Patent Application
20180370152
The present disclosure relates generally to composite material placement machines, and more specifically to apparatuses and methods utilized by composite material placement machines in the manufacture of composite material structures.
During formation of composite material structures, multiple fiber-containing layers are placed by a composite material placement machine onto a mold or other such underlying substrate. The composite material placement machine continues to place additional layers on top of previously placed layers until the desired thickness and shape of the composite material is achieved. In some embodiments, the fiber-containing layers include carbon fibers, graphite fibers, glass fibers, cellulose fibers, polymer fibers, and the like. Furthermore, the fiber-containing layers are often impregnated with resin, epoxy, or other such binding material which provides support and shape to the fiber-containing layers.
As each fiber-containing layer is placed, the composite material placement machine also applies heat to the newly placed layer in order to tack the resin, epoxy, or other such binding material of the fiber-containing layer to a layer underneath, for example, a previously placed carbon fiber layer. In some cases, the composite material structure is built up with dissimilar fiber-containing layers that respond differently to certain types of heat. For example, a composite material structure can be built up with layers of carbon fiber layers, glass fiber layers, and other such materials. The carbon fiber layers can be quickly heated and tacked with a radiant heat source, such as but not limited to, infrared heat because carbon fiber efficiently absorbs the radiant heat. However, glass fibers, or other non-carbon containing material may not be quickly heated and tacked with radiant heat because the radiant heat is not efficiently absorbed by glass fibers. Rather, another heat source, such as convection heat, may be used to heat the glass fiber layer, or other such non-carbon containing layer.
It is with respect to these considerations and others that the disclosure made herein are presented.
In accordance with one aspect of the present disclosure, a heating apparatus for heating a reinforcing layer of a composite material structure is disclosed. In an embodiment, the heating apparatus is configured with a housing which includes a base and a housing body extending upwards from the base to define a housing interior space. Furthermore, a radiant heating assembly is disposed within the housing interior space and configured to transfer a radiant heat to the reinforcing layer. Additionally, the heating apparatus includes a convection heating assembly formed within the housing and the convection heating assembly includes at least one convection assembly gas passage formed within the housing body. A convection assembly gas outlet is coupled to an end of the at least one convection assembly gas passage. Moreover, a convection assembly gas flows through the at least one convection assembly gas passage and the convection assembly gas exits through the convection assembly gas outlet such that the convection assembly gas outlet directs the convection assembly gas to flow along the radiant heating assembly in order to heat the convection assembly gas and produce a convection heat. The heating apparatus further includes at least one direction gas passage formed in the base of the housing, and the at least one redirection gas passage is configured to transport a redirection gas to a convection heat application point defined by the housing body. Additionally, the heating apparatus includes a redirection nozzle positioned at the convection heat application point, and the redirection nozzle is formed in the housing body and coupled to an end of the at least one redirection gas passage. Furthermore, as the redirection gas exits the redirection nozzle the redirection gas directs the convection assembly gas and the convection heat towards the reinforcing layer.
In accordance with another aspect of the present disclosure, a method of heating one or more reinforcing layers during the manufacture of a composite material structure is disclosed. The method includes producing a radiant heat from the radiant heating assembly and directing the radiant heat towards the reinforcing layer to heat the reinforcing layer. Moreover, the method further includes flowing a convection assembly gas along the radiant heating assembly to heat the convection assembly gas to produce a convection heat. Additionally, the method includes directing the flow of the convection assembly gas and the convection heat towards a convection heat application point. Furthermore, the method includes flowing a redirection gas from the at least one redirection nozzle formed at the convection heat application point. The method further includes directing the convection heat supply towards the composite material using the redirection gas flowing from the at least one redirection nozzle such that the reinforcing layer is simultaneously heated by the radiant heat and the convection heat.
In accordance with yet another aspect of the present disclosure, a composite material placement head for an automated material placement machine is disclosed. The composite material placement head includes a vee block configured with a first material placement module which defines a placement path of a first reinforcing layer and a second material placement module which defines a placement path of a second reinforcing layer. Moreover, the composite material placement head further includes a material application point formed at an intersection of the first material placement module and the second material placement module of the vee block, wherein the first reinforcing layer and the second reinforcing layer are applied to a substrate during lay-up of a composite material structure. Moreover, the composite material placement head includes a heating apparatus coupled to the composite material placement head and the heating apparatus is positioned adjacent to the material application point. The heating apparatus further includes a housing including a base and a housing body extending upwards from the base to define a housing interior space. The heating apparatus further includes a radiant heating assembly disposed within the housing interior space, and the radiant heating assembly is configured to transfer a radiant heat to the material application point such that the radiant heat is applied to each of the first reinforcing layer and the second reinforcing layer as they are applied to the substrate. Additionally, the heating apparatus includes a convection heating assembly formed within the housing including at least one convection assembly gas passage, wherein a convection assembly gas flows through the at least one convection assembly gas passage and the convection assembly gas exits through the convection assembly gas outlet. Moreover, the assembly gas outlet directs the convection assembly gas to flow along the radiant heating assembly in order to heat the convection assembly gas and produce a convection heat. The heating apparatus further includes at least one redirection gas passage formed in the base of the housing, the at least one redirection gas passage configured to transport a redirection gas to a convection heat application point defined by the housing body. The heating apparatus includes a redirection nozzle positioned at the convection heat application point, the convection heat application point corresponding with the material application point, the redirection nozzle formed in the housing body and coupled to an end of the at least one redirection gas passage, wherein the redirection gas exits the redirection nozzle such that the redirection gas directs the convection assembly gas towards the convection heat application point and the material application point such that the convection heat is applied to each of the first reinforcing layer and the second reinforcing layer as they are placed on the substrate. Furthermore, the composite material placement head includes an electronic controller communicably coupled to the composite material placement head and the heating apparatus, wherein the heating apparatus includes a control valve operably coupled to the at least one convection assembly gas passage and the at least one redirection gas passage, and wherein the electronic controller is programmed to selectively activate the control valve such that the convection assembly gas is supplied to the at least one convection assembly gas passage and the at least one redirection gas passage, as needed.
The features, functions, and advantages disclosed herein can be achieved independently in various embodiments or may be combined in yet other embodiments, the details of which may be better appreciated with reference to the following description and drawings.
It should be understood that the drawings are not necessarily to scale, and that the disclosed embodiments are illustrated diagrammatically, schematically, and in some cases in partial views. In certain instances, details which are not necessary for an understanding of the disclosed methods and apparatuses or which render other details difficult to perceive may have been omitted. It should be further understood that the following detailed description is merely exemplary and not intended to be limiting in its application or uses. As such, although the present disclosure is for purposes of explanatory convenience only depicted and described in illustrative embodiments, the disclosure may be implemented in numerous other embodiments, and within various systems and environments not shown or described herein.
Referring to
Generally, the fuselage 24, wings 26, tail section 28, or other such component of the vehicle 20 are constructed out of aluminum, aluminum alloy, titanium, composite material, other such material, or any combination thereof. Referring now to
In some embodiments, the reinforcing layers 48 used to form the composite material layup 46 can be pre-impregnated (i.e., pre-preg), or otherwise infused, with matrix material, such as resin, epoxy, or other such hardening material. Furthermore, during formation or build-up of the composite material layup 46 the reinforcing layers 48 are heated to tack the matrix material. This heating and tacking of the matrix material causes the newly placed reinforcing layer 48 to lightly stick to the underlying reinforcing layer 48. As a result, the build-up of reinforcing layers 48 doesn't move or slide out of position during formation of the composite material layup 46. Additionally, in some embodiments, the heating and tacking of the matrix material allows the reinforcing layers 48 to be molded or otherwise formed into different shapes during formation of the composite material layup 46.
Referring now to
As discussed above, the composite material layup 46 is used to fabricate, or otherwise construct, components and assemblies, such as but not limited to, the fuselage 24, the wings 26, the tail section 28, or other such components of the vehicle 20 (
Referring to
In one non-limiting example, the composite material placement head 64 includes a vee block 72 that includes a first material placement module 74 and a second material placement module 76. Furthermore, in some embodiments, the vee block 72 has a triangular shape and the first material placement module 74 and the second material placement module 76 define a material application point 78 at a vertex of the vee block 72. Moreover, in an embodiment, the material application point 78 is adjacent to the roller assembly 66 and the material application point 78 is configured to apply or otherwise position the reinforcing layers 48 of the composite material layup 46 onto the composite layup mold 68. The shape and orientation of the vee block 72 provides one non-limiting example of the composite material placement head 64. Other configurations of the first material placement module 74, the second material placement module 76, the material application point 78 and other components of the composite material placement head 64 are possible. Likewise,
As described above, during formation of the composite material layup 46, a plurality of composite material layers (i.e., reinforcing layers 48) are laid down, or otherwise positioned onto the composite layup mold 68. In some embodiments, the reinforcing layers 48 are built-up from bundles of reinforcing fibers 80 that are fed into the first material placement module 74 and the second material placement module 76. Furthermore, in some embodiments, the bundles of reinforcing fibers 80 take the form of slit tape, fiber tows, and the like as the bundles of reinforcing fibers 80 are fed into the composite material placement head 64 of the material placement machine 52. In some embodiments, the bundles of reinforcing fibers 80 are pre-impregnated (i.e., pre-preg), or otherwise infused, with matrix material, such as resin, epoxy, or other such hardening material. The bundles of reinforcing fibers 80 used to form the composite material layup 46 are placed on the composite layup mold 68 to shape the composite material layup 46. As such, each reinforcing layer 48 that is formed from the bundles of reinforcing fibers 80 is exposed to heat or other such energy to tack the matrix material (i.e., resin or epoxy) which causes the newly placed reinforcing layer 48 to stick or otherwise adhere to the underlying reinforcing layer 48 during the build-up of the composite material layup 46.
An embodiment of the composite material placement head 64 includes a heating apparatus 84 configured to apply heat to the reinforcing layers 48 during formation of the composite material layup 46. As shown in the exemplary embodiment illustrated in
In some embodiments, the composite material layup 46 is formed from reinforcing layers 48 including bundles of reinforcing fibers 80 are pre-impregnated with matrix material (i.e., resin, epoxy, or other hardening material). The reinforcing layers 48 are placed onto the composite layup mold 68 in an uncured or semi-cured state. Furthermore, the roller assembly 66 rolls along the composite layup mold 68 and the heating apparatus 84 applies heat to the newly placed reinforcing layers 48 to tack the matrix material of the newly placed reinforcing layers 48. As a result, the roller assembly 66 shapes or otherwise forms the newly placed reinforcing layers 48 according to the underlying layup mold 68 and the heating apparatus 84 heats and tacks the newly placed reinforcing layer 48 so each layer does not slide or otherwise move around during build-up of the composite material layup 46.
Referring now to
As described above, the heating apparatus 84 is configured to supply or otherwise generate heat which can be applied to the reinforcing layers 48 that are formed from the bundles of reinforcing fibers 80 during build-up of the composite material layup 46. In one non-limiting example, the heating apparatus 84 includes a radiant heating assembly 102 with a radiant heating element 104, such as but not limited to an IR heating element. The radiant heating element 104 is configured to generate radiant heat used to heat and tack the reinforcing layers 48. Generally, the radiant heating assembly 102 is used to supply IR radiant heat to the reinforcing layers 48 that contain carbon, graphite, or other such IR absorbing material. Additionally, the heating apparatus 84 includes a convection heating assembly 106 that is incorporated with the housing 86 of the heating apparatus 84. The convection heating assembly 106 is configured to include at least one convection assembly gas passage 108. In an embodiment, the convection assembly gas passage 108 is formed within the housing body 90. Furthermore, a convection assembly gas inlet 110 is coupled to a first end 112 of the convection assembly gas passage 108 and a convection assembly gas outlet 114 is connected to a second end of the convection assembly gas passage 108.
The convection assembly gas inlet 110 is in fluid communication with the convection assembly gas outlet 114 by the convection assembly gas passage 108. As a result, a convection assembly gas (i.e., compressed air, nitrogen, or other such gas) enters the convection assembly gas inlet 110, flows through the convection assembly gas passage 108, and flows, or otherwise exits through the convection assembly gas outlet 114. Moreover, the convection assembly gas outlet 114 is configured to direct the convection assembly gas to flow along the radiant heating assembly 102 such that the convection assembly gas is heated by the radiant heating element 104 to produce a convection heat supply. In one non-limiting example, the first end 112 of the convection assembly gas passage 108 is configured as a convection assembly gas manifold 116, or other such distribution structure, and the convection assembly gas manifold 116 branches into a plurality of convection assembly gas distribution passages 118 that are formed within the housing body 90. Furthermore, each passage of the plurality of convection assembly gas distribution passages 118 are coupled to a convection assembly gas outlet 114, and each of the convection assembly gas outlets 114 are configured to direct the convection assembly gas to flow over the radiant heating assembly 102 to heat the convection assembly gas and produce the convection heat supply.
In some embodiments, the heating apparatus 84, and more specifically the convection heating assembly 106, includes a bridge structure 120 positioned above the radiant heating assembly 102. Furthermore, in some embodiments the bridge structure 120 is configured to extend between the first sidewall 94 and the second sidewall 96 of the housing body 90. Additionally, one or more convection assembly gas outlets 114 are formed in an exterior surface 122 of the bridge structure 120 such that as the convection assembly gas exits the one or more convection assembly gas outlets 114 the convection assembly gas is directed to flow along the radiant heating assembly 102. As described above, the at least one convection assembly gas passage 108 may be formed within the first sidewall 94, the second sidewall 96, or other location of the housing 86. Additionally, the first end 112 of the convection assembly gas passage 108 is configured as the convection assembly gas manifold 116 which branches into a plurality of convection assembly gas distribution passages 118 which extend from the convection assembly gas manifold 116, through the interior of the bridge structure 120. Each passage of the plurality of convection assembly gas distribution passages 118 exit the bridge structure 120 through the convection assembly gas outlet 114 formed in the exterior surface 122 of the bridge structure 120.
Generally, the one or more convection assembly gas outlets 114 are formed as an opening in the exterior surface 122 of the bridge structure 120. Furthermore, the one or more convection assembly gas outlets 114 are configured with a circular, semi-circular, non-circular or other such convection outlet geometry that produces a turbulent airflow as the convection assembly gas exits the one or more convection assembly gas outlets 144. Moreover, in some embodiments, the one or more convection assembly gas outlets 114 include sharp edges and other such features to help produce the desired amount of turbulence as the convection assembly gas exits the one or more convection assembly gas outlets 114. Alternatively, in some embodiments, the one or more convection assembly gas outlets 114 are configured to produce a laminar airflow as the convection assembly gas exits the one or more convection assembly gas outlets 114. Generally, turbulent air flow generates more noise compared to laminar air flow. Therefore, in cases where noise is an issue and/or concern, the convection assembly gas noise can be reduced by configuring the convection assembly gas outlets 114 to provide a laminar air flow.
In one non-limiting example, the heating apparatus 84 may further be configured to include at least one redirection gas passage 124 formed within the base 88 of the housing 86 and, the redirection gas passage 124 may also be coupled to the convection assembly gas manifold 116. Moreover, the redirection gas passage 124 may be configured to extend along a length 126 of the housing 86 between the convection assembly gas manifold 116 and the end wall 98 of the housing body 90. Additionally, at the end wall 98, some embodiments of the redirection gas passage 124 extend upwards a height 132 from the base 88 through the end wall 98, and exit the housing body 90 through a redirection nozzle 128 formed through the surface 130 of the end wall 98. Furthermore, the redirection gas passage 124 may be enclosed within the base 88 and the end wall 98 of the housing 86, and the redirection nozzle 128 is formed at a second end of the redirection gas passage 124 which defines a convection heat application point 134 of the convection heating assembly 106.
As discussed above, some embodiments of the redirection gas passage 124 are coupled to the convection assembly gas manifold 116. As such, the convection assembly gas inlet 110 is also in fluid communication with the redirection nozzle 128 by way of the convection assembly gas manifold 116 and the redirection gas passage 124. As a result, the convection assembly gas (i.e., compressed air, nitrogen, or other such gas) which enters the convection assembly gas inlet 110, also flows through the redirection gas passage 124, and exits through the redirection nozzle 128 at the convection heat application point 134. In an alternative embodiment, the housing 86 may be configured with a geometry such that the heated convection assembly gas can be directed towards the surface of the composite layup mold 68 without the need to flow convection assembly gas through the redirection nozzle 128 in order to redirect the heated convection assembly gas to the desired location. As a result, some embodiments of the heating apparatus 84 may be configured without the redirection gas passage 124 and the redirection nozzle 128 formed in the housing 86.
Referring back to
The convection assembly gas directed through the convection assembly gas passage 108 flows through the convection assembly gas outlet 114 that is formed in the housing body 90 of the heating apparatus 84. As further illustrated in
In one non-limiting example, the ability to simultaneously provide radiant heat (i.e., IR heat) and convection heat is advantageous when the composite material layup 46 is composed of two or more dissimilar materials. For example, one of the bundles of reinforcing fibers 80 that form the reinforcing layers 48 includes carbon, graphite, (i.e., carbon fiber) or other such material capable of absorbing radiant heat. As a result, during build-up of the composite material layup 46 the radiant heat produced by the radiant heating assembly 102 heats and tacks the matrix material incorporated with the reinforcing layers 48 that contain carbon or graphite material. Moreover, the remaining one of the bundles of reinforcing fibers 80 that forms the reinforcing layers 48 includes a non-carbon, non-graphite containing material (i.e., glass fiber) or other such material that does not efficiently absorb radiant heat. As such, during build-up of the composite material layup 46 the radiant heating assembly 102 does not sufficiently heat and tack the matrix material incorporated with the reinforcing layers 48 that include non-carbon or non-graphite containing material because the radiant heat is not efficiently absorbed by these materials. Rather, during build-up of the composite material layup 46 the convection heating assembly 106 is configured to supply or otherwise provide convection heat in order to heat or tack the matrix material incorporated with the reinforcing layers 48 that contains non-carbon or non-graphite material.
Referring back to
As discussed above, the radiant assembly gas passage 144 is coupled to the radiant assembly gas inlet 146. As such, the radiant assembly gas inlet 146 is in fluid communication with the radiant assembly gas outlet 148 by way of the radiant assembly gas passage 144. As a result, a radiant assembly gas (i.e., compressed air, nitrogen, or other such gas) supplied to the radiant assembly gas inlet 146, and the radiant assembly gas flows through the radiant assembly gas passage 144 towards the end wall 98. Moreover, when the radiant assembly gas reaches the end wall 98, the radiant assembly gas flows out through the radiant assembly gas outlet 148 at the convection heat application point 134. In an embodiment, the radiant assembly gas outlet 148 is configured such that as the radiant assembly gas flows out of the radiant assembly gas outlet 148 such that the radiant assembly gas is directed to flow along or over the radiant heating assembly 102 in the opposite direction of arrow 142 illustrated in
Referring back to
In some embodiments, the electronic controller 136 is programmed, or otherwise configured to open the radiant assembly gas control valve 150 during operational conditions such as but not limited to, stopping or slowdown of the material placement machine 52 (
In one non-limiting example, the sensor 154 is configured to monitor the temperature at the material application point 78 (
Referring back to
In one non-limiting example, each of the first cooling gas passage 156 and the second cooling gas passage 158 are configured to extend along a length 165 of the first sidewall 94 and the second sidewall 96, respectively. Moreover, an embodiment of the first cooling gas passage 156 and the second cooling gas passage 158 are configured to follow a serpentine pattern, or other such pattern, within the housing body 90 and the cooling gas flows through each of the first cooling gas passage 156 and the second cooling gas passage 158 to cool the housing 86 of the heating apparatus 84 during operation.
Referring back to
In general, the foregoing disclosure finds utility in various applications such as in producing composite material structures that are incorporated into aircraft, construction equipment, automobiles, and other such machines and equipment. As outlined above, the composite material layup 46 is fabricated by placing a plurality of reinforcing layers 48 onto the composite layup mold 68, or other such substrate. Moreover, in some embodiments, the composite material layup 46 includes reinforcing layers 48 that are composed of dissimilar materials having different material properties, such as but not limited to, heat absorption, conductivity, and other such properties. In one non-limiting example, one of the reinforcing layers 48 has a low absorption of the radiant heat emitted from the radiant heating assembly 102. As a result, some embodiments of the material placement machine 52 include the heating apparatus 84 that is configured to provide multiple heat sources such as but not limited to, radiant heat, convection heat, and the like.
In a next block 174, the convection heating assembly 106 of the heating apparatus 84 produces convection heat that is used to heat and tack the reinforcing layers 48 that make up the composite material layup 46. In one non-limiting example, the convection heat is produced by flowing convection assembly gas over and/or along the radiant heating assembly 102. The convection assembly gas flows from the convection assembly gas outlet 114 in the housing body 90, and the convection assembly gas is directed to flow along the length 126, or other such dimension of the radiant heating assembly 102. In some embodiments, the convection assembly gas is heated by the radiant heating element 104 as the convection assembly gas flows from the convection assembly gas outlet 114 formed in the bridge structure 120. Moreover, in an embodiment, the bridge structure 120 is positioned above the radiant heating element 104 and the bridge structure 120 extends between the first sidewall 94 and the second sidewall 96 of the housing body 90. Additionally, in some embodiments the convection assembly gas outlet 114 is shaped using certain geometry to create a turbulent air flow as the convection assembly gas flows from the convection assembly gas outlet 114. In some cases, the turbulent airflow improves the heating of the convection assembly gas as it flows along the radiant heating element 104.
Furthermore, in a next block 176 the convection heat is directed towards the convection heat application point 134 which is located at the end wall 98 of the housing body 90. In one non-limiting example, the convection heat application point 134 is positioned adjacent to the surface of the composite material layup 46 that is being formed on the composite layup mold 68. In a next block 178, redirection gas flows from at least one redirection nozzle 128 formed in the surface 130 of the end wall 98, and the redirection gas directs the convection heat towards the surface of the composite material layup 46. In some embodiments, the redirection nozzle 128 is positioned adjacent to the convection heat application point 134. Therefore, as the convection heat reaches the convection heat application point 134, the redirection nozzle 128 is configured to direct the convection heat towards the composite material layup 46 in order to heat and tack the plurality of reinforcing layers 48.
While the foregoing detailed description has been given and provided with respect to certain specific embodiments, it is to be understood that the scope of the disclosure should not be limited to such embodiments, but that the same are provided simply for enablement and best mode purposes. The breadth and spirit of the present disclosure is broader than the embodiments specifically disclosed and encompassed within the claims appended hereto. Moreover, while some features are described in conjunction with certain specific embodiments, these features are not limited to use with only the embodiment with which they are described, but instead may be used together with or separate from, other features disclosed in conjunction with alternate embodiments.
