Composite Laminate Registration via Embedded Readable Elements
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Solution Overview
Problem
Existing laminate production processes face challenges in maintaining precise positional registration of uncured laminates due to the lack of stable, locatable features, leading to errors in positioning and orientation, especially when laminates are assembled on temporary surfaces or undergo forming operations.
Innovation Solution
Implanting readable elements, such as metal or organometallic materials, into the laminate that can be detected by sensors like proximity, ultrasonic, or thermal imaging sensors to enable precise positioning and unique identification during processing and curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If external markings are applied to laminate for positioning, then positioning information is provided, but the markings are temporary, imprecise and have poor machine readability
Solution Approach 1:
The patent introduces an intermediary registration feature (such as a reflective marker or target pattern) that mediates between the laminate and the detection system. This intermediary provides machine-readable positioning information that is precisely detectable by cameras or sensors, resolving the contradiction between providing positioning information and achieving measurement precision.
Solution Approach 2:
The patent replaces mechanical marking systems (physical markings on the laminate) with optical/electromagnetic detection systems. By using reflective markers or contrast patterns that can be detected by cameras and image processing, the system achieves precise machine-readable positioning without relying on temporary physical markings.
2Loss of information
If layment edges are used for positioning, then positioning is possible, but edges are subject to distortion, tolerance errors and may be covered by subsequent layers
Solution Approach 1:
The patent applies registration features to the laminate before any forming operations, cutting operations, or layer additions occur. This preliminary application ensures that the registration features are established on a stable surface before distortion or coverage can occur, maintaining reliable positioning information throughout subsequent processing.
Solution Approach 2:
The patent extracts the positioning function from the layment edges themselves and places dedicated registration features on the laminate surface. By separating the positioning reference from the structural edges, the system eliminates the problems of edge distortion and coverage while maintaining accurate positioning capability.
3Measurement precision
If tooling holes are used to orient metal parts, then precise orientation is achieved, but this technique is of little use with uncured laminates
Solution Approach 1:
The patent replaces mechanical tooling holes with optical/electromagnetic detection methods. By using camera systems and image processing to detect registration features on the laminate surface, the system achieves precise orientation without requiring physical holes or mechanical fixtures that would be incompatible with uncured laminates.
Solution Approach 2:
The patent changes the detection parameter from mechanical (physical holes and fixtures) to optical/electromagnetic (camera detection of visual features). This parameter change enables the same precision function to work with uncured laminates that cannot accommodate mechanical tooling holes.
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 implementation of readable elements allows for accurate and stable positioning of laminates, reducing errors and enabling precise alignment and identification throughout the manufacturing process, even after subsequent forming operations and layer additions.
Implementation Method 1
The detector preferably comprises proximity sensors, ultrasonic sensors, thermal imaging sensors, x-ray sensors, eddy current sensors
Implementation Method 2
The detector preferably comprises proximity sensors, ultrasonic sensors, thermal imaging sensors, x-ray sensors, eddy current sensors
Data Source
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Figure 5a~5b
AI summary
Method for dimensionally registering composite laminates (25), wherein readable elements (86) acting as alignment and identification features are incorporated integrally in laminates (25).