Electrorheological shape retention film

Abstract

The invention relates to an electrorheological shape retention film. Shape retaining films, methods of use, and end effectors using shape retaining films are presented. In one embodiment, a shape retention film comprises: a porous substrate impregnated with an electro-rheological fluid; a pair of high voltage electrodes located on either side of the porous substrate; and the skin is wrapped around the porous substrate and the pair of high-voltage electrodes.

Description

Technical Field

[0001] The present disclosure generally relates to a shape - retaining film and method of use. Background Art

[0002] Some manufacturing processes (such as composite manufacturing) include forming processes. Some manufacturing processes include using shape - conforming tools that can change rigidity as needed.

[0003] Current shape - changing tools include tools with mechanical locking mechanisms. The mechanical locking mechanisms are undesirably heavy and prone to mechanical wear and breakdown. Other shape - changing tools include using vacuum bags. Vacuum - bag shape - conforming systems change stiffness slowly and are prone to leakage, which can reduce or prevent the vacuum bag from maintaining the desired shape.

[0004] Accordingly, there is a desire for methods and devices that take into account at least some of the above problems and other possible problems. For example, there is a desire to provide a shape - conforming tool that is at least one of faster, lighter, and less prone to wear. Summary of the Invention

[0005] Embodiments of the present invention provide a shape - retaining film. The shape - retaining film includes: a porous substrate impregnated with an electrorheological fluid; a pair of high - voltage electrodes located on either side of the porous substrate; and a skin wrapped around the porous substrate and the pair of high - voltage electrodes.

[0006] Another embodiment of the present disclosure provides a method of moving and forming a composite laminate. When the shape - retaining film of a pick - and - place end - effector is in a first shape, and when an electric field is applied to the shape - retaining film on a lift surface that supports the pick - and - place end - effector, the composite laminate is held against the lift surface. When the shape - retaining film is in the first shape and when the composite laminate is held against the lift surface, the electric field is removed from the shape - retaining film. The shape of the shape - retaining film is changed to a second shape to form the composite laminate. An electric field is applied to the electrorheological fluid to hold the shape - retaining film in the second shape.

[0007] Yet another embodiment of the present disclosure provides a pick - and - place end - effector. The pick - and - place end - effector includes: a shape - retaining film that includes a porous substrate impregnated with an electrorheological fluid, a pair of high - voltage electrodes on either side of the porous substrate, and a skin wrapped around the porous substrate and the high - voltage electrodes; a lift surface configured to contact the composite laminate, the lift surface being connected to the shape - retaining film; and a connector configured to connect the pick - and - place end - effector to a robot or a rack, the connector being attached to the shape - retaining film.

[0008] In various embodiments of the present disclosure, the features and functions may be implemented independently or may be combined in other embodiments where further details can be seen with reference to the following description and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The novel features that are considered to be characteristics of the illustrative embodiments are set forth in the appended claims. However, the illustrative embodiments, their preferred modes of use, further objectives and features will be best understood when read in conjunction with the following detailed description of the illustrative embodiments of the present disclosure, where:

[0010] Figure 1 is a diagram of an aircraft according to an illustrative embodiment;

[0011] Figure 2 is a diagram of a block diagram of a manufacturing environment according to an illustrative embodiment;

[0012] Figure 3 is a diagram of a cross-sectional view of a shape-retaining film according to an illustrative embodiment;

[0013] Figure 4 is a diagram of a cross-sectional view of a shape-retaining film according to an illustrative embodiment;

[0014] Figure 5 is a diagram of a cross-sectional view of a shape-retaining film according to an illustrative embodiment;

[0015] Figure 6 is a diagram of a cross-sectional view of a shape-retaining film according to an illustrative embodiment;

[0016] Figure 7 is a diagram of a cross-sectional view of an end effector having a shape-retaining film according to an illustrative embodiment;

[0017] Figure 8 is an illustration of a cross-sectional view of an end effector having a shape-retaining film for holding a composite laminate according to an exemplary embodiment;

[0018] Figure 9 is an illustration of a cross-sectional view of an end effector having a shape-retaining film for forming a composite laminate according to an exemplary embodiment;

[0019] Figure 10A and Figure 10B is a flowchart of a method of moving and forming a composite laminate according to an illustrative embodiment;

[0020] Figure 11 is a diagram of a method of manufacturing and maintaining an aircraft in the form of a block diagram according to an illustrative embodiment; and

[0021] Figure 12is an illustration of an aircraft in the form of a block diagram that can implement the illustrative embodiments. Detailed Description

[0022] Now turning to Figure 1 , an illustration of an aircraft is depicted in accordance with the illustrative embodiments. The aircraft 100 has wings 102 and 104 attached to a body 106. The aircraft 100 includes an engine 108 attached to wing 102 and an engine 110 attached to wing 104.

[0023] The body 106 has a tail 112. A horizontal stabilizer 114, a horizontal stabilizer 116, and a vertical stabilizer 118 are attached to the tail 112 of the body 106.

[0024] The aircraft 100 is an example of an aircraft that can be manufactured using a shape - retaining film as disclosed. In some illustrative examples, the composite components of the aircraft 100 can be formed using an end - effector of a shape - retaining film having illustrative examples. In some illustrative examples, a portion of at least one of the wings 102, wings 104, and body 106 can be formed using a shape - retaining film of illustrative examples.

[0025] Now turning to Figure 2 , an illustration of a block diagram of a manufacturing environment is depicted in accordance with the illustrative embodiments. The manufacturing environment 200 has a shape - retaining film 202. The shape - retaining film 202 can be used to form a composite laminate 258.

[0026] The shape - retaining film 202 includes a porous substrate 204 impregnated with an electrorheological fluid 206, a pair of high - voltage electrodes 208 positioned on either side of the porous substrate 204, and a skin 210 wrapped around the porous substrate 204 and the pair of high - voltage electrodes 208. In some illustrative examples, due to the presence of the electrorheological fluid 206, the shape - retaining film 202 can be referred to as an electrorheological shape - retaining film.

[0027] As shown, the pair of high - voltage electrodes 208 includes a negative high - voltage electrode 216 on a first face 212 of the porous substrate 204 and a positive high - voltage electrode 218 on a second face 214 of the porous substrate 204. Between the positive high - voltage electrode 218 and the negative high - voltage electrode 216 is a space 220. In some illustrative examples, the space 220 between the pair of high - voltage electrodes 208 is configured to reduce arcing.

[0028] The pair of high - voltage electrodes 208 can utilize any desired voltage that changes the viscosity of the electrorheological fluid 206. The pair of high - voltage electrodes 208 can utilize any desired voltage that causes the electrorheological fluid 206 to transition between rigidity 238 and flexibility 240. In some illustrative examples, the high voltage can be in the range of 1 to 50 kV.

[0029] Based on the desired flexibility of the shape-maintaining film, the desired voltage to be applied by a pair of high-voltage electrodes 208, and reducing or preventing arcing between the pair of high-voltage electrodes 208, the thickness of the porous substrate 204 is selected. The thinner the layer of the porous substrate 204 with the electrorheological fluid 206, the higher the chance of arcing for a given voltage. The thinner the layer of the porous substrate 204 with the electrorheological fluid 206, the higher the electric field strength for a given voltage. Increasing the thickness of the porous substrate 204 is used to prevent or reduce arcing between the pair of high-voltage electrodes 208.

[0030] A pair of high-voltage electrodes 208 can apply an electric field 244 to the electrorheological fluid 206 in the porous substrate 204. Applying the electric field 244 to the electrorheological fluid 206 causes the shape-maintaining film 202 to become rigid 238. Removing the electric field 244 from the electrorheological fluid 206 causes the shape-maintaining film 202 to become flexible 240. When the shape-maintaining film 202 is flexible 240, the shape 242 of the shape-maintaining film 202 can be changed. When the shape-maintaining film 202 is rigid 238, the shape 242 of the shape-maintaining film 202 is maintained. By selectively applying and removing the electric field 244, the shape 242 of the shape-maintaining film 202 can be selectively changed and maintained.

[0031] Generating the electric field 244 can use lower power than generating a vacuum for conventional vacuum shape change. Applying the electric field 244 to the electrorheological fluid 206 changes the viscosity of the electrorheological fluid 206. Applying the electric field 244 causes the shape-maintaining film 202 to become rigid 238 faster than a conventional vacuum-based shape change layer can become rigid.

[0032] The porous substrate 204 is formed of a material configured to be flexible enough to allow the shape 242 to be changed. The porous substrate 204 is formed of a material configured not to chemically react with the electrorheological fluid 206. In some illustrative examples, the porous substrate 204 includes a polymeric material 222. In some illustrative examples, the porous substrate 204 is a consumable. In some other illustrative examples, the porous substrate 204 is reusable and replaceable. In some illustrative examples, the porous substrate 204 is durable and for the life of the shape-maintaining film 202.

[0033] The skin 210 is configured to hold the electrorheological fluid 206 within the shape - retaining film 202. The electrorheological fluid 206 is present within the porous substrate 204 such that the porous substrate 204 is saturated, but the excess electrorheological fluid 206 does not drip from the porous substrate 204. The skin 210 is not completely sealed. The skin 210 is present to reduce contamination of the composite laminate 258. The skin 210 is configured to be flexible enough to allow the shape 242 of the shape - retaining film 202 to be changed. In some illustrative examples, the skin 210 includes a flexible non - porous material 224. In some illustrative examples, the skin 210 includes silicone. In some illustrative examples, the skin 210 includes nitrile rubber or thermoplastic polyurethane (TPU). In some illustrative examples, the skin 210 includes a polymeric material 228.

[0034] In some illustrative examples, the skin 210 includes an electrically insulating material 226. In some illustrative examples, when the skin 210 includes the electrically insulating material 226, the skin 210 can prevent or reduce arcing outside the shape - retaining film 202. In some illustrative examples, when the skin 210 includes the electrically insulating material 226, the skin 210 can protect the surrounding structure from the electric field 244. In some illustrative examples, when the skin 210 includes the electrically insulating material 226, the skin 210 can protect the surrounding structure from arc discharge.

[0035] In some illustrative examples, the shape - retaining film 202 further includes an insulating layer 246 on the outer side of the skin 210. In some illustrative examples, the shape - retaining film 202 includes the insulating layer 246 to reduce the electric field 244 from leaving the shape - retaining film 202. In some illustrative examples, the shape - retaining film 202 includes the insulating layer 246 to protect the surrounding structure from arc.

[0036] In some illustrative examples, the porous substrate 204 is one of a plurality of porous substrates 229. In some illustrative examples, the shape - retaining film 202 further includes a plurality of high - voltage electrode pairs 233 spaced apart from the plurality of porous substrates 229, the plurality of high - voltage electrode pairs 233 including a pair of high - voltage electrodes 208 on either side of the porous substrate 204. The plurality of porous substrates 229 includes any desired number of porous substrates. In this illustrative example, the plurality of porous substrates 229 includes the porous substrate 204, the porous substrate 230, and the porous substrate 232. Each of the plurality of porous substrates 229 is impregnated with the electrorheological fluid 206.

[0037] The plurality of high - voltage electrode pairs 233 includes any desired number of high - voltage electrodes. As shown, the plurality of high - voltage electrode pairs 233 includes a pair of high - voltage electrodes 208 on either side of the porous substrate 204, a pair of high - voltage electrodes 234 on either side of the porous substrate 230, and a pair of high - voltage electrodes 236 on either side of the porous substrate 232.

[0038] In some illustrative examples, some pairs among the plurality of high-voltage electrode pairs 233 share electrodes with at least another pair among the plurality of high-voltage electrode pairs 233. In some illustrative examples, a pair of high-voltage electrodes 234 shares the positive high-voltage electrode 218 of a pair of high-voltage electrodes 208. In some illustrative examples, a pair of high-voltage electrodes 234 shares the negative high-voltage electrode with a pair of high-voltage electrodes 236.

[0039] In some illustrative examples, having a plurality of porous substrates 229 and a plurality of high-voltage electrode pairs 233 creates a layered configuration in the shape-maintaining film 202. The layered configuration in the shape-maintaining film 202 can be used to avoid or reduce shear between the shape-maintaining film 202 and the composite laminate 258. The multi-layer approach of the shape-maintaining film 202 can allow movement with the shape-maintaining film 202. Instead of trying to bend a thick block of porous material, the alternating layers of high-voltage electrodes and the thinner layers of porous material in the shape-maintaining film 202 allow each layer to slide / shear during movement of the shape-maintaining film 202.

[0040] In some illustrative examples, the inlet port 292 extends through the skin 210 of the shape-maintaining film 202. The inlet port 292 can supply power to the plurality of high-voltage electrode pairs 233. In some illustrative examples, the inlet port 292 can extend through the shape-maintaining film 202 to provide access to facilities of other systems. In some illustrative examples, the inlet port 292 can extend through the shape-maintaining film 202 to provide access to facilities of aspects of the pick-and-place end effector 248, such as the lifting surface 252.

[0041] In some illustrative examples, the shape-maintaining film 202 is part of the pick-and-place end effector 248. In some illustrative examples, the pick-and-place end effector 248 includes the shape-maintaining film 202, is configured to contact the lifting surface 252 of the composite laminate 258, and a connector 250 configured to connect the pick-and-place end effector 248 to a robot or a rack. The lifting surface 252 is connected to the shape-maintaining film 202. The connector 250 is attached to the shape-maintaining film 202. The connector 250 can take any desired form. In some illustrative examples, the connector 250 can take the form of a spring-loaded connector (such as "Pogos"). The shape-maintaining film 202 includes a porous substrate 204 impregnated with an electrorheological fluid 206, a pair of high-voltage electrodes 208 on either side of the porous substrate 204, and a skin 210 wrapped around the porous substrate 204 and the pair of high-voltage electrodes 208.

[0042] The lifting surface 252 can hold the composite laminate 258 against the lifting surface 252 using electrostatic charge 257, a vacuum 256, or any other desired method. The lifting surface 252 is flexible to allow for a change in shape to form the composite laminate 258. In some illustrative examples, the lifting surface 252 is a flexible vacuum surface 254 that can move between multiple shapes.

[0043] The pick and place end effector 248 can be used to lift, shape, and place the composite laminate 258. In some illustrative examples, the pick and place end effector 248 lifts the composite laminate 258 from the laying tool 274. The laying tool 274 has a surface 276 with a first shape 278. When the pick and place end effector 248 lifts the composite laminate 258 from the surface 276 of the laying tool 274, the composite laminate 258 has a first shape 260. When the pick and place end effector 248 lifts the composite laminate 258 from the surface 276 of the laying tool 274, the shape retention film 202 has a first shape 266. In some illustrative examples, the first shape 266 is a plane 270. The shape retention film 202 is held in the first shape 266 by an electric field 244. The shape retention film 202 is made rigid by applying an electric field 244 to the electrorheological fluid 206 to increase the viscosity of the electrorheological fluid 206 to hold the first shape 266.

[0044] The pick and place end effector 248 is used to change the composite laminate 258 to a second shape 262. The pick and place end effector 248 is changed to a second shape 268 to change the composite laminate 258 to the second shape 262. In some illustrative examples, the second shape 268 has a curvature 272. To change the shape 242 of the shape retention film 202, the electric field 244 is removed. By removing the electric field 244, the electrorheological fluid 206 has a lower viscosity, and the shape retention film 202 changes from being rigid 238 to flexible 240.

[0045] In some illustrative examples, to form the composite laminate 258 to have the second shape 262, the pick and place end effector 248 places the composite laminate 258 on the surface 282 of a forming mandrel 280 having a second shape 284. In some illustrative examples, the forming mandrel 280 is only used to form the composite laminate 258. In some illustrative examples, after the second shape 262 is formed in the composite laminate 258, the pick and place end effector 248 removes the composite laminate 258 from the forming mandrel 280.

[0046] In some illustrative examples, after the second shape 262 is formed as the composite laminate 258, the composite laminate 258 is deposited on the surface 282. In these illustrative examples, the composite laminate 258 is formed against the same tool, where the composite laminate is deposited on the same tool.

[0047] In other illustrative examples, the second shape 262 is formed as the composite laminate 258 using a tool different from the tool on which the composite laminate 258 is deposited. In some illustrative examples, after the second shape 262 is formed as the composite laminate 258, the composite laminate 258 is deposited onto the surface 288 of the tool 286 having the second shape 290.

[0048] The shape retention film 202 includes: a pair of high-voltage electrodes 208 on either side of the porous substrate 204; an electrorheological fluid 206 between the pair of high-voltage electrodes 208; and a skin 210 that wraps around the porous substrate 204 and the pair of high-voltage electrodes 208. In the shape retention film 202, there is an inverse relationship between the electrode voltage and the separation distance, such that as the space 220 between the pair of high-voltage electrodes 208 increases, the voltage required to reduce the viscosity in the electrorheological fluid 206 decreases.

[0049] In some illustrative examples, the shape retention film 202 further includes a porous substrate 204 impregnated with the electrorheological fluid 206 located between the pair of high-voltage electrodes 208. In some illustrative examples, the space 220 between the pair of high-voltage electrodes 208 is configured to reduce arcing.

[0050] Figure 2 The illustration of the manufacturing environment 200 in does not imply any physical or architectural limitations on the ways in which the illustrative embodiments can be implemented. Other components can be used in addition to or instead of the components shown. Some components may be unnecessary. Also, the boxes are presented to illustrate some functional components. When implemented in the illustrative embodiments, one or more of these blocks can be combined, divided, or combined and divided into different blocks.

[0051] For example, the shape retention film 202 can include any desired number of porous substrates. In some illustrative examples, the shape retention film 202 has only one porous substrate (porous substrate 204). In other illustrative examples, the plurality of porous substrates 229 includes only two porous substrates. In some illustrative examples, the plurality of porous substrates 229 includes more than three porous substrates. Similarly, in some illustrative examples, there is only one pair of high-voltage electrodes 208 in the shape retention film 202. In some illustrative examples, the plurality of high-voltage electrode pairs 233 has two pairs of high-voltage electrodes. In some illustrative examples, the plurality of high-voltage electrode pairs 233 has more than three pairs of high-voltage electrodes. Additionally, the insulating layer 246 can be optional.

[0052] In some illustrative examples, the second shape 284 and the second shape 290 are the same. In other illustrative examples, the second shape 284 is substantially the same as the second shape 290, but has variations within 10% of the second shape 290. In some illustrative examples, the second shape 284 is an iterative step in achieving the second shape 290. In these illustrative examples, before the composite laminate 258 is formed into the second shape 262 against the tool 286, the composite laminate 258 can change from the first shape 260 to an intermediate shape on the forming mandrel 280.

[0053] Although not depicted in Figure 2 , discontinuous regions of opposite electrode polarities can be present in the same layer. In these illustrative examples, more than one pair of high-voltage electrodes can be associated with the porous substrate. For example, a positive high-voltage electrode can be associated with a portion of the first face 212, while a negative high-voltage electrode 216 is associated with a different portion of the first face 212. In this example, the negative high-voltage electrode is associated with a portion of the second face 214, while a positive high-voltage electrode 218 is associated with a different portion of the second face 214.

[0054] In some illustrative examples, discontinuous regions of the same electrode polarity can be present in the same layer. For example, multiple positive high-voltage electrodes can be on the second face 214 of the porous substrate 204, and multiple negative high-voltage electrodes can be on the first face 212 of the porous substrate 204. By selectively activating the multiple positive high-voltage electrodes and the multiple negative high-voltage electrodes, a portion of the porous substrate 204 can be rigid 238, while a different portion of the porous substrate 204 is flexible 240. In some illustrative examples, the porous substrate 204 can be cut, discontinuous, or scored to allow for greater flexibility between different portions of the porous substrate 204.

[0055] Now turning to Figure 3 , an illustration of a cross-sectional view of a shape-retaining film is depicted according to an illustrative embodiment. The shape-retaining film 300 is a physical implementation of the shape-retaining film 202 Figure 2 .

[0056] The shape-retaining film 300 includes a porous substrate 302 impregnated with an electrorheological fluid 303. A pair of high-voltage electrodes 304 are positioned on either side of the porous substrate 302. A skin 310 wraps the porous substrate 302 and the pair of high-voltage electrodes 304.

[0057] As shown, the pair of high-voltage electrodes 304 includes a negative high-voltage electrode 308 on the first face 312 of the porous substrate 302 and a positive high-voltage electrode 306 on the second face 314 of the porous substrate 302. In some illustrative examples, the porous substrate 302 includes a polymeric material.

[0058] In some illustrative examples, the skin 310 includes a flexible non-porous material. In some illustrative examples, the skin 310 includes a polymeric material. In some illustrative examples, the skin 310 includes an electrically insulating material. When the skin 310 includes an electrically insulating material, the skin 310 can reduce or prevent arcing to an external structure.

[0059] In some illustrative examples, the space 316 between a pair of high voltage electrodes is configured to reduce arcing. Although not shown in Figure 3 , other layers may be attached to the skin 310. In some illustrative examples, an electrically insulating layer may be placed on the outer side of the skin 310 to protect any adjacent structures (such as tools, robots, or any other surrounding structures) from an electric field or arcing.

[0060] Now turning to Figure 4 , an illustration of a cross-sectional view of a shape retention film is depicted in accordance with an illustrative embodiment. The shape retention film 400 is a physical implementation of the shape retention film 202 of Figure 2 .

[0061] The shape retention film 400 includes a plurality of porous substrates 402. The plurality of porous substrates 402 includes a porous substrate 404, a porous substrate 406, a porous substrate 408, and a porous substrate 410. Each of the plurality of porous substrates 402 is impregnated with an electrorheological fluid.

[0062] The shape retention film 400 further includes a plurality of pairs of high voltage electrodes 412 spaced apart from the plurality of porous substrates 402. The plurality of pairs of high voltage electrodes 412 includes pairs of high voltage electrodes on either side of each respective porous substrate. As shown, each pair of high voltage electrodes has at least one voltage electrode shared with another pair of high voltage electrodes.

[0063] The plurality of pairs of high voltage electrodes 412 includes a positive high voltage electrode 414, a negative high voltage electrode 416, a positive high voltage electrode 418, a negative high voltage electrode 420, and a positive high voltage electrode 422. The positive high voltage electrode 414 and the negative high voltage electrode 416 serve as a pair of high voltage electrodes to generate an electric field in the electrorheological fluid in the porous substrate 404. The negative high voltage electrode 416 and the positive high voltage electrode 418 serve as a pair of high voltage electrodes to generate an electric field in the electrorheological fluid in the porous substrate 406. As shown, the pairs of high voltage electrodes for generating an electric field in the porous substrate 404 and the porous substrate 406 share a high voltage electrode, the negative high voltage electrode 416.

[0064] A skin 424 wraps around the plurality of porous substrates 402 and the plurality of pairs of high voltage electrodes 412. The skin 424 is configured to hold the plurality of porous substrates 402 and the plurality of pairs of high voltage electrodes 412 in an enclosure. The skin 424 is configured to hold the electrorheological fluid within the shape retention film 400.

[0065] The skin 424 is configured to be flexible enough to allow the shape of the shape - retaining membrane 400 to be changed. In some illustrative examples, the skin 424 includes a flexible non - porous material. In some illustrative examples, the skin 424 includes a polymeric material. In some illustrative examples, the skin 424 includes an electrically insulating material.

[0066] In some illustrative examples, when the skin 424 includes an electrically insulating material, the skin 424 can prevent or reduce arcing outside the shape - retaining membrane 400. In some illustrative examples, when the skin 424 includes an electrically insulating material, the skin 424 can protect the surrounding structures from the influence of the electric field.

[0067] Now turning to Figure 5 , an illustration of a cross - sectional view of a shape - retaining membrane is depicted according to an illustrative embodiment. The shape - retaining membrane 500 is Figure 2 a physical implementation of the shape - retaining membrane 202.

[0068] The shape - retaining membrane 500 includes discontinuous regions of opposite electrode polarities in the same layer and can be captured to expand the configuration range of the shape - retaining membrane. The shape - retaining membrane includes a plurality of porous substrates 502. The plurality of porous substrates 502 includes porous substrate 504, porous substrate 506, porous substrate 508, and porous substrate 510. Each of the plurality of porous substrates 502 is impregnated with an electrorheological fluid.

[0069] The shape - retaining membrane 500 also includes a plurality of high - voltage electrode pairs 512 spaced apart from the plurality of porous substrates 502. The plurality of high - voltage electrode pairs 512 includes high - voltage electrode pairs on either side of each respective porous substrate. As shown, each pair of high - voltage electrode pairs has at least one voltage electrode shared with another pair of high - voltage electrode pairs.

[0070] In this illustrative example, the corresponding faces of the porous substrates are associated with high - voltage electrodes of more than one polarity. In this illustrative example, the plurality of high - voltage electrode pairs 512 includes a positive high - voltage electrode 514, a negative high - voltage electrode 516, a positive high - voltage electrode 518, a negative high - voltage electrode 520, and a positive high - voltage electrode 522. The positive high - voltage electrode 514 and the negative high - voltage electrode 516 serve as a pair of high - voltage electrodes to generate an electric field in the electrorheological fluid in the porous substrate 504. The positive high - voltage electrode 514 is associated with a portion of the first face 505 of the porous substrate 504. The negative high - voltage electrode 516 is associated with a portion of the second face 507 of the porous substrate 504.

[0071] The plurality of high-voltage electrode pairs 512 further includes a negative high-voltage electrode 526, a positive high-voltage electrode 528, a negative high-voltage electrode 530, a positive high-voltage electrode 532, and a negative high-voltage electrode 534. The negative high-voltage electrode 526 is associated with a portion of the first face 505 of the porous substrate 504. The positive high-voltage electrode 528 is associated with a portion of the second face 507 of the porous substrate 504.

[0072] The discontinuous regions of the opposing electrodes create regions 536 and 538 of the shape-retaining film 500. The regions 536 and 538 of the shape-retaining film 500 can be independently controlled. The independent control of the regions can allow for different forming methods. The independent control allows for the independent control of the amount and timing of the rigidity of each region. The independent control of the regions can result in a more repeatable forming process. The independent control of the regions can reduce the undesirable effects on the composite laminate during forming.

[0073] The skin 524 wraps around the plurality of porous substrates 502 and the plurality of high-voltage electrode pairs 512. The skin 524 is configured to hold the plurality of porous substrates 502 and the plurality of high-voltage electrode pairs 512 in an enclosure. The skin 524 is configured to hold the electrorheological fluid within the shape-retaining film 500.

[0074] Although a high-voltage generator is not depicted in Figures 3 to 5 , the high-voltage electrodes (such as a pair of high-voltage electrodes 304, a plurality of high-voltage electrode pairs 412, or a plurality of high-voltage electrode pairs 512) will be connected to a high-voltage generator external to the respective shape-retaining film. In Figures 3 to 4 , the connectors extend external to the skins 310 and 424 such that a pair of high-voltage electrodes 304 and a plurality of high-voltage electrode pairs 412 can be connected to the high-voltage generator. Although not shown for ease of description and illustration, the connectors extending external to the skin 524 will be present to connect the plurality of high-voltage electrode pairs 512 to the high-voltage generator.

[0075] Now turning to Figure 6 , an illustration of a cross-sectional view of a shape-retaining film is depicted in accordance with an illustrative embodiment. The shape-retaining film 600 is a Figure 2 physical implementation of the shape-retaining film 202 of

[0076] The shape-retaining film 600 has three individually controllable regions (regions 602, 604, and 606). Each of the regions 602, 604, and 606 can be made rigid or flexible independent of each other region of the shape-retaining film 600. As shown, regions 602 and 606 are currently rigid while region 604 is flexible. The shape-retaining film can have any desired number of regions, dimensions of the regions, layout of the regions, and other characteristics of the regions.

[0077] Now turning toFigure 7 , an illustration of a cross - sectional view of an end - effector with a shape - retaining membrane is depicted according to an exemplary embodiment. View 700 is a view of the pick - and - place end - effector 702 before lifting the composite laminate 704 from the layup tool 706. In view 700, the composite laminate 704 is in a first shape. As shown, the composite laminate 704 and the layup tool 706 are substantially planar. To lift the composite laminate 704, the pick - and - place end - effector 702 is in a first shape 716.

[0078] The pick - and - place end - effector 702 includes a shape - retaining membrane 708, a lifting surface 712, and a connector 714. The shape - retaining membrane 708 includes a porous substrate impregnated with an electrorheological fluid, a pair of high - voltage electrodes on either side of the porous substrate, and a skin wrapped around the porous substrate and the high - voltage electrodes. The shape - retaining membrane 708 is Figure 2 a physical implementation of the shape - retaining membrane 202. In some illustrative examples, the shape - retaining membrane 708 is the same as Figure 3 the shape - retaining membrane 300. In some illustrative examples, the shape - retaining membrane 708 is the same as Figure 4 the shape - retaining membrane 400.

[0079] The lifting surface 712 is configured to contact the composite laminate 704. The lifting surface 712 is connected to the shape - retaining membrane 708. The lifting surface 712 is flexible to move between multiple shapes. The shape - retaining membrane 708 is used to hold the shape of the lifting surface 712. By applying an electric field to the shape - retaining membrane 708, the shape - retaining membrane 708 is placed in a rigid state to hold the shape of the lifting surface 712.

[0080] The connector 714 is configured to connect the pick - and - place end - effector 702 to a robot or a frame. As shown, the connector 714 is attached to the shape - retaining membrane 708.

[0081] The composite laminate 704 can be lifted by any desired method. In some illustrative examples, the lifting surface 712 is the surface of a vacuum surface 710. In these illustrative examples, the vacuum surface 710 applies a vacuum to the lifting surface 712. In these illustrative examples, the lifting surface 712 is a flexible vacuum surface to move between multiple shapes.

[0082] In other illustrative examples, the composite laminate 704 can be held against the lifting surface 712 by an electrostatic charge. When the lifting surface 712 utilizes an electrostatic charge, a vacuum may not be used, and 710 can be referred to as an electrostatic layer rather than a vacuum surface.

[0083] Now turning to Figure 8, an illustration of a cross-sectional view of an end effector having a shape retention film for holding a composite laminate is depicted in accordance with an illustrative embodiment. View 800 is a view of a pick-and-place end effector 702 holding a composite laminate 704. In this illustrative example, the pick-and-place end effector 702 is still in a first shape 716. In view 800, the pick-and-place end effector 702 transfers the composite laminate 704 while in the first shape 716. In view 800, an electric field is supplied to the electrorheological fluid within the shape retention film 708 such that the shape retention film 708 is rigid. In view 800, an electric field is supplied to the electrorheological fluid within the shape retention film 708 to maintain the first shape 716.

[0084] Now turning to Figure 9 , an illustration of a cross-sectional view of an end effector having a shape retention film for shaping a composite laminate is depicted in accordance with an illustrative embodiment. View 900 is a view of the pick-and-place end effector 702 and the composite laminate 704 in a second shape 902. In this illustrative example, the composite laminate 704 is in contact with a tool 904 having a surface 906, where the surface 906 has a second shape 908.

[0085] In some illustrative examples, the tool 904 is a forming tool. In some illustrative examples, the tool 904 is used to shape the composite laminate 704 and to change the pick-and-place end effector 702 to the second shape 902. In some illustrative examples, after the composite laminate 704 is formed into the second shape 902 against the tool 904, the pick-and-place end effector 702 lifts the composite laminate 704 from the tool 904 in the second shape 902. In these illustrative examples, an electric field is applied to cause the shape retention film 708 to maintain the second shape 902 while the pick-and-place end effector 702 lifts and moves the composite laminate 704 away from the tool 904 in the second shape 902.

[0086] In some other illustrative examples, after the composite laminate 704 is formed into the second shape 902, the pick-and-place end effector 702 leaves the composite laminate 704 on the tool 904. In some illustrative examples, an electric field is applied to cause the shape retention film 708 to maintain the second shape 902 while the pick-and-place end effector 702 moves away from the composite laminate 704. In these illustrative examples, after the composite laminate 704 is deposited on the tool 904, the pick-and-place end effector 702 can be changed to any desired shape.

[0087] To change the pick and place end effector 702 between the first shape 716 and the second shape 902, an electric field is removed from the shape retention membrane 708. Applying an electric field to the shape retention membrane 708 causes the shape retention membrane 708 to be rigid. When the electric field is removed from the shape retention membrane 708, the shape retention membrane 708 is flexible.

[0088] To place the composite laminate 704 against the tool 904, the electric field is stopped to shape the retention membrane 708 and to make the retention membrane 708 flexible.

[0089] Now turning Figure 10A and Figure 10B , a flowchart of a method of moving and forming a composite laminate is depicted in accordance with an illustrative embodiment. Method 1000 may be used to form Figure 1 the composite component of the aircraft 100. Method 1000 may be performed using Figure 2 the shape retention membrane 202. Method 1000 may be performed using Figure 3 the shape retention membrane 300. Method 1000 may be performed using Figure 4 the shape retention membrane 400, Figure 5 the shape retention membrane 500 or Figure 6 the shape retention membrane 600. Method 1000 may be performed using Figures 7 to 9 the pick and place end effector 702.

[0090] When the shape retention membrane of the pick and place end effector is in the first shape and when an electric field is applied to the shape retention membrane of the support lift surface of the pick and place end effector, method 1000 holds the composite laminate against the lift surface (operation 1002). Applying an electric field to the electrorheological fluid causes the shape retention membrane to be rigid. Applying an electric field to the electrorheological fluid holds the pick and place end effector in the first shape.

[0091] When the shape retention membrane is in the first shape and when the composite laminate is held against the lift surface, method 1000 removes the electric field from the shape retention membrane (operation 1004). Removing the electric field from the electrorheological fluid causes the shape retention membrane to become flexible. When the shape retention membrane is flexible, the shape of the shape retention membrane can be changed.

[0092] Method 1000 changes the shape of the shape retention membrane to the second shape to form the composite laminate (operation 1006). Thereafter, method 1000 terminates.

[0093] In some illustrative examples, method 1000 includes connecting a pick and place end effector to a robot or gantry using a connector attached to a retention membrane (operation 1009). In some illustrative examples, the connector can take the form of a spring loaded connector (such as "Pogos").

[0094] In some illustrative examples, forming the composite laminate is performed while placing the composite laminate onto a tool. In some illustrative examples, while the shape retention membrane is flexible, the shape of the shape retention membrane is changed to a second shape by pressing the composite laminate against the tool. In some illustrative examples, after the composite laminate is formed against the tool by the shape retention membrane, the composite laminate remains on the tool.

[0095] In some illustrative examples, the shape retention membrane includes an electrorheological fluid in a porous substrate, and wherein applying an electric field to the shape retention membrane causes the shape retention membrane to be rigid (operation 1013). Applying an electric field to the shape retention membrane increases the viscosity of the electrorheological fluid.

[0096] In some illustrative examples, method 1000 applies an electric field to the shape retention membrane to hold the shape retention membrane in a second shape (operation 1008). In some of these illustrative examples, the shape retention membrane is held in the second shape to apply a force to press against the composite laminate against the tool. In some of these illustrative examples, as part of depositing the composite laminate onto the tool, the shape retention membrane is held in the second shape.

[0097] In some illustrative examples, the composite laminate is formed on a forming mandrel that is separate from the tool onto which the composite laminate is deposited. In these illustrative examples, an electric field is applied to the electrorheological fluid to hold the shape retention membrane in the second shape such that the pick and place end effector can move the composite laminate in the second shape within a manufacturing environment.

[0098] In some illustrative examples, method 1000 places a lift surface of the pick and place end effector into contact with the composite laminate (operation 1010). In some illustrative examples, while applying an electric field to the shape retention membrane, method 1000 applies at least one of a vacuum and an electrostatic charge to the composite laminate to lift the composite laminate (operation 1012).

[0099] In some illustrative examples, when the shape retention membrane is in the second shape, method 1000 moves the pick and place end effector holding the composite laminate toward the tool (operation 1014). In some illustrative examples, when the shape retention membrane is in the second shape, method 1000 places the composite laminate onto the tool (operation 1016).

[0100] In some illustrative examples, when the composite laminate is placed on a tool, the shape retention film can be in a flexible (soft) state. If the composite laminate is placed on the tool while the shape retention film is in a flexible (soft) state, the shape retention film can push the composite laminate into the tool slots.

[0101] In some illustrative examples, after moving the pick and place end effector away from the composite laminate and the tool, method 1000 removes the electric field from the shape retention film (operation 1018). In some illustrative examples, method 1000 returns the shape of the shape retention film to the first shape (operation 1020). In some illustrative examples, method 1000 applies an electric field to the shape retention film to hold the shape retention film in the first shape (operation 1022). In some illustrative examples, when the shape retention film is in the first shape, method 1000 uses the pick and place end effector to lift a second composite laminate (operation 1024).

[0102] In some illustrative examples, changing the shape of the shape retention film includes placing the pick and place end effector against a forming mandrel (operation 1026). In some illustrative examples, the composite laminate is deposited on the forming mandrel. In some illustrative examples, the forming mandrel is used to change the shape of the composite laminate before depositing the composite laminate on a different tool.

[0103] As used herein, when used in reference to a list of items, the phrase "at least one" means that different combinations of one or more of the listed items can be used and that possibly only one of each item in the list is required. For example, "at least one of item A, item B, or item C" can include, but is not limited to, item A, item A and item B, or item B. This example can also include item A, item B, and item C, or item B and item C. Of course, any combination of these items can exist. In other examples, "at least one" can be, for example but not limited to, two of item A; one of item B; and ten of item C; four of item B and seven of item C; or other suitable combinations. The items can be specific objects, things, or categories. In other words, it means that at least one of any combination of items and number of items can be used from the list, but not all items in the list are required.

[0104] As used herein, when used in reference to an item, "a plurality" means one or more items.

[0105] The flowcharts and block diagrams in the different depicted embodiments illustrate the architecture, functionality, and operation of some possible implementations of the devices and methods in the illustrative embodiments. In this regard, each block in the flowchart or block diagram can represent at least one of a module, segment, function, or part of an operation or step.

[0106] In some alternative embodiments of the illustrative embodiments, one or more of the functions indicated in the blocks may not occur in the order indicated in the figures. For example, in some cases, depending on the functions involved, two consecutively shown blocks may be executed substantially simultaneously, or the blocks may sometimes be executed in the reverse order. Additionally, other blocks may be added in addition to those shown in the flowcharts or block diagrams. Some blocks may be optional. For example, operations 1010 to 1026 may be optional.

[0107] May be in the context of Figure 11 the aircraft manufacturing and maintenance method 1100 as shown and Figure 12 the aircraft 1200 as shown to describe the illustrative embodiments of the present disclosure. First turning to Figure 11 , a diagram of an aircraft manufacturing and maintenance method in block diagram form is depicted according to the illustrative embodiments. During pre-production, the aircraft manufacturing and maintenance method 1100 may include Figure 12 the specification and design 1102 and material procurement 1104 of the aircraft 1200 in

[0108] During production, the component and sub-component manufacturing 1106 and system integration 1108 of the aircraft 1200 are performed. Thereafter, the aircraft 1200 may undergo certification and delivery 1110 for use 1112. When put into use 1112 by a customer, the aircraft 1200 is scheduled for routine maintenance and servicing 1114, which may include modification, reconfiguration, refurbishment, or other maintenance and servicing.

[0109] Each process of the aircraft manufacturing and maintenance method 1100 may be performed or carried out by a system integrator, a third party, and / or an operator. In these examples, the operator may be a customer. For the purposes of this specification, a system integrator may include, but is not limited to, any number of aircraft manufacturers and prime system subcontractors; a third party may include, but is not limited to, any number of suppliers, subcontractors, and vendors; and an operator may be an airline, a leasing company, a military entity, a service organization, etc.

[0110] Now referring to Figure 12 , a diagram of an aircraft in block diagram form is depicted, in which the illustrative embodiments may be implemented. In this example, the aircraft 1200 is produced by Figure 11 the aircraft manufacturing and maintenance method 1100 and may include a fuselage 1202 having a plurality of systems 1204 and an interior 1206. Examples of the systems 1204 include one or more of a propulsion system 1208, an electrical system 1210, a hydraulic system 1212, and an environmental system 1214. Any number of other systems may be included.

[0111] The apparatus and methods embodied herein can be employed during at least one stage of an aircraft manufacturing and maintenance method 1100. One or more illustrative embodiments can be manufactured or used during at least one of Figure 11 the manufacture 1106 of components and subassemblies, system integration 1108, service 1112, or maintenance and repair 1114.

[0112] Illustrative examples provide a shape - retaining film. The shape - retaining film is generally flexible but can lock its shape when high pressure is applied. The shape - retaining film includes a flexible bag filled with an electrorheological fluid soaked in a porous material. Two electrodes provide an electric field to change the viscosity of the fluid such that the entire film becomes rigid.

[0113] In some illustrative examples, the shape - retaining film can be used in an end - effector (EE). A conformable end - effector can assume a shape that defines a mandrel. The shape of a pick - and - place end - effector can be changed by selectively applying high voltage to the shape - retaining film.

[0114] The pick - and - place end - effector can be placed against the mandrel with no voltage in the electrodes. When the desired shape is reached, high voltage is applied to each electrode of the shape - retaining film to change the viscosity of the electrorheological fluid, thereby locking the shape of the shape - retaining film. By applying high voltage, the bending of the pick - and - place end - effector is restricted.

[0115] The lower surface of the pick - and - place end - effector can be attached to a composite laminate using electrostatic or other means for pick - up / transfer and placement. The lifting surface of the pick - and - place end - effector can lift the composite laminate using vacuum or other methods.

[0116] Some aerospace manufacturing processes (such as carbon layup) require the use of a shape - conforming film whose stiffness can be changed as needed. Illustrative examples provide a method for forming a carbon layup using an all - electric method that enhances performance and reliability. Compared to mechanical systems, using an electrorheological fluid to control the stiffness of a shape - retaining film has lower weight, faster shape change, and lower maintenance than mechanical systems. In illustrative examples, the change in stiffness is nearly instantaneous. Using an electrorheological fluid to control the stiffness of a shape - retaining film has greater reliability and faster shape change than a vacuum - bag system. Ports, cuts, leaks, or other passages through the skin of the shape - retaining film do not undesirably affect the performance of the shape - retaining film with an electrorheological fluid. Additionally, the shape - changing film of illustrative examples can be thinner and more rigid.

[0117] This application relates to the following clauses:

[0118] Clause 1. A shape - retaining film (202, 300, 400, 500, 600, 708), the shape - retaining film comprising:

[0119] A porous substrate (204, 302, 404, 504) impregnated with an electrorheological fluid (206, 303);

[0120] A pair of high-voltage electrodes (208, 304, 414, 416, 514, 516) located on either side of the porous substrate (204, 302, 404, 504); and

[0121] A skin (210, 310, 424, 524) wrapping around the porous substrate (204, 302, 404, 504) and the pair of high-voltage electrodes (208, 304, 414, 416, 514, 516).

[0122] Clause 2. The shape-retaining film (202, 300, 400, 500, 600, 708) according to Clause 1, wherein the pair of high-voltage electrodes (208, 304, 414, 416, 514, 516) includes:

[0123] A negative high-voltage electrode (216, 308, 416, 516) on a first surface (212, 312, 505) of the porous substrate (204, 302, 404, 504); and

[0124] A positive high-voltage electrode (218, 306, 414, 514) on a second surface (214, 314, 507) of the porous substrate (204, 302, 404, 504).

[0125] Clause 3. The shape-retaining film (202, 300, 400, 500, 600, 708) according to Clause 1, wherein the porous substrate (204, 302, 404, 504) comprises a polymer material (222).

[0126] Clause 4. The shape-retaining film (202, 300, 400, 500, 600, 708) according to Clause 1, the shape-retaining film further comprising:

[0127] An insulating layer (246) on the outer side of the skin (210, 310, 424, 524).

[0128] Clause 5. The shape-retaining film (202, 300, 400, 500, 600, 708) according to Clause 1, wherein the porous substrate (204, 302, 404, 504) is one of a plurality of porous substrates (229, 402, 502), and the shape-retaining film further comprises:

[0129] Multiple high-voltage electrode pairs (233, 412, 512), the multiple high-voltage electrode pairs being spaced apart from the multiple porous substrates (229, 402, 502), the multiple high-voltage electrode pairs (233, 412, 512) including the pair of high-voltage electrodes (208, 304, 414, 416, 514, 516) on either side of the porous substrates (204, 302, 404, 504).

[0130] Clause 6. The shape-retaining film (202, 300, 400, 500, 600, 708) according to Clause 1, the shape-retaining film further comprising: an inlet port (292) extending through the skin (210, 310, 424, 524) of the shape-retaining film (202, 300, 400, 500, 600, 708).

[0131] Clause 7. The shape-retaining film (202, 300, 400, 500, 600, 708) according to Clause 1, wherein the skin (210, 310, 424, 524) comprises a flexible non-porous material (224).

[0132] Clause 8. The shape-retaining film (202, 300, 400, 500, 600, 708) according to Clause 1, wherein the skin (210, 310, 424, 524) contains a polymeric material (228).

[0133] Clause 9. The shape-retaining film (202, 300, 400, 500, 600, 708) according to Clause 1, wherein the skin (210, 310, 424, 524) comprises an electrically insulating material (226).

[0134] Clause 10. The shape-retaining film (202, 300, 400, 500, 600, 708) according to Clause 1, wherein the space (220) between the pair of high-voltage electrodes (208, 304, 414, 416, 514, 516) is configured to reduce arcing.

[0135] Clause 11. A method (1000) of moving and forming a composite laminate (258, 704), the method comprising:

[0136] When the shape retention films (202, 300, 400, 500, 600, 708) of the pick-and-place end effectors (248, 702) are in a first shape (266, 716), and when an electric field (244) is applied to the shape retention films (202, 300, 400, 500, 600, 708) on the support lifting surfaces (252, 712) of the pick-and-place end effectors (248, 702), a composite laminate (258, 704) is held (1002) against the lifting surfaces (252, 712);

[0137] When the shape retention films (202, 300, 400, 600, 708) are in the first shape (266, 716), and when the composite laminate (258, 704) is held against the lifting surfaces (252, 712), the electric field (244) is removed (1004) from the shape retention films (202, 300, 400, 500, 600, 708); and

[0138] The shape (242) of the shape retention films (202, 300, 400, 500, 600, 708) is changed (1006) to a second shape (268, 902) to form the composite laminate (258, 704).

[0139] Clause 12. The method (1000) according to Clause 11, wherein the shape retention films (202, 300, 400, 500, 600, 708) include an electrorheological fluid (206, 303) in a porous substrate (204, 302, 404, 504), and applying the electric field (244) to the shape retention films (202, 300, 400, 500, 600, 708) causes the shape retention films (202, 300, 400, 500, 600, 708) to be rigid (238) (1013).

[0140] Clause 13. The method (1000) according to Clause 11, the method further comprising:

[0141] Applying (1008) the electric field (244) to the shape retention films (202, 300, 400, 500, 600, 708) to hold the shape retention films (202, 300, 400, 500, 600, 708) in the second shape.

[0142] Clause 14. The method (1000) according to Clause 11, the method further comprising:

[0143] Place (1010) the lifting surfaces (252, 712) of the pick-and-place end effector (248, 702) in contact with the composite laminate (258, 704); and

[0144] When applying the electric field (244) to the shape-retaining film (202, 300, 400, 500, 600, 708), apply (1012) at least one of a vacuum (256) and an electrostatic charge (257) to the composite laminate (258, 704) to lift the composite laminate (258, 704).

[0145] Clause 15. The method (1000) according to clause 13, the method further comprising:

[0146] When the shape-retaining film (202, 300, 400, 500, 600, 708) is in the second shape, move (1014) the pick-and-place end effector (248, 702) holding the composite laminate (258, 704) towards the tool (286, 904); and

[0147] When the shape-retaining film (202, 300, 400, 500, 600, 708) is in the second shape, place (1016) the composite laminate (258, 704) onto the tool (286, 904).

[0148] Clause 16. The method (1000) according to clause 15, the method further comprising:

[0149] After moving the pick-and-place end effector (248, 702) away from the composite laminate (258, 704) and the tool (286, 904), remove (1018) the electric field (244) from the shape-retaining film (202, 300, 400, 500, 600, 708);

[0150] Return (1020) the shape (242) of the shape-retaining film (202, 300, 400, 500, 600, 708) to the first shape (266, 716);

[0151] Apply (1020) the electric field (244) to the shape-retaining film (202, 300, 400, 500, 600, 708) to hold the shape-retaining film (202, 300, 400, 500, 600, 708) in the first shape (266, 716); and

[0152] When the shape - retaining film (202, 300, 400, 500, 600, 708) is in the first shape (266, 716), lift (1022) the second composite laminate using the pick - and - place end - effector (248, 702).

[0153] Clause 17. The method (1000) according to Clause 11, wherein changing the shape (242) of the shape - retaining film (202, 300, 400, 500, 600, 708) comprises: placing the pick - and - place end - effector (248, 702) against a forming mandrel (280) (1024).

[0154] Clause 18. The method (1000) according to Clause 11, the method further comprising:

[0155] Connecting (1009) the pick - and - place end - effector (248, 702) to a robot or gantry using a connector (250, 714) attached to the shape - retaining film (202, 300, 400, 500, 600, 708).

[0156] Clause 19. A pick - and - place end - effector (248, 702), the pick - and - place end - effector comprising:

[0157] A shape - retaining film (202, 300, 400, 500, 600, 708), the shape - retaining film comprising a porous substrate (204, 302, 404, 504) impregnated with an electrorheological fluid (206, 303), a pair of high - voltage electrodes (208, 304, 414, 416, 514, 516) on either side of the porous substrate (204, 302, 404, 504), and a skin (210, 310, 424, 524) wrapped around the porous substrate (204, 302, 404, 504) and the pair of high - voltage electrodes (208, 304, 414, 416, 514, 516);

[0158] A lifting surface (252, 712), the lifting surface being configured to contact a composite laminate (258, 704), the lifting surface (252, 712) being connected to the shape - retaining film (202, 300, 400, 500, 600, 708); and

[0159] A connector (250, 714), the connector being configured to connect the pick - and - place end - effector (248, 702) to a robot or gantry, the connector (250, 714) being attached to the shape - retaining film (202, 300, 400, 500, 600, 708).

[0160] Clause 20. The pick-and-place end effector (248, 702) according to Clause 19, wherein the lifting surface (252, 712) is a flexible vacuum surface (254) for moving between a plurality of shapes (266, 268).

[0161] Clause 21. The pick-and-place end effector (248, 702) according to Clause 19, wherein the pair of high-voltage electrodes (208, 304, 414, 416, 514, 516) includes:

[0162] A negative high-voltage electrode (216, 308, 416, 516) on a first surface (212, 312, 505) of the porous substrate (204, 302, 404, 504); and

[0163] A positive high-voltage electrode (218, 306, 414, 514) on a second surface (214, 314, 507) of the porous substrate (204, 302, 404, 504).

[0164] Clause 22. The pick-and-place end effector (248, 702) according to Clause 19, wherein the porous substrate (204, 302, 404, 504) comprises a polymer material (222).

[0165] Clause 23. The pick-and-place end effector (248, 702) according to Clause 19, the pick-and-place end effector further comprising:

[0166] An insulating layer (246) on an outer side of the skin (210, 310, 424, 524).

[0167] Clause 24. The pick-and-place end effector (248, 702) according to Clause 19, wherein the porous substrate (204, 302, 404, 504) is one of a plurality of porous substrates (229, 402, 502), and the pick-and-place end effector further comprises:

[0168] A plurality of high-voltage electrode pairs (233, 412, 512) spaced apart from the plurality of porous substrates (229, 402, 502), the plurality of high-voltage electrode pairs (233, 412, 512) including the pair of high-voltage electrodes (208, 304, 414, 416, 514, 516) on either side of the porous substrate (204, 302, 404, 504).

[0169] Clause 25. The pick-and-place end effector (248, 702) according to Clause 19, the pick-and-place end effector further comprising: an access port (292) that extends through the skin (210, 310, 424, 524) of the shape-maintaining film (202, 300, 400, 500, 600, 708).

[0170] Clause 26. The pick-and-place end effector (248, 702) according to Clause 19, wherein the skin (210, 310, 424, 524) comprises a flexible non-porous material (224).

[0171] Clause 27. The pick-and-place end effector (248, 702) according to Clause 19, wherein the skin (210, 310, 424, 524) comprises a polymeric material (228).

[0172] Clause 28. The pick-and-place end effector (248, 702) according to Clause 19, wherein the skin (210, 310, 424, 524) comprises an electrically insulating material (226).

[0173] Clause 29. The pick-and-place end effector (248, 702) according to Clause 19, wherein the space (220) between the pair of high-voltage electrodes (208, 304, 414, 416, 514, 516) is configured to reduce arcing.

[0174] Clause 30. A shape-maintaining film (202, 300, 400, 500, 600, 708), the shape-maintaining film comprising:

[0175] A pair of high-voltage electrodes (208, 304, 414, 416, 514, 516) located on either side of a porous substrate (204, 302, 404, 504);

[0176] An electrorheological fluid (206, 303) located between the pair of high-voltage electrodes (208, 304, 414, 416, 514, 516); and

[0177] A skin (210, 310, 424, 524) that wraps around the porous substrate (204, 302, 404, 504) and the pair of high-voltage electrodes (208, 304, 414, 416, 514, 516).

[0178] Clause 31. The shape-maintaining film (202, 300, 400, 500, 600, 708) according to Clause 30, wherein there is an inverse relationship between the electrode voltage and the separation distance, such that as the space (220) between the pair of high-voltage electrodes (208, 304, 414, 416, 514, 516) increases, the voltage required to reduce the viscosity in the electrorheological fluid (206, 303) decreases.

[0179] Clause 32. The shape-maintaining film (202, 300, 400, 500, 600, 708) according to Clause 30, the shape-maintaining film further comprising: the porous substrate (204, 302, 404, 504), the porous substrate being impregnated with the electrorheological fluid (206, 303) located between the pair of high-voltage electrodes (208, 304, 414, 416, 514, 516).

[0180] Clause 33. The shape-maintaining film (202, 300, 400, 500, 600, 708) according to Clause 30, wherein the space (220) between the pair of high-voltage electrodes (208, 304, 414, 416, 514, 516) is configured to reduce arcing.

[0181] Descriptions of various illustrative embodiments have been presented for purposes of illustration and description, and are not intended to be exhaustive or limited to the embodiments in the disclosed forms. Many modifications and variations will be obvious to those of ordinary skill in the art. Additionally, different illustrative embodiments may provide different features compared to other illustrative embodiments. The one or more selected embodiments are chosen and described in order to best explain the principles of the embodiments, practical applications, and to enable those of ordinary skill in the art to understand the disclosure of the various embodiments with various modifications suitable for the particular purposes contemplated.

Claims

1. A shape-retaining film (202, 300, 400, 500, 600, 708), the shape-retaining film comprising: a porous substrate (204, 302, 404, 504) impregnated with an electrorheological fluid (206, 303); a pair of high voltage electrodes (208, 304, 414, 416, 514, 516), the pair of high voltage electrodes being located on either side of the porous substrate (204, 302, 404, 504); as well as A skin (210, 310, 424, 524) is wrapped around the porous substrate (204, 302, 404, 504) and the pair of high voltage electrodes (208, 304, 414, 416, 514, 516).

2. The shape-retaining film (202, 300, 400, 500, 600, 708) according to claim 1, wherein: The pair of high voltage electrodes (208, 304, 414, 416, 514, 516) comprises: a negative high voltage electrode (216, 308, 416, 516), the negative high voltage electrode being on the first side (212, 312, 505) of the porous substrate (204, 302, 404, 504); and A positive high voltage electrode (218, 306, 414, 514) is disposed on the second side (214, 314, 507) of the porous substrate (204, 302, 404, 504).

3. The shape-retaining film (202, 300, 400, 500, 600, 708) according to claim 1, wherein: The porous substrate (204, 302, 404, 504) comprises a polymer material (222).

4. The shape-retaining film (202, 300, 400, 500, 600, 708) according to claim 1, further comprising: An insulating layer (246) is on the outside of the skin (210, 310, 424, 524).

5. The shape-retaining film (202, 300, 400, 500, 600, 708) according to claim 1, wherein: The porous substrate (204, 302, 404, 504) is one of a plurality of porous substrates (229, 402, 502), and the shape-retaining membrane further comprises: A plurality of high-voltage electrode pairs (233, 412, 512), the plurality of high-voltage electrode pairs being spaced apart from the plurality of porous substrates (229, 402, 502), the plurality of high-voltage electrode pairs (233, 412, 512) comprising the pair of high-voltage electrodes (208, 304, 414, 416, 514, 516) on either side of the porous substrates (204, 302, 404, 504).

6. The shape-retaining film (202, 300, 400, 500, 600, 708) according to claim 1, further comprising: An access port (292) extends through the skin (210, 310, 424, 524) of the shape-retaining membrane (202, 300, 400, 500, 600, 708).

7. The shape-retaining film (202, 300, 400, 500, 600, 708) according to claim 1, wherein: The skin (210, 310, 424, 524) comprises a flexible non-porous material (224).

8. A method (1000) of moving and forming a composite laminate (258, 704), the method comprising: When a shape-retaining film (202, 300, 400, 500, 600, 708) of a pick and place end effector (248, 702) is in a first shape (266, 716), and when an electric field (244) is applied to the shape-retaining film (202, 300, 400, 500, 600, 708) supporting a lifting surface (252, 712) of the pick and place end effector (248, 702), a composite laminate (258, 704) is held (1002) against the lifting surface (252, 712); removing (1004) the electric field (244) from the shape-retaining film (202, 300, 400, 500, 600, 708) when the shape-retaining film (202, 300, 400, 600, 708) is in the first shape (266, 716) and when the composite laminate (258, 704) is held against the lifting surface (252, 712); as well as The shape (242) of the shape-retaining film (202, 300, 400, 500, 600, 708) is changed (1006) to a second shape (268, 902) to form the composite laminate (258, 704).

9. A pick and place end effector (248, 702), the pick and place end effector comprising: A shape-retaining membrane (202, 300, 400, 500, 600, 708) comprising a porous substrate (204, 302, 404, 504) impregnated with an electrorheological fluid (206, 303), a pair of high-voltage electrodes (208, 304, 414, 416, 514, 516) on either side of the porous substrate (204, 302, 404, 504), and a skin (210, 310, 424, 524) wrapped around the porous substrate (204, 302, 404, 504) and the pair of high-voltage electrodes (208, 304, 414, 416, 514, 516); a lifting surface (252, 712) configured to contact the composite laminate (258, 704), the lifting surface (252, 712) being connected to the shape-retaining film (202, 300, 400, 500, 600, 708); as well as A connector (250, 714) configured to connect the pick and place end effector (248, 702) to a robot or gantry, the connector (250, 714) being attached to the shape retaining film (202, 300, 400, 500, 600, 708).

10. A shape-retaining film (202, 300, 400, 500, 600, 708), the shape-retaining film comprising: a pair of high voltage electrodes (208, 304, 414, 416, 514, 516) located on either side of the porous substrate (204, 302, 404, 504); an electrorheological fluid (206, 303) disposed between the pair of high voltage electrodes (208, 304, 414, 416, 514, 516); and A skin (210, 310, 424, 524) is wrapped around the porous substrate (204, 302, 404, 504) and the pair of high voltage electrodes (208, 304, 414, 416, 514, 516).

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