FTIR Tack Assessment for In-Process Composite Prepreg Quality
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Solution Overview
Problem
Current methods for testing unconsolidated composite components, such as prepreg rolls, are inefficient as they require testing multiple portions to identify out-of-tolerance sections, leading to time-consuming quality assessments and potential waste, and cannot determine the cause of quality issues during manufacturing, resulting in halted production and reduced capacity.
Innovation Solution
A system comprising a computer system, Fourier transform infrared spectroscopy, and an analyzer that generates real-time scans to assess tack quality in unconsolidated composite materials by comparing them to reference scans, allowing for in-process quality determination and adjustment of manufacturing parameters to ensure desired quality levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple portions of prepreg rolls are tested using current methods, then quality assessment accuracy is improved, but testing time and production downtime increase significantly
Solution Approach 1:
The patent replaces mechanical contact-based testing methods with non-contact infrared spectroscopy. The infrared sensor system detects chemical composition and quality characteristics of prepreg materials through electromagnetic radiation without physical contact, enabling rapid real-time quality assessment without halting production.
Solution Approach 2:
The patent transforms quality assessment from a time-consuming multi-point mechanical testing process to a rapid spectral analysis process. By measuring infrared absorption spectra and analyzing chemical composition parameters, the system determines quality characteristics instantly, converting a slow mechanical process into a fast optical measurement process.
2Reliability
If traditional quality testing methods are used, then quality issues can be detected, but the cause of quality issues cannot be identified, resulting in production halts
Solution Approach 1:
The patent implements a real-time feedback system where infrared spectral data is continuously collected during manufacturing, analyzed by a computer system, and used to immediately identify both quality deviations and their root causes. This feedback loop enables continuous production without halts, as the system provides actionable information for immediate process adjustment.
Solution Approach 2:
The patent introduces infrared spectroscopy as an intermediary measurement technique that bridges the gap between manufacturing processes and quality outcomes. The spectral measurements serve as intermediate parameters that reveal both the presence of quality issues and their underlying causes, enabling continuous production with real-time quality control.
3Manufacturing precision
If out-of-tolerance sections are identified after manufacturing, then quality control is maintained, but material waste increases and production efficiency decreases
Solution Approach 1:
The patent performs quality assessment during the manufacturing process itself, before the prepreg material is fully produced or committed to subsequent processing steps. By identifying quality issues in real-time during manufacturing, the system prevents waste of subsequent materials and processing steps that would be required for defective sections.
Solution Approach 2:
The patent enables rapid quality assessment that allows the manufacturing process to continue without interruption. The fast infrared measurement technique identifies and isolates only the defective sections, allowing good material to be rapidly processed through the manufacturing line without being held up by quality testing, thus minimizing overall production delays and waste.
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 real-time prediction of composite material properties and quality assessment, reducing waste and increasing production efficiency by identifying out-of-tolerance sections and allowing for corrective actions during manufacturing, thereby improving the quality and yield of composite materials.
Implementation Method 1
Fourier transform infrared spectroscopy system configured to generate Fourier transform infrared scans of absorbed infrared energy for frequencies in an infrared spectrum
Data Source
AI summary
A tack assessment system comprising a computer system and an analyzer in the computer system. The analyzer is configured to control a spectroscopy system to generate a test electromagnetic scan for a test section of an unconsolidated composite material at a test location in a composite material manufacturing system in real time during manufacturing of the unconsolidated composite material by the composite material manufacturing system. The analyzer is configured to determine a tack quality for the test section of the unconsolidated composite material at the test location based on a distance between the test electromagnetic scan and a number of reference electromagnetic scans for a number of reference unconsolidated composite materials having a number of known tack qualities.