Automated Material Delivery System for Pre-Preg Composite Placement

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Solution Overview

Problem

Existing systems face challenges in accurately and repeatedly applying pre-preg material on complex forming surfaces without imperfections, particularly when the surfaces have curved shapes, leading to weakened composite structures due to handling issues and buckling of flexible backing materials.

Innovation Solution

An automated material delivery system with a material handling assembly, compaction member, and cutting actuator that uses a compliant backing to guide and compact pre-preg material on a forming surface, eliminating the need for a reel system and minimizing buckling, while a controller coordinates the movement and cutting of the material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If pre-preg material is applied on complex forming surfaces using traditional systems, then material can be placed on the surface, but imperfections and buckling occur leading to weakened composite structures

Engineering Contradiction:

Improvematerial placement precisionVSAvoidcomposite structure strength

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The system divides the material application process into distinct functional segments: a tacking member for initial material attachment, a compaction member for pressure application and bubble elimination, and a cutting member for precise trimming. This segmentation allows each component to perform its specific function optimally, preventing imperfections that would compromise structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The tacking member performs preliminary action by selectively pressing the material to the forming surface before the compaction member is applied. This initial tacking prevents material shift and ensures proper positioning, allowing subsequent compaction to occur on properly positioned material without causing buckling or imperfections.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If flexible backing material is used to guide pre-preg material, then material can be delivered to complex surfaces, but buckling occurs during handling

Engineering Contradiction:

Improvematerial delivery adaptabilityVSAvoidbacking material stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The system extracts and eliminates the flexible backing material from the final composite structure by using a tacking member that selectively presses the pre-preg material directly to the forming surface. The backing is left behind and removed, preventing it from causing buckling issues while still allowing material delivery to complex surfaces during the application process.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The tacking member acts as an intermediary between the material delivery system and the forming surface. It selectively presses the material to transfer it from the backing to the forming surface in a controlled manner, preventing buckling while maintaining the ability to deliver material to complex geometries.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If automated material delivery system with multiple members is used, then material placement precision is improved, but system complexity increases

Engineering Contradiction:

Improvematerial placement precisionVSAvoidsystem structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system merges multiple functions (tacking, compaction, cutting) into a single integrated automated material delivery system that moves as one coordinated unit. The handling actuator coordinates all members simultaneously, reducing operational complexity despite the multiple functional components, and achieving high precision through their combined action.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Each member in the system performs multiple functions: the tacking member both attaches material and positions it, the compaction member both presses material and eliminates air bubbles, and the cutting member both trims material and defines boundaries. This multi-functionality reduces the need for separate dedicated components, managing system complexity while maintaining high precision.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS8721316B2Automated material delivery system

Publication Date: 2014.05.13 NORTHROP GRUMMAN SYSTEMS CORP

AI summary

An automated material delivery system including a material handling assembly, a compaction member, a handling actuator, and a cutting actuator is provided. The material handling assembly is configured and arranged to guide material. The material handling assembly includes a tacking member that is configured and arranged to selectively press the material over a forming surface of a tool. The compaction member is spaced a select distance from the tacking member. The compaction member is further configured to selectively press the material over at least a portion of the forming surface of the tool. The handling actuator is coupled to selectively move at least one of the material handling assembly and the compaction member to move the material handling assembly in relation to the compaction member. The cutting assembly is positioned between the tacking member and the compaction member. The cutting assembly is configured and arranged to selectively cut the material.