Conductive Laminate for Automated Tape Lay-Up
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Solution Overview
Problem
The high tensions applied during automatic tape lay-up of composite materials cause deformation and reshaping of conductive elements, such as metal foils, making it difficult to automate the application of electromagnetic hazard protectors, which is a significant cost and time burden in aerospace manufacturing.
Innovation Solution
A laminate comprising a conductive metal layer sandwiched between resin layers and a substantially non-reshapable solid material, which is flexible and adheres well to the mold surface, allowing it to be laid down without significant stretching or reshaping under high tensions, thus enabling automated application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual deposition of conductive element is used, then application precision and care can be maintained, but labor cost and time burden increase significantly
Solution Approach 1:
The patent changes the physical parameters of the conductive element by laminating it to a non-reshapable solid material substrate. This substrate provides mechanical support that prevents deformation under tension, enabling the conductive element to withstand the high tensions (50-300 N) applied during automated tape lay-up without stretching or reshaping, thus allowing automated application while maintaining precision
Solution Approach 2:
The patent creates a composite structure where a conductive element (metal foil or mesh) is laminated to a substantially non-reshapable solid material (such as polyester veil or glass fiber mat). This composite provides both the electrical conductivity needed for electromagnetic hazard protection and the mechanical rigidity required for automated handling and application without deformation
2Productivity
If automated tape lay-up apparatus is used, then productivity increases, but the high tensions cause deformation and stretching of the conductive element
Solution Approach 1:
The patent changes the mechanical parameters of the conductive element assembly by bonding it to a non-reshapable substrate. This substrate has sufficient tensile strength and dimensional stability to resist the high tensions (50-300 N) applied during automated tape lay-up, preventing the conductive element from stretching or deforming while allowing automated high-speed application
Solution Approach 2:
The substantially non-reshapable solid material acts as an intermediary carrier between the conductive element and the automated tape lay-up apparatus. It absorbs and distributes the mechanical stresses and tensions applied during automated handling, protecting the conductive element from direct mechanical damage while enabling automated application
3Shape
If conductive element is applied manually, then deformation can be avoided, but application time and labor cost increase
Solution Approach 1:
The conductive element is preliminarily laminated to a substantially non-reshapable solid material substrate before application. This pre-preparation creates a self-supporting assembly that maintains its shape and dimensions, allowing it to be handled and applied automatically without deformation, thus eliminating the need for manual application while preserving structural integrity
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
The laminate remains coherent and adheres well to the mold surface, preventing deformation and allowing for efficient automated lay-up, reducing the need for manual labor and improving the surface finish while maintaining effective electromagnetic protection.
Implementation Method 1
A common way for such a conductive element to be applied is to deposit manually, by the hand of a skilled handler, the conductive element onto the surface of a mold for an aerospace body structure
Implementation Method 2
an external face of the laminate comprising tacky curable thermosetting resin contacts the mold surface and the laminate adheres to the mold surface
Implementation Method 3
A laminate comprising a conductive metal layer sandwiched between resin layers and a substantially non-reshapable solid material, which is flexible and adheres well to the mold surface, allowing it to be laid down without significant stretching or reshaping under high tensions
Data Source
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AI summary
A curable flexible electromagnetic hazard resistance laminate, comprising a layer of electrically conductive metal material and thermosetting resin, wherein an external face of the laminate comprises a releasable backing sheet in contact with resin, and the laminate further comprises a substantially non-reshapable sheet of solid material.