Lightning Protection Tape Layup Head with Press Roller and Separator

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Solution Overview

Problem

Existing layup methods for lightning protection tapes on large or curved surfaces, such as aircraft fuselage components, face challenges with orientation, creasing, and deformation due to excessive tension, which are not adequately addressed by layup machines designed for carbon fiber tapes.

Innovation Solution

A method and device for laying up lightning protection tapes using a mobile layup head with a press roller and separator, where the tape is pressed firmly against the surface before interliner removal, and a synchronization system ensures controlled payout and reduced tension, preventing curling and wrinkling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If a standard layup head with separation roller and layup roller is used for lightning protection tapes, then the tape can be laid up automatically, but the tape may deform locally or tear due to excessive tension in the zone between the separation roller and layup roller

Engineering Contradiction:

Improveautomatic laying upVSAvoidtape integrity

Core Design Contradiction:

Extent of automationVSReliability

Solution Approach 1:

The patent introduces an intermediary support element (such as a support roller or support surface) positioned between the separation roller and the layup roller to provide temporary support to the tape during the critical transition phase when the interliner is removed. This intermediary support prevents excessive tension and deformation by distributing the load and maintaining tape stability during the separation process.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent applies beforehand cushioning by providing support structures in advance of the separation zone to prevent tape deformation before it occurs. The support elements are positioned upstream to cushion the tape against tensile loads that would otherwise cause deformation or tearing during the interliner removal process.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Ease of manufacture

If the interliner is removed before the tape is pressed firmly against the layup surface, then the separation can be performed, but the unsupported part of the tape tends to curl on itself and is not correctly pressed against the surface

Engineering Contradiction:

Improveseparation processVSAvoidtape alignment

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pressing the tape firmly against the layup surface before the interliner is completely removed. This ensures that the tape is properly positioned and supported on the layup surface during the separation process, preventing curling and ensuring correct alignment. The pressing action is performed in advance of the separation to establish proper tape positioning.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent inverts the conventional sequence by pressing the tape against the layup surface first, then removing the interliner, rather than removing the interliner first and then pressing. This reversed sequence ensures that the tape is supported and stabilized before the separation process begins, preventing deformation and ensuring proper alignment.

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of operation

If operators manually lay up long segments on large or curved surfaces, then flexibility is maintained, but correct orientation is difficult to maintain and gaps or overlaps increase as the laying process progresses

Engineering Contradiction:

Improvemanual flexibilityVSAvoidsegment orientation

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent introduces feedback mechanisms such as laser projection systems or alignment markers that provide real-time visual feedback to operators during the manual laying process. This feedback enables operators to maintain correct orientation of long segments on large or curved surfaces by continuously monitoring the position and angle of the tape relative to the layup surface, preventing gaps and overlaps.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces purely manual mechanical operations with automated or assisted systems such as robotic layup heads, laser guidance systems, or automated positioning mechanisms. These systems substitute human judgment and manual adjustment with precision-controlled mechanical or optical systems that maintain accurate orientation throughout the laying process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9931824B2Method for laying up a tape of material and device for implementing same

Publication Date: 2018.04.03 AIRBUS OPERATIONS (SAS)

AI summary

A method of laying up a segment on a layup surface using a layup head that is mobile with respect to the layup surface, the layup head supporting a spool of a tape of material which includes at least one layer to be laid up from which said segment is cut and at least one interliner, the method including applying the tape of material against the layup surface and removing the interliner using a separator. The tape of material is pressed firmly by a press roller against the layup surface before the interliner is removed as the layup head moves in an advancing movement. A layup head for implementing the method and a layup machine including the layup head are also described.