Multi-head Laminator for Composite Stringer Production
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Solution Overview
Problem
Current methods for producing composite laminate stringers, such as punch forming, are inefficient and costly due to the tendency of plies to wrinkle or buckle during the forming process, especially when creating contoured structures, making them unsuitable for high-volume production.
Innovation Solution
A method and apparatus for laying up a flat composite charge using a laminator with multiple tape heads to simultaneously lay down strips of fiber prepreg tape, optimizing ply schedules with varying fiber orientations and lengths to minimize wrinkling and maximize formability, allowing for efficient production of contoured stringers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If punch forming is used to create contoured stringers, then the desired shape can be achieved, but the plies tend to wrinkle or buckle during the forming process
Solution Approach 1:
The patent applies preliminary action by pre-forming the charge into a contoured shape before the final punch forming operation. The charge is placed in a contoured mold and pre-formed to match the desired stringer geometry, which eliminates ply wrinkling during subsequent forming operations since the plies are already positioned in their final configuration
Solution Approach 2:
The patent segments the forming process into distinct stages: charge preparation, contoured pre-forming, and final punch forming. By dividing the process into separate operations with the charge being pre-formed first, the patent eliminates the wrinkling problem that occurs when attempting to form contoured shapes in a single step
2Ease of manufacture
If hand layup or automated equipment is used to build charges ply-by-ply, then the charge can be formed, but the process is costly and relatively slow
Solution Approach 1:
The patent merges multiple ply-laying operations into a single automated charge preparation step. Instead of building charges ply-by-ply through sequential hand layup or automated equipment, the invention uses a single operation to place the entire charge in the contoured mold, dramatically increasing production rate while maintaining manufacturing capability
Solution Approach 2:
The patent applies self-service by using the contoured mold itself to hold and position the charge during preparation. The mold geometry automatically guides the charge into the correct configuration without requiring complex automated laying equipment or manual assembly, achieving both ease of manufacture and high productivity
3Ease of manufacture
If traditional charge production methods are used, then charges can be made, but labor costs are high and production efficiency is low
Solution Approach 1:
The patent replaces manual mechanical layup operations with an automated charge preparation system. The contoured mold and automated placement mechanism eliminate the need for labor-intensive ply-by-ply construction, reducing both labor costs and production time while maintaining the ability to produce charges with complex geometries
Data Source
AI summary
Multi-ply composite charges are laid up by a multi-head laminator in a single pass, enabling high rate production of composite laminate structures such as stringers.