a thickness of less than 1 micrometer. A precursor is introduced into the pre-treated portion of coating matrix 1620 to form tie layer 1604. Epoxy-based thermosetting layer 1605 may be applied to the bottom of tie layer 1604. In an embodiment, epoxy-based thermosetting layer 1605 is not included. Epoxy-based thermosetting layer 1614 may include a material having an epoxy-based chemistry.

[0122] The coating film may be a thermoplastic laminate coating film comprising a coating matrix 1620, one or more base coats 1622 and one or more clear coats 1624. In an embodiment, the coating matrix 1620 is chemically compatible with the thermosetting carbon fiber reinforced sheet (or layer 1612) via pretreatment and the formation of the tie layer 1604. For example, the coating matrix 1620 may include a fluorocarbon polymer, polypropylene or other suitable material. The coating matrix 1620 may be a polymer film. The base coat 1622 may be a colored base coat. Layers 1622 and 1624 are elastic to a predetermined strain rate and a predetermined maximum strain amount. One or more coating film layers 1606 may include conductive elements, such as metal mesh and / or metal particles, to provide one or more conductive layers. In an embodiment, the conductive layer is formed for lightning protection that may be experienced by the outside of a vehicle (e.g., a motor vehicle or an aircraft). The metal mesh and metal particles may be formed of copper and / or other conductive materials.

[0123] Layer 1604 improves the bonding of coating film layer 1606 to carbon fiber prepreg layer 1612. Tie layer 1604 is formed and / or bonded to coating matrix 1620 before the coating film is applied to carbon fiber prepreg layer 1612. Tie layer 1604 is formed before compression molding of stack 1600. Tie layer 1604 is formed using an in-line deposition process that does not require a curing step. Tie layer 1604 is applied at atmospheric pressure using atmospheric pressure plasma enhanced deposition. The plasma process can be performed for at least one of pretreatment and precursor deposition.

[0124] The bottom surface of the coating substrate 1620 is pretreated with plasma to prepare for the deposition of one or more precursors to form the tie layer 1604. The pretreatment is performed to change the surface energy and oxidize the surface of the coating substrate 1620, thereby improving the adhesion of the deposited tie layer 1604 to the coating substrate 1620. The plasma includes a non-deposition gas, such as air, nitrogen, argon, hydrogen, oxygen or water vapor. The tie layer 1604 is then formed by introducing one or more chemical precursors, which deposit a thin film (e.g., less than 1 micron thick) containing functional groups on the bottom surface of the pretreated portion of the coating substrate 1620. The functional groups react with compounds in the fast-curing thermosetting resin of the epoxy-based thermosetting layer 1605 and / or the carbon fiber prepreg layer 1612. This reaction provides strong adhesion, such as covalent bonds, hydrogen bonds, mechanical interlocking, etc. The chemical precursors can include chemical substances containing organic groups, such as epoxides, amines and other nitrogen compounds, ethers, carbonyl compounds and hydroxyls. The chemical precursor may include an organic metal hybrid compound, such as an organic silane, an alkoxysilane, and a hydrolyzed metal compound containing an organic group. For example, the total overall thickness of the tie layer may be less than 300 nanometers (nm). The precursor enhances the adhesion of the coating film to the carbon fiber prepreg layer 1612.

[0125] The formation of pretreatment and / or bonding layer 1604 can be formed using a plasma process including a plasma jet, wherein each jet is a single plasma source. An jet array can be used. The jet can scan the surface to be treated and / or the surface on which the material is to be deposited. The bonding layer 1604 can be formed and the coating film layer 1606 is inverted on the workbench so that the bonding layer 1604 can be formed on the bottom surface of the coating matrix 1620. In an embodiment, the jet array uses a pulsed direct current (DC) or alternating current (AC) scan surface in the range of 20 kilohertz (kH) to 300 gigahertz (GHz). In another embodiment, a dielectric barrier discharge (DBD) plasma configuration is used.

[0126] Fig.17An example embodiment is shown that includes the use of two injectors 1700, 1702. The first injector 1700 can be used to introduce a pre-treatment gas and / or plasma. The second injector 1702 can be used to introduce a precursor plasma. The injectors 1700, 1702 can be scanned over a stack 1704 on a workbench 1706 of a mobile robot 1708 (moving in the X and Y directions). Fig.18 Example configurations that may be used for each injector 1700 , 1702 are shown.

[0127] Fig.18 An injector 1800 that can be used to introduce gas and / or plasma is shown. The injector 1800 includes a housing 1802, an electrode 1804, and a center member 1806. The electrode 1804 is mounted on the center member 1806 and receives power via a line 1808. The center member 1806 includes a hole 1810 to facilitate the passage of gas received via an inlet member 1812. The power can be DC and / or AC power. The housing 1802 can be grounded. The electrode 1804 is used to generate an arc 1813 between the electrode 1804 and the housing 1802 to form a plasma 1814, which is output from a venturi nozzle 1818 of the injector 1800. The plasma is directed to the surface of the layer 1820 being processed.

[0128] Fig.19 A portion 1900 of a part forming system is shown, which may include Figures 1 to 15 and Figure 17 to Figure 18 Any robot, system, component, equipment, etc. Fig.19 In the example shown, the part 1900 includes a control station 1902 , a mobile robot 1904 , a heat press 1906 , a material feeding device 1908 , a laser cutter 1909 , a camera 1910 , a layer pulling robot 1912 , a pressing robot 1914 , and an ejector 1916 .

[0129] The control station 1902 may include a control module 1920, a transceiver 1922, and a memory 1924. The control module 1920 may communicate with the mobile robot 1904 via the transceiver 1922. The control module 1920 may also control the mobile robot 1904 and / or provide instructions, required settings, and / or parameters to the mobile robot 1904. The control module 1920 may also control and / or provide instructions, required settings, and / or parameters to the heat press 1906, the material feeder 1908, the laser cutter 1909, the camera motor and actuator 1926, and / or the robots 1912, 1914. The laser cutter 1909 is moved by a motor 1927. This may include moving a beam on which the laser cutter 1909 is mounted. The camera motor and actuator 1926 moves the camera 1910 in the X and Y directions, and tilts the camera 1910. This may include moving the beam on which the camera is mounted. The memory 1924 may store algorithms, instructions, parameters, stack layer orientations, stack layer sequences, bonding layer recipes, coating layer recipes, and / or other relevant information.

[0130] The mobile robot 1904 may include a control module 1930, a transceiver 1932, a pump 1934, and a motor 1936. The control module 1930 may control the pump 1934 and the motor 1936. The motor 1936 may include a motor for raising, lowering, and rotating a workbench, such as one of the workbench mentioned herein. The motor 1936 may also include a motor for moving and / or rotating the mobile robot 1904 in the X and Y directions. The pump 1934 may be used to maintain layers stacked on the workbench.

[0131] The hot press 1906 may include one or more high pressure press motors 1940 for compressing and forming a stack of layers and one or more heaters 1942 for curing the stack of layers. The material feed device 1908 may include a roller motor 1950, a carbon fiber prepreg feed motor 1952, and a coating film feed motor 1954. The camera 1910 may be moved and / or oriented via the camera motor and actuator 1926.

[0132] The layer pulling robot 1912 may include one or more gripper motors 1960 and one or more material pulling motors 1962. The gripper motor 1960 may drive one or more grippers to grab material, which is, for example, to be pulled onto at least a portion of the workbench of the mobile robot 1904. The pressing robot 1914 may include one or more low-pressure pressing motors 1970 and / or other actuating motors 1972 for moving parts of the robot 1914. As described above, after the layer is applied, the low-pressure pressing motor 1970 may be used to stamp the stack and / or apply a small amount of pressure to the stack. The low-pressure pressing motor 1970 may move the stamping plate or pressing roller in the Z direction and / or in an angular motion. The actuating motor 1972 may be used to move the stamping plate or pressing roller in the X and Y directions.

[0133] The ejector 1916 receives gas from the gas supply system 1964 and supplies gas and / or plasma to the coating film to form a bonding layer on the coating film before the coating film is disposed on the carbon fiber prepreg layers stacked on the worktable of the mobile robot 1904. The ejector 1916 may receive power from the power supply 1966, which may be controlled by the control module 1920.

[0134] The following Figure 20 to Figure 21 Can be Fig.19 The parts forming system is realized. Fig. 20 A coated part forming method for forming a coated part (e.g., a body panel) is shown. In 2000, Fig.19 The control module 1920 can determine the part composition, including the number of each layer, the orientation of the layers, the order of the layers in the stack, the type of layers, the layer composition, the manufacturing method, etc.

[0135] At 2001, one or more of the control modules 1920, 1930 orient the mobile robot 1904 and / or the workstation of the mobile robot 1904 prior to forming a part matrix. At 2002, the part matrix is ​​formed. This may include placing material for the part matrix on the workstation of the mobile robot 1904. The part matrix may be a first carbon fiber prepreg layer. The material may be cut (i.e., sized) according to a predetermined set pattern, which may be determined at 2000. The part matrix may be stamped or pressed.

[0136] At 2004, one or more control modules 1920, 1930 determine whether to reorient the mobile robot 1904 and / or the workbench for the next level. If so, operation 2006 is performed, otherwise operation 2008 is performed.

[0137] At 2006, one or more control modules 1920, 1930 reorient the mobile robot 1904 and / or the work table. At 2008, one or more of the control modules 1920, 1930 applies a layer of carbon fiber prepreg to the stack.

[0138] At 2010, one or more control modules 1920, 1930 determine whether another carbon fiber prepreg layer is to be formed. If so, a stack of carbon fiber prepreg layers has been formed and operation 2004 is performed, otherwise operation 2012 is performed.

[0139] At 2012, one or more of the control modules 1920, 1930 determines whether to apply a coating film with a tie layer, if yes, then operation 2014 is performed, otherwise, operation 2016 is performed.

[0140] In 2014, one or more of the control modules 1920, 1930 applies a tie layer to the coating film and stacks the coating film with the tie layer on the formed stack of carbon fiber prepreg layers to provide a resulting stack. In 2016, one or more of the control modules 1920, 1930 stacks the coating film without the tie layer on the formed stack of carbon fiber prepreg layers to provide a resulting stack.

[0141] At 2018, the resulting stack is placed in a heat press. At 2020, the resulting stack is heated and compressed as described above to form and cure the resulting stack into a finished part having a finished paint finish. The method can end after operation 2020.

[0142] Fig.21 A coating film forming method is shown, which can be Fig. 20 The steps of steps 2100 and 2110 may be performed before and / or during operations 2012, 2014, and 2016. At 2100, the composition of the coating film and the tie layer may be determined, including the number of each layer, the orientation of the layers, the order of the layers in the stack, the type of layers, the recipe of the tie layer, etc. The recipe may include materials, temperature, gas and / or plasma application pressure and duration, voltage, etc.

[0143] At 2101, the control module 1920 can control the formation of a coating matrix. At 2102, the control module 1920 applies a base coat to the coating matrix.

[0144] At 2104, the control module 1920 may determine whether another basecoat layer is to be applied. If so, operation 2102 is performed, otherwise operation 2106 is performed. At 2106, the control module 1920 applies a clearcoat layer to the last formed basecoat layer.

[0145] At 2108, the control module 1920 can determine whether another clear coat layer is to be applied. If so, operation 2106 is performed, otherwise operation 2110 is performed.

[0146] At 2110, the control module 1920 may determine whether one or more bonding layers are formed. If so, operation 2112 is performed, otherwise operation 2124 is performed.

[0147] At 2112, the control module 1920 may determine whether to pre-treat the coating substrate. If so, operation 2114 is performed, otherwise operation 2116 is performed.

[0148] At 2114, control module 1920 pre-treats the coating substrate, as described above. At 2116, control module 1920 applies a precursor layer over the pre-treatment layer, or, if not pre-treated, over the coating substrate.

[0149] At 2118, the control module 1920 may determine whether to form an epoxy-based thermosetting layer on the precursor layer. If yes, operation 2120 is performed, otherwise operation 2122 is performed. At 2120, the control module 1920 applies the epoxy-based thermosetting layer to the precursor layer.

[0150] At 2122, the control module 1920 moves the resulting coating film with the formed tie layer(s) to the coating film application station. At 2124, the control module 1920 moves the resulting coating film without the tie layer to the coating film application station. The method can end after operations 2122, 2124.

[0151] Figure 20 to Figure 21 The operations described above are illustrative examples. Depending on the application, these operations may be performed sequentially, synchronously, simultaneously, continuously, during overlapping time periods, or in a different order. In addition, depending on the implementation and / or the order of events, any operation may not be performed or skipped.

[0152] The examples described above include rapid processing techniques for high strength automotive grade carbon fiber panels and high quality paint film coatings applied in a mold to obtain a high quality paint finish on a part such as a panel. In an embodiment, the molding process uses a single molding tool and takes 20 minutes or less in cycle time without the need for subsequent hot pressing and without any additional coating and / or polishing processes.

[0153] These examples include combining two manufacturing processes - compression molding and film-over-part (FOP) application - into one operation. The operation includes forming a part with a coating film directly in a die. This reduces the amount of fixtures required (i.e., eliminating the FOP machine and / or coating room for the part), which reduces the manufacturing footprint required to manufacture the finished coated part. Multiple carbon fiber prepreg layers are molded together with a fast-curing thermosetting resin and a compatible coating film layer through a compression molding process to form and cure a part with a finished coated surface. The part can have a predetermined geometry associated with, for example, a body panel of a vehicle.

[0154] These examples enable custom designed blanks with material properties that are directionally aligned to any desired angle and in any combination of layer stacking sequences as desired through precise carbon fiber layer orientation. The term "blank" refers to a layer of carbon fiber prepreg. These examples enable the flexible production of different blanks, including sizing each layer including a selected number of layers, and orienting and sequencing each layer in a selected order. The resulting stack can be heated, pressed, formed and finished in one machine (or press) with a batch size of one. This reduces cycle time and enables mass production.

[0155] These embodiments provide high speed in-mold co-curing of a part (or panel) structural layer and a coating film with a tie layer (or adhesive) without subsequent hot pressing. A high strength fast curing epoxy thermosetting structural resin is used with an in-mold curing time of less than 20 minutes. The disclosed method provides a complete part that is ready to be assembled on a vehicle after curing without the need for subsequent operations such as trimming, coating and polishing. The complete part can be assembled on a space-time frame vehicle.

[0156] The disclosed examples enable custom designed carbon fiber blanks to have material properties that are directionally aligned to any desired angle and in any sequential order of layer orientation via a part forming system (or an automated ply stacking, cutting and curing system) through precise carbon fiber layer orientation. In the system, multiple unidirectional or pre-woven carbon fiber prepreg layers are stacked and cut so that different layers with different orientations are arranged and sequenced to achieve quasi-isotropic material strength and performance. The system enables flexible production of different blanks (size, number of layers, orientation order) in one or more stations with a batch size of one. The system also reduces cycle time through automation, which enables mass production.

[0157] The part forming system includes a material capture and feeding device and a robot that can capture the edge of the sheet roll after the roll is pre-cut, and then feed the material to the gripper of the pulling robot. The system also includes a pulling robot for grabbing and pulling the sheet (or material) from the sheet roll on the stacking platform (or the workbench of the mobile robot). The system also includes a stacking workbench based on the mobile robot, which has a lifting mechanism and a mobile robot omnidirectional drive mechanism, which enables the sheets to be stacked in different orientations (e.g., 0°, 45°, -45°, 90°). As an alternative, the stacking workbench of the robot of a linear motion system (e.g., a track-guided motion system) is implemented. The overhead visual guidance system monitors the edges and / or boundaries of the stack for the control module to determine and program the cutting path. A programmable cutting system (e.g., a laser cutter) mounted on an overhead stand cuts each layer from the sheet roll and trims the contours of each layer into a predefined part shape.

[0158] The lifting mechanism is configured to move the stack vertically after each new layer is added to the stack. A portion of the pressing mechanism presses the new layer down onto the stack and then lifts away, and the lifting mechanism adjusts the height of the table so that the next layer is pulled over and laid on the stack. Alternatively, the rollers of the rolling mechanism can be used to roll each new layer to press the new layer down onto the stack. Thereafter, the rollers are lifted away, and the stacking table lifting mechanism lowers the table so that another layer can be pulled over and laid on the stack.

[0159] These examples enable: micro / mini-factory design for low-volume vehicle production without the need for traditional paint shop infrastructure; a sustainable coating process with no ovens, no sludge tanks and no emissions; and reduced processing time for fully cured, in-mold coated, high-strength carbon fiber panels with Class A surface quality and durability.

[0160] The foregoing description is merely illustrative in nature and is not intended to limit the present disclosure, its application or use. The broad teachings of the present disclosure can be implemented in various forms. Therefore, although the present disclosure includes specific examples, the true scope of the present disclosure should not be so limited, because other modifications will become apparent when studying the drawings, the specification and the following claims. It should be understood that one or more steps in the method can be performed in different orders (or simultaneously) without changing the principles of the present disclosure. Further, although each of the embodiments is described above as having certain features, any one or more of those features described in any embodiment of the present disclosure can be implemented in any of the other embodiments and / or combined with its features, even if the combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and the transformation of one or more embodiments to each other is still within the scope of the present disclosure.

[0161] Spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including "connected," "engaged," "coupled," "adjacent," "immediately adjacent," "on top of," "above," "below," and "disposed." Unless explicitly described as "directly," when describing a relationship between a first element and a second element in the above disclosure, the relationship can be a direct relationship in which no other intervening elements exist between the first element and the second element, but can also be an indirect relationship in which one or more intervening elements exist (either spatially or functionally) between the first element and the second element. As used herein, the phrase "at least one of A, B, and C" should be interpreted to mean a logical (A or B or C) using a non-exclusive logical or, and should not be interpreted to mean "at least one of A, at least one of B, and at least one of C."

[0162] In a diagram, the direction of the arrows generally shows the flow of information (e.g., data or instructions) of interest in the diagram. For example, when element A and element B exchange various information but the information transmitted from element A to element B is relevant to the diagram, the arrow may point from element A to element B. This unidirectional arrow does not mean that no other information is transmitted from element B to element A. In addition, for information sent from element A to element B, element B may send a request for the information or a receipt confirmation to element A.

[0163] In this application, including the following definitions, the term "module" or the term "controller" may be replaced with the term "circuit". The term "module" may refer to, be part of, or include an application specific integrated circuit (ASIC); a digital, analog, or mixed analog / digital discrete circuit; a digital, analog, or mixed analog / digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor circuit (shared, dedicated, or group) that executes code; a memory circuit (shared, dedicated, or group) that stores code executed by the processor circuit; other suitable hardware components that provide the functionality; or a combination of some or all of the above, such as in a system on a chip.

[0164] The module may include one or more interface circuits. In some examples, the interface circuit may include a wired or wireless interface connected to a local area network (LAN), the Internet, a wide area network (WAN), or a combination thereof. The functions of any given module of the present disclosure may be distributed between multiple modules connected by the interface circuit. For example, multiple modules may allow load balancing. In another example, a server (also referred to as a remote or cloud) module may perform some functions on behalf of a client module.

[0165] The term code, as used above, may include software, firmware, and / or microcode, and may refer to programs, routines, functions, classes, data structures, and / or objects. The term shared processor circuit encompasses a single processor circuit that executes some or all of the code from multiple modules. The term group processor circuit encompasses a processor circuit that, in conjunction with additional processor circuits, executes some or all of the code from one or more modules. References to multi-processor circuits include multiple processor circuits on discrete wafers, multiple processor circuits on a single wafer, multiple cores of a single processor circuit, multiple threads of a single processor circuit, or a combination of the above. The term shared memory circuit encompasses a single memory circuit that stores some or all of the code from multiple modules. The term group memory circuit encompasses a memory circuit that, in conjunction with additional memory, stores some or all of the code from one or more modules.

[0166] The term memory circuit is a subset of the term computer-readable medium. As used herein, the term computer-readable medium does not include transient electrical or electromagnetic signals propagated through a medium (e.g., on a carrier wave); thus, the term computer-readable medium may be considered to be tangible and non-transient. Non-limiting examples of non-transient tangible computer-readable media are non-volatile memory circuits (e.g., flash memory circuits, erasable programmable read-only memory circuits, or mask read-only memory circuits), volatile memory circuits (e.g., static random access memory circuits or dynamic random access memory circuits), magnetic storage media (e.g., analog or digital tapes or hard drives), and optical storage media (e.g., CDs, DVDs, or Blu-ray discs).

[0167] The apparatus and methods described in this application may be implemented in part or in whole by a special purpose computer created by configuring a general purpose computer to perform one or more specific functions contained in a computer program. The above functional blocks, flow chart components and other elements serve as software specifications that can be translated into a computer program by the routine work of a skilled technician or programmer.

[0168] The computer program includes processor executable instructions stored on at least one non-transitory tangible computer readable medium. The computer program may also include or rely on stored data. The computer program may include a basic input / output system (BIOS) that interacts with the hardware of the special-purpose computer, device drivers that interact with specific devices of the special-purpose computer, one or more operating systems, user applications, background services, background applications, etc.

[0169] A computer program may include: (i) descriptive text to be parsed, such as HTML (Hypertext Markup Language), XML (Extensible Markup Language), or JSON (JavaScript Object Notation); (ii) assembly code; (iii) object code generated by a compiler from source code; (iv) source code executed by an interpreter; (v) source code compiled and executed by a just-in-time compiler, etc. By way of example only, source code may be written using syntax from the following languages: C, C++, C#, Objective C, Swift, Haskell, Go, SQL, R, Lisp, Fortran, Perl, Pascal, Curl, OCaml, HTML5 (Hypertext Markup Language Version 5), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Visual Lua, MATLAB, SIMULINK, and

Claims

1. A part forming system, comprising: Mobile robots; a first material feeding device configured to feed carbon fiber prepreg material onto the mobile robot one layer at a time to form a stack of carbon fiber prepreg layers on the mobile robot; a second material feed device configured to feed a coating film onto the stack of carbon fiber prepreg plies to provide a resulting stack of plies; as well as A hot press is configured to form and cure the resulting stack of layers by heating and compressing the resulting stack of layers to provide a resulting coated part.

2. The part forming system according to claim 1, wherein the mobile robot is configured to rotate and adjust the orientation of the carbon fiber prepreg layer during laying so that the carbon fiber prepreg layer is in a different orientation relative to the material feeding direction of the first material feeding device.

3. The part forming system according to claim 1, wherein: The mobile robot comprises a workbench; and The workbench is configured to rotate and adjust the orientation of the stack of current carbon fiber prepreg layers before each application of the carbon fiber prepreg material, so that the carbon fiber prepreg layers in the stack of carbon fiber prepreg layers are laid in different orientations relative to the material feeding direction of the first material feeding device.

4. The part forming system according to claim 1, wherein at least one of the mobile robot and the worktable of the mobile robot is configured to rotate so that at least one of the carbon fiber prepreg layers is in each of the 0°, 45°, 90°, and -45° orientations.

5. The part forming system of claim 1 , further comprising a laser cutter configured to cut the carbon fiber prepreg layers as they are laid up and before another layer is stacked on each of the carbon fiber prepreg layers.

6. The part forming system according to claim 1, further comprising: one or more overhead cameras configured to detect a perimeter of one of the carbon fiber prepreg layers; Laser cutting machine; as well as A control module is configured to control the laser cutting machine to cut the other one of the carbon fiber prepreg layers or the coating film based on the detected perimeter. 7 . The part forming system of claim 1 , wherein the mobile robot is configured to adjust a height of a work table of the mobile robot before stacking each of the carbon fiber prepreg layers.

8. The part forming system of claim 1, further comprising a gripper robot configured to pull at least one of the carbon fiber prepreg material and the coating film onto the mobile robot.

9. The part forming system according to claim 1 further includes at least one of a punch and a press configured to apply pressure to flatten and remove air under a corresponding one of the carbon fiber prepreg layers each time the corresponding one of the carbon fiber prepreg layers is stacked.

10. The part forming system according to claim 1, further comprising a roller configured to roll and apply pressure on the corresponding one of the carbon fiber prepreg layers each time the corresponding one of the carbon fiber prepreg layers is stacked, and to remove air under the corresponding one of the carbon fiber prepreg layers.

Images