FTIR Composite Chemistry Verification During Prepreg Manufacturing
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Solution Overview
Problem
Current methods for testing unconsolidated composite materials, such as prepreg rolls, are inefficient as they require testing multiple portions to identify out-of-tolerance sections, leading to time-consuming quality control processes and potential delays in manufacturing due to the inability to determine the cause of quality issues in real-time during production.
Innovation Solution
A system comprising a computer system, Fourier transform infrared spectroscopy, and a scan classifier that generates and classifies infrared scans of unconsolidated composite materials in real-time, allowing for immediate verification of material chemistry and prediction of properties during manufacturing, enabling the identification of in-tolerance and out-of-tolerance sections without halting production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional testing methods are used to verify material chemistry in unconsolidated composite materials, then quality control can be performed, but the testing process is time-consuming and requires halting production to test multiple portions
Solution Approach 1:
The patent replaces traditional mechanical contact-based testing methods with Fourier transform infrared spectroscopy, a non-contact optical analysis system. This substitution enables real-time material chemistry verification without physical sampling or production interruption, simultaneously maintaining quality control reliability and eliminating productivity losses from halted production
Solution Approach 2:
The patent introduces an intermediary Fourier transform infrared spectroscopy system that acts as a mediator between the manufacturing process and quality verification. This intermediary enables continuous monitoring of material chemistry by analyzing infrared spectra of the composite material during production, allowing quality control without direct intervention or production stoppage
2Manufacturing precision
If multiple portions of unconsolidated composite materials are tested to identify out-of-tolerance sections, then quality assurance can be achieved, but the testing process becomes time-consuming and delays manufacturing
Solution Approach 1:
The patent implements preliminary action by performing Fourier transform infrared spectroscopy analysis on material portions before they proceed through the manufacturing process. The system proactively identifies out-of-tolerance sections in real-time, allowing immediate corrective action without waiting for traditional post-manufacturing testing, thereby eliminating time delays while ensuring quality assurance
Solution Approach 2:
The patent enables continuous quality verification by maintaining uninterrupted Fourier transform infrared spectroscopy monitoring throughout the manufacturing process. The system continuously analyzes material chemistry without stopping production, eliminating the intermittent testing approach that causes time delays while maintaining precise quality assurance through constant monitoring
3Measurement precision
If traditional quality testing methods are used, then material defects can be detected, but the inability to determine the cause of quality issues in real-time leads to waste of material and reduced production efficiency
Solution Approach 1:
The patent implements real-time feedback by continuously monitoring material chemistry through Fourier transform infrared spectroscopy and immediately identifying out-of-tolerance sections. The system provides instantaneous feedback on material quality, enabling operators to adjust manufacturing parameters or isolate defective portions before they become waste, thereby maintaining precise defect detection while minimizing material loss through proactive correction
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 approach reduces waste by allowing for real-time quality assessment and adjustment of manufacturing parameters, increasing production efficiency and reducing the amount of discarded material by enabling the use of in-tolerance sections while addressing the inefficiencies of traditional testing methods.
Implementation Method 1
Fourier transform infrared spectroscopy configured to generate Fourier transform infrared scans of absorbed infrared energy for frequencies in an infrared spectrum for unconsolidated composite materials
Data Source
AI summary
A method for verifying a material chemistry. A Fourier transform infrared scan for a section of an unconsolidated composite material is received in real time during manufacturing of the unconsolidated composite material by a composite material manufacturing system. Verifying whether the material chemistry for the section of the unconsolidated composite material is correct is verified in real time during manufacturing of the unconsolidated composite material by the composite material manufacturing system using the Fourier transform infrared scan and a scan classifier.