Low Tack Prepreg Ultrasonic Welding Automation

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Solution Overview

Problem

Existing methods for producing composite articles using high tack prepreg materials are labor intensive and cost inefficient due to the need for manual separation of carrier films and handling, which can lead to material sticking and rendering it useless if not properly separated.

Innovation Solution

A system and method for cutting two-dimensional prepreg blanks from low tack prepregs using a cutting table, followed by robotic removal and ultrasonic welding to connect the pieces, which are then formed into a composite article using compression molding, eliminating the need for manual handling and carrier film removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If high tack prepreg materials are used to prevent sticking, then material stability is improved, but ease of operation deteriorates due to manual handling requirements

Engineering Contradiction:

Improveprereg material stabilityVSAvoidhandling ease

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The patent changes the tack parameter of the prepreg material from high to low, enabling automated robotic handling while maintaining material stability through controlled low-tack formulations that prevent sticking during storage and processing

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces manual mechanical handling with automated robotic pick-and-place systems, eliminating the need for carrier films and manual separation operations, thereby improving ease of operation while maintaining material stability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If carrier films are added to separate prepreg plies, then ease of operation is improved during cutting, but device complexity increases due to additional removal equipment

Engineering Contradiction:

Improveply separation easeVSAvoidcarrier film removal system complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the carrier film component entirely from the prepreg system, using low-tack prepreg materials that can be directly handled and stacked without additional separation aids, thereby reducing device complexity

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The low-tack prepreg material inherently provides the separation function without requiring external carrier films, allowing the material to serve its own handling needs through controlled adhesion properties

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If manual handling and carrier film removal are used, then manufacturing precision can be maintained, but productivity decreases due to labor intensive processes

Engineering Contradiction:

Improvecomposite part precisionVSAvoidproduction rate

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces manual handling operations with automated robotic systems that perform pick-and-place operations and ultrasonic welding, maintaining manufacturing precision through controlled automation while dramatically increasing productivity by eliminating labor-intensive processes

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements continuous automated processing where robotic arms continuously pick, place, and weld prepreg plies without interruption, eliminating the discontinuous nature of manual operations and carrier film removal, thereby increasing production rate while maintaining precision

Inventive Principle:

Principle #20Continuity of useful action

4Ease of manufacture

If ultrasonic welding is used to connect composite pieces, then ease of manufacture is improved, but use of energy increases due to welding requirements

Engineering Contradiction:

Improvecomposite stack assembly easeVSAvoidultrasonic welding energy consumption

Core Design Contradiction:

Ease of manufactureVSUse of energy by moving object

Solution Approach 1:

The patent uses ultrasonic welding to replace traditional mechanical fastening or adhesive bonding methods, simplifying the manufacturing process by directly fusing composite pieces together, though this requires significant ultrasonic energy input

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 efficient separation and alignment of prepreg materials, reduces labor and costs, and allows for robotic handling and ultrasonic welding, resulting in a cost-effective and efficient production of composite articles with improved handling safety.

Implementation Method 1

an ultrasonic welding device for connecting two or more of the composite pieces to form a composite stack

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Implementation Method 2

a compression molding device for forming a composite article from the composite stack

Methodology Applied

Scientific EffectCompression molding: Compression

Data Source

PatentUS11318644B2System and process for producing a composite article

Publication Date: 2022.05.03 FORD GLOBAL TECH LLC

AI summary

A method of producing a composite article is disclosed that includes generating composite plies from a low tack composite prepreg material, connecting, by an ultrasonic welding device, two or more of the composite plies by increasing their tackiness to form a composite stack, and forming, by a compression molding device, a composite article from the composite stack.