Heated Pressure Roller Assembly for Uniform Fiber Tow Bonding
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Solution Overview
Problem
Existing methods for forming composite components, such as those used in turbine engines, face challenges in achieving consistent and efficient adhesion and bonding of fiber tows to substrates due to inconsistent heat and pressure application during the fiber placement process.
Innovation Solution
An automated fiber placement assembly that utilizes a heated pressure roller with integrated temperature control and pressure application to ensure consistent heat and pressure distribution during the application of fiber tows, enhancing the bond between the fiber tows and the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat and pressure are applied during fiber placement, then adhesion and bonding of fiber tows to substrate is improved, but inconsistency in heat and pressure application leads to poor bonding quality
Solution Approach 1:
The patent combines the heating function and pressure application function into a single integrated roller assembly. The roller includes a heated roll that applies both thermal energy and mechanical pressure simultaneously to the fiber tows as they are being placed on the substrate. This merging of functions ensures that heat and pressure are applied concurrently and uniformly across the same contact area, eliminating the inconsistency that arises when these functions are performed by separate devices at different locations or times.
Solution Approach 2:
The roller assembly serves multiple functions: it applies pressure to compact the fiber tows, provides heat through the heated roll to facilitate bonding, and acts as a placement guide for the fiber tows. By making the roller a multi-functional device, the patent ensures that all critical bonding parameters (pressure, temperature, and placement alignment) are controlled at a single location, improving consistency and reliability of the bonding process.
2Reliability
If a heated pressure roller is used, then adhesion is improved, but device complexity increases
Solution Approach 1:
The patent merges the pressure application mechanism and the heating mechanism into a single integrated roller assembly. Instead of using a separate pressure roller and a separate heating device, the system employs one roller that performs both functions. This reduces the overall number of components and simplifies the system architecture while maintaining reliable adhesion through coordinated heat and pressure application.
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
The system provides improved adhesion and bonding of fiber tows to substrates by ensuring uniform heat and pressure application, reducing the likelihood of poor adhesion and enhancing the structural integrity of composite components.
Implementation Method 1
a roller heater positioned to heat the pressure roller
Implementation Method 2
a pressure roller for applying the strip of fiber tows to the substrate
Data Source
AI summary
The disclosure herein provides an automated fiber placement assembly for forming a component, such as for a turbine engine or non-turbine engine system, by the placement of separate layers or strips of fiber tows. The automated fiber placement assembly comprises a heated pressure roller to heat the strip of fiber tows as they are placed during formation of the component. The pressure roller can be heated to heat the strip of fiber tows, or an alternate roller, separate from the pressure roller, can be heated to heat the strip of fiber tows.