Curable Flexible Laminate for Automated Tape Lay-Up
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Solution Overview
Problem
Existing methods lack an effective automated solution for applying electromagnetic hazard protectors to composite materials during the automated tape lay-up process, as they fail to adhere to the mold surface while detaching from the backing sheet without losing coherence.
Innovation Solution
A curable flexible laminate with a layer of electrically conductive metal material and thermosetting resin, featuring a releasable backing sheet and an adhesive resin face that adheres stronger to the mold than to the backing sheet, ensuring coherence and easy detachment, and incorporating a substantially non-reshapable solid material to maintain shape under high tensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive element is manually deposited onto the mold surface, then electromagnetic hazard protection is achieved, but labor cost and manufacturing time increase
Solution Approach 1:
The laminate is designed to automatically adhere to the mold surface and automatically release from the backing sheet during the ATL process without manual intervention. The differential adhesion properties enable the conductive element to self-position on the mold while the backing sheet self-detaches, eliminating the need for manual deposition operations
Solution Approach 2:
The conductive element is pre-laminated onto a backing sheet with controlled adhesion properties before the ATL process. This preliminary preparation allows the conductive element to be handled as a complete laminate unit that will automatically position itself during automated lay-up, converting a manual surface deposition task into an automated material placement operation
2Productivity
If the conductive element is laid down automatically during ATL, then productivity increases, but the element may lose coherence and fail to adhere properly to the mold surface
Solution Approach 1:
The laminate is engineered with spatially varying adhesion properties: the first external face has lower adhesion to the backing sheet for easy release, while the second external face has higher adhesion to ensure strong bonding to the mold surface. This local differentiation of adhesive characteristics enables automatic adhesion during ATL while maintaining element coherence
Solution Approach 2:
The adhesion parameters of the laminate faces are specifically controlled to create differential bonding characteristics. The resin formulation and surface treatment are optimized so that adhesion strength varies by location and interface, allowing the laminate to release from one surface while firmly adhering to another during the automated process
3Manufacturing precision
If high tension is applied during ATL to ensure material adherence, then lay-up quality improves, but the conductive element may deform and lose its shape
Solution Approach 1:
The laminate combines the conductive element with thermosetting resin and potentially reinforcing layers to create a composite structure. This composite construction provides the necessary mechanical strength and dimensional stability to withstand the high tensions (50-300 N) applied during ATL without deforming the conductive element's geometry
Solution Approach 2:
The laminate structure is designed in advance to withstand the expected tension loads during ATL. The resin impregnation and layer construction provide pre-engineered mechanical support that cushions the conductive element against deformation forces, ensuring shape retention before the actual lay-up process begins
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
Enables the automated and efficient application of electromagnetic hazard protectors during composite material lay-up, maintaining coherence and surface finish quality, and reducing labor and time costs in aerospace manufacturing.
Implementation Method 1
a second external face of the laminate comprises resin in contact with a molding surface of the mold, wherein the adhesive force between the second external face and the molding surface is greater than that between the backing sheet and the resin on the first external face
Implementation Method 2
Following the lay-up procedure, the arrangement is cured by exposure to elevated temperature, and optionally to elevated pressure, to produce a cured composite laminate
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
A curable flexible electromagnetic hazard resistance laminate, comprising a layer of electrically conductive metal material and thermosetting resin, wherein a first external face of the laminate comprises a releasable backing sheet in contact with resin, and a second external face of the laminate comprises resin, wherein the second external face has greater adhesiveness than the first external face with the backing sheet removed.