Composite Tack Assessment Using Real-Time FTIR Scans
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Solution Overview
Problem
Current quality testing of unconsolidated composite components, such as prepreg rolls, is inefficient as it often requires testing multiple portions to identify out-of-tolerance areas, leading to time-consuming processes and unnecessary discarding of entire rolls due to undetected issues.
Innovation Solution
A real-time tack assessment system using Fourier transform infrared spectroscopy or electromagnetic spectroscopy, combined with machine learning models, to analyze unconsolidated composite materials during manufacturing, allowing for immediate identification of quality issues in specific portions and enabling corrective actions before completion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional quality testing methods are used to inspect unconsolidated composite materials, then quality issues can be detected, but the testing process is time-consuming and requires testing multiple portions leading to unnecessary discarding of entire rolls
Solution Approach 1:
The patent replaces traditional mechanical/contact-based quality testing methods with electromagnetic radiation-based spectroscopy (FTIR or Raman). This substitution enables non-contact, rapid analysis of the composite material's chemical composition and quality characteristics, dramatically reducing testing time while maintaining or improving detection accuracy.
Solution Approach 2:
The patent uses spectroscopy to create a chemical/fingerprint copy or signature of the material's properties without physically sampling or destroying the material. By analyzing the electromagnetic interaction with the material, the system obtains quality information that replicates what traditional physical testing would reveal, but much faster and without consuming the tested portion.
2Reliability
If traditional quality testing methods are used, then quality issues can be identified, but entire rolls must be discarded due to undetected issues requiring multiple portions to be tested
Solution Approach 1:
By replacing destructive or consumptive testing methods with non-contact electromagnetic spectroscopy, the system can assess quality without removing or damaging material portions. This enables continuous monitoring and precise identification of defective sections, allowing only those specific portions to be discarded rather than entire rolls.
Solution Approach 2:
The system enables the manufacturing process to self-monitor and self-assess quality in real-time during production. The spectroscopy system continuously analyzes the material as it is being manufactured, allowing immediate detection and correction of quality issues without requiring separate post-manufacturing testing that would necessitate larger safety margins and waste.
3Productivity
If real-time spectroscopy analysis is implemented, then quality issues can be identified immediately enabling corrective actions, but the system complexity increases
Solution Approach 1:
The patent replaces complex mechanical testing equipment and manual inspection procedures with electromagnetic spectroscopy systems. While spectroscopy instruments are sophisticated, they consolidate multiple functions (sampling, preparation, analysis) into a single non-contact measurement process, potentially reducing overall system complexity despite the advanced nature of the spectroscopy instrument itself.
Solution Approach 2:
The patent introduces spectroscopy as an intermediary measurement technique between the manufacturing process and quality assessment. This intermediary system translates complex material properties into simple spectral signatures that can be rapidly analyzed by computer systems, creating an efficient bridge between production and quality control without requiring direct complex interaction with the material.
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 system reduces waste by identifying and addressing quality issues in real-time, ensuring only in-tolerance portions are discarded, thereby increasing manufacturing efficiency and reducing the need for halting production lines to rectify issues.
Implementation Method 1
Fourier transform infrared spectroscopy system configured to generate Fourier transform infrared scans of absorbed infrared energy for frequencies in an infrared spectrum
Data Source
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AI summary
A tack assessment system (3000) comprising a computer system (3012) and an analyzer (3014) in the computer system (3012). The analyzer (3014) is configured to control a spectroscopy system (3071) to generate a test electromagnetic scan (3075) for a test section (3027, 3324) of an unconsolidated composite material (3024) at a test location (3219, 3319) in a composite material manufacturing system (3023) in real time during manufacturing of the unconsolidated composite material (3024) by the composite material manufacturing system (3023). The analyzer (3014) is configured to determine a tack quality (3082, 3202, 3302) for the test section (3027, 3324) of the unconsolidated composite material (3024) at the test location (3219, 3319) based on a distance between the test electromagnetic scan (3075) and a number of reference electromagnetic scans (3086) for a number of reference unconsolidated composite materials (3086) having a number of known tack qualities (3087).