Conical Composite Heatshield Tape Layering for Thick Uniform Builds
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Solution Overview
Problem
Conventional manual tape wrapping methods for creating heatshields are impractical for thicknesses greater than an inch and result in non-uniform, delaminated products, particularly when using prepreg materials.
Innovation Solution
Modified automated tape layering (ATL) techniques with high tape placement precision and tape steering are employed to deploy tape over a conically shaped tool, enabling precise laying of one edge against the tool and the other edge extending outward, allowing for thicker and more uniform heatshields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual tape wrapping is used to create heatshields, then the process is simple and flexible, but it cannot achieve thicknesses greater than about an inch and produces non-uniform, delaminated products
Solution Approach 1:
The patent replaces the manual mechanical wrapping process with an automated tape layering system that uses robotic or computer-controlled mechanisms to deposit tape layers. This substitution enables precise control of tape placement, pressure application, and layer alignment, achieving uniform heatshields with thicknesses greater than one inch while eliminating the delamination issues caused by manual operation.
Solution Approach 2:
The automated tape layering system performs self-aligned tape placement where the system automatically positions and secures each tape layer without human intervention. The automated pressure application and layer positioning ensure consistent results across multiple layers, enabling the system to produce uniform, thick heatshields reliably.
2Reliability
If manual tape wrapping is used, then the process is flexible and simple, but it cannot consistently apply pressure and produces delaminated products
Solution Approach 1:
The patent replaces manual pressure application with an automated pressing mechanism that maintains consistent pressure throughout the tape layering process. This mechanical or robotic pressing system ensures uniform pressure distribution across all tape layers, preventing delamination while maintaining operational simplicity through automation.
Solution Approach 2:
The automated tape layering system incorporates sensors and control mechanisms that monitor and adjust pressure application in real-time. This feedback control ensures consistent pressure is maintained throughout the process, preventing delamination while keeping the operation simple through automated control.
3Manufacturing precision
If automated tape layering is used on conical surfaces, then high tape placement precision and tape steering are achieved, but the process complexity increases
Solution Approach 1:
The patent adapts the automated tape layering system specifically for conical surfaces by designing the ATL mechanism to accommodate curved geometries. The system uses conical tooling and adjusted deposition paths that match the conical shape, enabling precise tape placement on curved surfaces while managing system complexity through geometry-specific design.
Solution Approach 2:
The automated tape layering system applies different control parameters and positioning techniques at different locations on the conical surface. The system adjusts tape placement precision and steering locally to match the varying curvature and geometry requirements, achieving high precision while managing overall system complexity through localized optimization.
Data Source
AI summary
Techniques for providing a heatshield involve receiving a starting portion of a tape from a tape supply, positioning the starting portion of the tape in contact with a tool structure, and after the starting portion of the tape is positioned in contact with the tool structure, and robotically moving the tool structure and a tape deployment head relative to each other to precisely guide the tape onto the tool structure. Robotically moving the tool structure and the tape deployment head relative to each other includes receiving a set of sensing signals indicating current position of the tool structure and the tape deployment head relative to each other, and based on the set of sensing signals, applying the tape under pressure (e.g., via pressure and temperature control) to form the heatshield.