Fiber Placement Laser Scan Heating for Composite Consolidation
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Solution Overview
Problem
Laser heating in fiber placement technologies can be difficult to control, leading to overheating of fiber tow and underlying layup during the manufacturing of composite structures, particularly when using thermoplastic resin, which affects the consolidation process.
Innovation Solution
A fiber placement system that includes a compaction roller and a laser heating assembly with a scan head capable of varying optical power and pulse frequency, allowing precise control of heating across scan rows to prevent overheating, using a laser that emits electromagnetic radiation within a specific wavelength range to heat the composite ply and substrate during the placement process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a laser beam is projected toward the compaction nip to heat the fiber tow and underlying layup, then heating is achieved to soften the thermoplastic resin, but the heating becomes difficult to control resulting in overheating
Solution Approach 1:
The laser heating process is segmented into multiple scan rows that collectively cover the compaction nip region. Instead of using a single continuous laser beam that is difficult to control, the heating is divided into discrete scan rows (first scan row, second scan row, etc.) that can be independently controlled. This segmentation allows for better temperature control and prevents overheating by distributing the heating action across multiple controlled segments.
Solution Approach 2:
The laser heating system uses dynamic scanning motion to move the laser beam across the compaction nip region in a controlled manner. The scan head moves the laser beam in scan rows across the width of the fiber tow, creating a dynamic heating process rather than a static one. This dynamic approach allows for precise control of heating distribution and prevents localized overheating.
2Strength
If laser heating is applied to soften thermoplastic resin for consolidation, then layer-to-layer bonding is achieved, but overheating occurs affecting the consolidation process
Solution Approach 1:
The laser heating system applies heating with local quality by targeting specific regions within the compaction nip region. Different scan rows can be applied with different heating parameters to match the local requirements of different areas of the fiber tow and underlying layup. This localized heating approach ensures adequate consolidation where needed while avoiding overheating in other areas.
Solution Approach 2:
The laser heating process uses periodic scanning action where the laser beam is moved back and forth in scan rows across the compaction nip region. This periodic motion allows heat to be distributed evenly across the material while providing cooling intervals between scan passes, preventing overheating while ensuring thorough consolidation.
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 enables controlled radiative heating, reducing the risk of overheating and improving the consolidation of composite layers by varying the heating intensity and frequency, ensuring consistent and efficient layer-to-layer bonding.
Implementation Method 1
a laser that emits a beam of electromagnetic radiation... controlled radiative heating... heating the composite ply and substrate during the placement process
Implementation Method 2
a laser heating assembly comprising: a laser that emits a beam of electromagnetic radiation... Typical laser heating can be difficult to control, resulting in overheating
Data Source
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AI summary
A fiber placement system including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a compaction nip region, and a laser heating assembly including a laser that emits a beam of electromagnetic radiation and a scan head defining a scan field, the scan field being aligned with the compaction nip region, wherein the scan head scans the beam within the scan field.