Conical Composite Tape Layering for Uniform Thick Heatshields

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Solution Overview

Problem

Conventional manual tape wrapping processes for creating heatshields are impractical for thicknesses greater than an inch and result in non-uniform, delaminated products, particularly with prepreg materials, limiting their application in hypersonic environments.

Innovation Solution

Modified automated tape layering (ATL) techniques for conical structures, employing high tape placement precision, consistent pressures, and tape steering, using a conical tool structure, tape deployment head, and robotic assembly to form conical composite components like heatshields with improved uniformity and quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual tape wrapping is used to create heatshields, then the process is simple and flexible, but the heatshields are non-uniform and prone to delamination

Engineering Contradiction:

Improveheatshield uniformityVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces manual mechanical tape wrapping with an automated tape layering system that uses robotic or automated mechanisms to apply tape layers. This substitution eliminates human operator variability and ensures consistent pressure, alignment, and layer uniformity throughout the heatshield construction process, directly resolving the non-uniformity and delamination issues caused by manual operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The automated tape layering system incorporates self-aligning and self-regulating mechanisms that automatically maintain proper tape positioning and pressure without continuous manual intervention. The system self-corrects for variations in tape application, ensuring uniform layer thickness and consistent bonding pressure, thereby eliminating the delamination problems associated with manual wrapping.

Inventive Principle:

Principle #25Self-service

2Quantity of substance

If manual tape wrapping is used, then the equipment is simple, but the heatshield thickness is limited to about an inch

Engineering Contradiction:

Improveheatshield thicknessVSAvoidequipment complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The automated tape layering system enables continuous application of multiple tape layers without interruption or manual repositioning. The system can efficiently apply numerous thin layers to achieve greater overall thickness, as the automated mechanism maintains continuous contact and consistent layer deposition, overcoming the thickness limitation of manual wrapping while managing equipment complexity through systematic automation.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent segments the heatshield construction into multiple discrete tape layers applied sequentially by the automated system. Each layer is precisely controlled and bonded to the previous layer, allowing the accumulation of greater total thickness through controlled layering. This segmentation approach enables thickness exceeding one inch while managing complexity through programmable layer deposition rather than monolithic construction.

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If automated tape layering is used on conical structures, then tape placement precision is improved, but the device complexity increases

Engineering Contradiction:

Improvetape placement precisionVSAvoidATL equipment complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The automated tape layering system incorporates conical or spherical tooling that matches the geometry of the heatshield being constructed. This curved tooling enables the automated tape application mechanism to maintain proper contact and alignment across the conical surface, achieving precise tape placement on three-dimensional geometries while managing equipment complexity through geometrically adapted tooling rather than overly complex positioning systems.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The automated tape layering equipment is designed with universal capabilities that can handle various conical and curved geometries through programmable control and adjustable tooling. This multi-functionality allows the same basic system to achieve precise tape placement on different conical heatshield configurations, reducing overall equipment complexity by eliminating the need for specialized dedicated machinery for each specific conical geometry.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12528259B2Automated tape layering for conical composite components

Publication Date: 2026.01.20 TEXTRON SYSTEMS CORP

AI summary

Techniques for providing a conical composite involve receiving a starting portion of a tape from a tape supply, the tape having a first tape edge and a second tape edge. The techniques further involve positioning the starting portion of the tape in contact with a conical tool structure. The techniques further involve, after the starting portion of the tape is positioned in contact with the conical tool structure, maneuvering at least one of (i) a tape deployment head relative to the conical tool structure and (ii) the conical tool structure relative to the tape deployment head to deploy the tape around the conical tool structure with the first tape edge adjacent to conical tool structure and the second tape edge extending outwardly from the conical tool structure to form the conical composite.