Laser Cutting Tape Laying System for FRP Manufacturing
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Solution Overview
Problem
Current Automated Tape Laying (ATL) systems for manufacturing fiber reinforced plastic (FRP) parts are bulky, require frequent maintenance, and have inefficient cutting systems that need frequent blade replacements, limiting their use and increasing costs.
Innovation Solution
A compact tape laying system with a miniaturized cutting sub-system that includes rollers for guiding and feeding tape, a resin impregnation and mixing system, and a laser cutter for precise cutting, allowing for 3D surface laying and reducing post-processing by trimming each layer of the FRP.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional ultrasonic blade cutting systems are used in ATL machines, then cutting function is achieved, but the system becomes bulky and requires frequent maintenance and blade replacements
Solution Approach 1:
The patent replaces the traditional mechanical ultrasonic blade cutting system with a laser-based cutting system. The laser cutter uses optical energy to cut the fiber tape instead of mechanical contact, eliminating the need for physical blades that wear out and require frequent replacement. This substitution reduces mechanical complexity while improving reliability and reducing maintenance needs.
Solution Approach 2:
The patent extracts the cutting function from the main tape laying head, placing a separate laser cutter at the end of the tape path. This modular approach allows the cutting system to be independent and miniaturized, reducing the overall complexity of the ATL system while maintaining reliable cutting capability.
2Productivity
If automated tape laying systems are implemented for FRP manufacturing, then manufacturing automation and productivity improve, but the system becomes bulky and costly
Solution Approach 1:
The patent segments the tape laying system into distinct functional modules: a tape laying head for depositing fibers, a separate laser cutter for cutting, and a resin injection system. This segmentation allows each component to be optimized independently and miniaturized, reducing the overall system size while maintaining high automation and productivity.
Solution Approach 2:
The patent employs a 5-axis movement system (X, Y, Z linear movements plus A, B rotational movements) that allows the compact tape laying head to access complex 3D surfaces from multiple angles. This multi-dimensional capability enables a small system to manufacture large and complex parts that would otherwise require a much larger machine.
3Productivity
If traditional cutting blades are used, then cutting is achieved, but frequent blade replacements are needed after about 6000 cuts
Solution Approach 1:
The laser cutting system replaces mechanical blades with a non-contact optical cutting method. The laser beam can cut continuously without wearing out, eliminating the need for periodic blade replacements every 6000 cuts. This maintains high cutting speed while eliminating maintenance downtime.
4Strength
If resin impregnation is performed after tape laying, then fiber reinforcement is achieved, but human exposure to hazardous materials increases
Solution Approach 1:
The system performs preliminary actions by laying down the dry fiber tape first in a controlled environment, then automatically injecting and impregnating the resin in a closed system. This separates the fiber laying process (safe for operators) from the resin handling process (enclosed and automated), minimizing human exposure to hazardous resin materials while ensuring proper impregnation for strong FRP parts.
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 enables efficient, automated manufacturing of FRP parts with reduced maintenance needs, lower costs, and improved quality, while allowing for complex geometry and consistent fiber orientation, thus reducing human exposure to hazardous materials and enabling the production of high-strength parts.
Implementation Method 1
a laser cutter for precise cutting
Data Source
Figure 1
Figure 2
AI summary
This patent application focuses on the cutting, laying and impregnating the fiber tape using a tape laying and cutting head. The head contains a stationary or moving laser system with an in- situ mixing of resin and hardener, rollers (1,2) and a spreader (6) for pressing. The head enables manufacturing of small fiber reinforced parts avoiding the problems in manufacturing them.