Automated Fiber Placement With Heated Pressure Roller Bonding
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Solution Overview
Problem
Existing automated fiber placement systems face challenges in achieving consistent and controlled heat and pressure application during the formation of composite components, leading to inconsistent bond and adhesion between fiber tows and substrates.
Innovation Solution
The use of a heated pressure roller and optional additional heated rollers to apply controlled heat and pressure simultaneously, ensuring consistent adhesion and bond formation by integrating a temperature sensor for precise temperature control and a controller for automated operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heated rollers are used to apply heat and pressure during fiber placement, then bond and adhesion between fiber tows and substrate are improved, but device complexity increases due to integration of temperature sensors and heating elements
Solution Approach 1:
The patent combines the heating function and pressure application function into a single integrated roller assembly. The heated roller includes both the heating element and the pressure application mechanism in one component, rather than using separate heating devices and pressure devices. This merging reduces the overall number of components and simplifies the system architecture while achieving both heat application and pressure application simultaneously.
Solution Approach 2:
The roller assembly serves multiple functions: it applies heat to the fiber tows and substrate, applies pressure to ensure contact and bonding, and acts as a support structure for the temperature sensor. This multi-functional design eliminates the need for separate heating devices, pressure devices, and support structures, thereby reducing device complexity while improving bond and adhesion.
2Manufacturing precision
If temperature control is precisely monitored using temperature sensors, then manufacturing precision of composite components is improved, but device complexity increases due to additional sensing and control components
Solution Approach 1:
The temperature sensor is integrated into the roller assembly and provides real-time temperature feedback during the fiber placement process. This feedback mechanism allows the system to monitor and adjust the heating process dynamically, ensuring that the temperature remains within the optimal range for bond and adhesion. The feedback loop enables precise temperature control without requiring complex external monitoring systems.
Solution Approach 2:
The temperature sensor is self-contained within the roller assembly, eliminating the need for separate external temperature monitoring devices. The sensor directly measures the temperature at the contact point between the roller and the fiber tows/substrate, providing accurate data for process control. This self-service approach simplifies the overall system by integrating the sensing function into the existing roller structure.
3Reliability
If multiple heated rollers are used to apply consistent heat and pressure, then reliability of bond formation is improved, but device complexity and cost increase
Solution Approach 1:
The heating and pressure application process is divided into discrete zones along the roller assembly. Different sections of the roller can be independently controlled to provide varying temperature and pressure levels at different stages of the fiber placement process. This segmentation allows for optimized process parameters in each zone, improving reliability while maintaining a manageable system complexity through modular control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the bond and adhesion between fiber tows and substrates, improving the quality and consistency of composite component formation by minimizing inconsistencies due to varying temperatures or pressures.
Implementation Method 1
a roller heater positioned to heat the pressure roller
Data Source
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AI summary
The disclosure herein provides an automated fiber placement assembly (150) for forming a component (154), such as for a turbine engine (10) or non-turbine engine system, by the placement of separate layers or strips of fiber tows (152). The automated fiber placement assembly (150) comprises a heated pressure roller (160) to heat the strip of fiber tows (152) as they are placed during formation of the component (154). The pressure roller (160) can be heated to heat the strip of fiber tows (152), or an alternate roller (220, 222, 224, 240), separate from the pressure roller (160), can be heated to heat the strip of fiber tows (154).