• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    FIBER AND AUTOMATED RESIN DEPOSITION FOR RESIN INFUSION. The present invention relates to a composite structure that is manufactured by stacking at least one fiber reinforcement pleat and at least one layer of resin on a tool. The layer of resin film is formed by laying strips of resin film. The fiber reinforcement is infused with resin from the resin layer.
    公开号:BR102012015808B1
    申请号:R102012015808-6
    申请日:2012-06-26
    公开日:2020-12-01
    发明作者:Michael D. Silcock；Christopher A. Howe；Brice A. Johnson
    申请人:The Boeing Company；
    IPC主号:
    专利说明:

    TECHNICAL FIELD
    [001] The present description relates in general to the manufacture of composite structures, and deals more particularly with a method and an apparatus for the deposition of fiber reinforcements and resin film used to infuse the reinforcements with resin. BACKGROUND
    [002] Large composite structures can be manufactured using automated equipment such as automatic tape laying machines and automatic fiber laying machines. These automated machines stack blades on a tool by depositing multiple layers of pre-impregnated tape or tow. The automated stacking of pre-impregnated materials has several disadvantages, including the relatively short shelf life of pre-impregnated materials, the potential gum formation on the tape laying heads, the need for capital-intensive autoclaves for curing and limitations on variety of pre-impregnated formats that are available.
    [003] Some of the above disadvantages can be overcome with the use of liquid molding techniques, such as, without limitation, infusion of fiber preform resin. However, the resin infusion process also has some disadvantages, including limited flexibility in controlling the location and deposition of resin in conventional tools and difficulties in infusing high-modulating or highly hardened resins into large structures. In addition, resin infusion is time consuming and requires relatively complex resin transfer systems and burlap arrangements and may require technicians to come into direct contact with resins. In addition, resin infusion can be relatively expensive in terms of material waste and consumable materials.
    [004] In order to improve the resin distribution and reduce processing times, it has been proposed to infuse fiber preforms with the use of resin film pieces that are sectioned from a large sheet and placed in a mandrel followed by a dry preform. A relatively complex dam and various consumable materials are required to control the flow of resin. Thus, the resin film infusion process and equipment may not be suitable for higher production environments, where automation is desirable.
    [005] Resin spraying techniques have been used in which the resin is deposited using a spray gun by automated means in a tool. However, this process requires the tool to be kept at low temperatures in order to control the change in state of the resin from liquid to solid when transferred from the spray gun to the tool.
    [006] Therefore, there is a need for a method of manufacturing composite structures, particularly large-scale structures, with the use of a resin infusion process that reduces costs and is well suited to automation. There is also a need for a method and an apparatus for automated deposition of resin films that allows for high settlement rates, improved control over the quality, location and distribution of the resin, and that allows the use of high modulus and hardened resins. SUMMARY
    [007] The method and apparatus described provide an automated deposition of resin films that can be used in the infusion of resin from fiber preforms to produce large-scale composite structures. The described modalities allow the deposition of resin in an adapted format that meets process and design requirements, while reducing weight and achieving a low use of energy and materials. The automated resin deposition process described can reduce recurring costs by eliminating processing steps previously required to prepare the material. Improved quality and performance can be achieved through highly repeatable automation. Material waste can also be reduced to minimize or eliminate direct contact between operators and resins. The need for autoclave processing can be eliminated, as well as the need for resin pots, piping and resin handling facilities.
    [008] According to a described modality, a method is provided to manufacture a composite structure. The method comprises feeding a resin film to a compacting roller, moving the compacting roller along the surface of the substrate, and compacting the film on and / or inside the substrate as the roller moves along the substrate. Feeding the resin film includes guiding a strip of resin film to the compaction roller, and cutting the resin film to desired lengths as the compaction roller moves along the substrate surface. The method may additionally comprise feeding a fiber reinforcement to a compaction roller, and compacting the fiber reinforcement on the substrate as the roller moves along the substrate. The fiber reinforcement and the resin film can be fed to the compaction roller substantially simultaneously. An automatically controlled manipulator can be used to move the compaction roller along the substrate and place the strips of resin film substantially over the edge.
    [009] According to another described embodiment, a method of manufacturing a composite structure is provided, which comprises feeding separately a fiber reinforcement and a resin film to a compaction roller. The method also includes moving the compacting roller along the surface of the substrate, and compacting the resin film and fiber reinforcement against the substrate using the compacting roller. Separately feeding the fiber reinforcement and the resin film may include taking strips of the fiber reinforcement and the resin film from the coils and guiding the strips to the compaction roller. In one embodiment, the fiber reinforcement is fed between the substrate and the resin film, while in another embodiment the resin film is fed between the substrate and the fiber reinforcement. The method additionally comprises cutting lengths of fiber reinforcement and resin film as the compaction roller moves along the surface of the substrate.
    [0010] According to an additional modality, a method of making a composite structure is provided. The method comprises assembling a laminate on a tool, which includes stacking at least one pleat of fiber reinforcement on the tool and stacking at least one layer of resin on a tool when stacking strips of a resin film. The method also comprises infusing the fiber reinforcement with resin from the resin layer. Stacking the strips of resin film may include using an end effector to cut the resin film to desired lengths, and using the end effector to compress the film strips against the tool. Infusing the fiber reinforcement may include sealing a vacuum bag over the laminate, evacuating the vacuum bag and applying heat to the laminate.
    [0011] According to another additional embodiment, an apparatus is provided to manufacture a composite structure, comprising an end effector adapted to be moved along the surface of a substrate, and a supply of resin film in the end effector. The apparatus additionally comprises a compaction roller on the end effector to compact the resin film against the substrate as the end effector moves along the substrate surface. The film supply may include a reel of resin film, and the end effector may include a guide to guide the resin film from the reel to the compaction roller, and a cutter to cut the resin film to desired lengths. The apparatus may also include a fiber reinforcement coil in the end effector and a guide to guide the fiber reinforcement from the coil to the compaction roller.
    [0012] In summary, according to one aspect of the invention, a method of making a composite structure is provided, which includes separately feeding a fiber reinforcement and a resin film to a compaction roller; moving the compaction roller along the surface of a substrate; and compact the resin film and fiber reinforcement against the substrate using the compaction roller.
    [0013] Advantageously, the method in which the fiber reinforcement and resin film are fed separately from the fiber reinforcement strip from a fiber supply coil, and from a resin film strip from one film from a resin supply coil, and guide the fiber reinforcement strips and the resin film to the compaction roller.
    [0014] Advantageously, the method in which the fiber reinforcement is fed between the substrate and the resin film, and compacting the resin film and fiber includes using the compaction roller to compact the resin film on the reinforcement of fiber.
    [0015] Advantageously, the method in which the resin film is fed between the substrate and the fiber reinforcement, and compacting the resin film and the fiber includes using the compaction roller to compact the fiber reinforcement on the resin film .
    [0016] Advantageously, the method additionally includes cutting lengths of fiber reinforcement and resin films as the compaction roller moves along the substrate surface.
    [0017] According to another aspect of the invention, a method of manufacturing a composite structure is provided, which includes mounting a laminate on a tool, which includes stacking at least one pleat of a fiber reinforcement on the tool and stacking at least one layer of resin on the tool when stacking strips of a resin film; and infusing the fiber reinforcement with resin from the resin layer.
    [0018] Advantageously, the method in which to stack the resin film strips includes using an end effector to cut the strips of resin film, and using the end effector to compact the film strips against the tool.
    [0019] Advantageously, the method in which to stack the fiber reinforcement pleat includes using the end effector to cut strips of fiber reinforcement to the desired lengths, and using the end effector to compact the cut lengths of the fiber reinforcement against the tool.
    [0020] Advantageously, the method in which to infuse fiber reinforcement includes sealing a vacuum bag over the laminate, evacuating the vacuum bag, and applying heat to the laminate.
    [0021] In accordance with yet another aspect of the invention, a method of laminating a composite aircraft structure is provided, which includes moving an end effector over the surface of a tool; use a programmed manipulator to automatically control the movement of the end effector over the tool surface; removing a strip of resin film from a reel of resin film on the end effector; cutting the strip of resin film to a desired length; feeding the cut length of resin film to a compaction roller at the end effector; removing a dry fiber reinforcement strip from a dry fiber reinforcement coil in the end effector; cutting the dry fiber reinforcement strip to a desired length; feeding the cut length of the resin film strip to a first roll; use the first roll to compact the cut length of the resin film strip against the tool; feeding the cut length of the dry fiber reinforcement to a second roll; use the second roller to compact the cut length of the dry fiber reinforcement against the tool in alignment with the strip of compacted resin film; independently control the compaction pressure applied by the first and second rolls on the resin film strip and the dry fiber reinforcement strip, respectively.
    [0022] According to another aspect of the invention, an apparatus is provided for stacking a composite aircraft structure, which includes a manipulator; an end effector armed in the manipulator, the end effector, which includes a frame, a resin film reel on the frame, a dry fiber reinforcement coil on the frame, a compaction roller on the frame to compact strips of a film from resin and fiber reinforcement on a tool, guides on the board to guide the strips from the reels to the roll, a cut-off mechanism on the board to cut the resin film and fiber reinforcement into strips of desired lengths, a pick-up spool on the board to capture a lining paper on the resin film; a compaction control to control the compaction pressure applied by the roller, and a controller to control the operation of the manipulator, end effector and compaction control.
    [0023] Other features, benefits and advantages of the described modalities will become apparent from the following description of the modalities, when viewed in accordance with the attached drawings and claims. BRIEF DESCRIPTION OF THE ILLUSTRATIONS
    [0024] Figure 1 is an illustration of a diagram showing the steps of a method of making a composite structure using automated resin film deposition.
    [0025] Figure 2 is an illustration of a cross-sectional view of a vacuum bagged laminate assembly used in the manufacturing method shown in figure 1.
    [0026] Figure 3 is an illustration of a functional block diagram for stacking pleats of the laminates shown in figure 1.
    [0027] Figure 4 is an illustration of a perspective view of a modality of the end effector that forms part of the apparatus shown in figure 3.
    [0028] Figure 5 is an illustration of a sectional view taken over line 5-5 in figure 4.
    [0029] Figure 6 is an illustration of a side view of another type of end effector.
    [0030] Figure 7 is an illustration of the area designated as "figure7" in figure 6.
    [0031] Figure 8 is an illustration of a side view of an additional modality of the end effector.
    [0032] Figure 9 is an illustration of the area designated as "figure9" in figure 8.
    [0033] Figure 10 is an illustration of yet another modality of the end defector.
    [0034] Figure 11 is an illustration of a flow diagram of one method of forming the laminates shown in Figure 1 using the end effector described.
    [0035] Figure 12 is an illustration of a diagram of aircraft production and service methodology.
    [0036] Figure 13 is an illustration of a block diagram of an aircraft. DETAILED DESCRIPTION
    [0037] Referring first to figure 1, a composite structure 20 can be manufactured using standard or non-standard tooling 22 and automated laminate. In the illustrated example, composite structure 20 is a flat panel formed in substantially flat tooling 22 supported on a tool base 24, however, other tooling geometries 22 can be employed, which includes those with simple or complex contours. As shown at 28, a manipulator 27 comprising a robot, gantry system or other handling system is automatically controlled by a controller 30 and includes an end effector 26 for stacking multiple layers 50 and pleats 52 on the tool 22.
    [0038] As shown in 31, layers 50 and pleats 52 are stacked using coils 32, 34 of continuous resin film and dry fiber reinforcement, respectively. The resin film can be selected to impregnate and distribute effective resin on the dry fiber reinforcement using robotic processes. The resin film may be of the thermoset type, such as, without limitation, bismaleimide or thermosetting epoxy benzoxazine, alternatively, however, the resin film may be a thermoplastic or a combination of a thermoset and a thermoplastic. The resin film may contain hardening agents, which include organic or inorganic fillers. The reinforcement can be any continuous fiber format. The resin film is calculated to provide a desired area weight, thickness, physical state and chemical status in order to meet processing requirements to achieve efficient deposition, consolidation, curing and laminate properties.
    [0039] The coils 32, 34 are respectively loaded in the coil holders 32a, 34a which are mounted on the end effector 26 shown in 36. As the end effector 26 is moved on tool 22 by manipulator 27, strips 38, 40 of resin film and dry fiber are respectively taken from the reel holders 32a, 34a and are fed to the compaction roller 42, in substantially aligned overlap relationship. The compaction roller 42 compresses the overlapping strips 38, 40 on a substrate 44 that can comprise any suitable support surface, such as, without limitation, tooling 22 or an underlying layer 50 or pleat 52 that has previously been laminated to manual or automatic mode by end effector 26. End effector 26 laminates paths 98 of strips 38, 40 in relation to edge to edge and generally parallel to each other. As will be discussed below, end effector 26 can be used to fix double layer pathways 98 comprising a layer of resin film 38, and a layer (pleat) of fiber reinforcement 40 as discussed above, or, alternative, it can be used to fix a single layer path, either from resin film 38 or fiber reinforcement 40.
    [0040] As shown in 46, end effector 26 can be used to assemble laminate 48a comprising a stack 50a of individual layers of resin 50 which are laminated over stack 52a of fiber reinforcement pleats 52. Pleats 52 can have different fiber orientations, according to a predetermined fold plan for a particular structure. Alternatively, a laminate 48b can be formed by alternately stacking interleaved layers 50 of resin film 38 and fiber reinforcement pleats 52, using the double layer strips 98 described above. After laminate 48 has been assembled on tooling 22, as shown in 54, laminate 48 can be compacted and cured using non-autoclave processes, such as vacuum bag processing and curing oven. For example, referring to figure 2, a laminate 48a mounted on tooling 22 comprises a stack 50a of resin layers 50 laminated on a stack 52a of fiber reinforcement pleats 52 of the desired fiber orientations. Other layers 62 of consumable materials, such as vents, removal pleats, etc. are placed on laminate 48a. A vacuum bag 49 is placed on laminate 48a and sealed to tooling 22 by edge seals 64 which may comprise conventional sealing tape. A suitable vacuum source 66 is coupled to bag 49 in order to evacuate bag 49 of air, moisture and volatile substances.
    [0041] Returning to figure 1, as shown in 56, the vacuum laminated laminate 48a is placed in an oven 58 where heat 60 is used to cure laminate 48a. Other equipment can be used to heat laminate 48a, such as, without limitation, autoclaves, microwaves, fully heated molds, etc., all not shown. During the curing process, the heat 60 melts the resin layers 50, allowing a controlled amount of resin to flow into the fiber reinforcement pleats 52 substantially uniformly, thus infusing fiber reinforcement with resin as the compaction pressure is applied. laminate 48a through vacuum bag 49 (figure 2).
    [0042] Figure 3 illustrates in general terms the functional components of the apparatus that can be used in the execution of the method of making composite structures shown in figure 1. The end effector 26 is mounted on the manipulator 27 and includes a compaction control 85 that controls the amount of compaction pressure applied by the compaction roller 42. A controller 30, which can comprise any properly programmed computer, controls the operation of manipulator 27, compaction control 85 and end effector functions 26. The effector end 26 includes a reel of resin film 32 and a fiber reinforcement reel 34 contained, respectively, in reel holders 32a, 34a. The strips 38, 40 of the resin film and the fiber reinforcement are directed, respectively, by guides 82,84 to a cutting mechanism 88 and decompaction roller 42. The cutting mechanism 88 cuts strips 38, 40 to the desired length according to the strips 38, 40 are compressed on a substrate 44 by the compaction roller 42. The end effector 26 may additionally include a liner paper pick-up reel 96 which captures a liner paper 94 on the resin film strip 38 according to the liner 94 is removed from the resin film strip 38 after passing through the guides 82, just before being compacted against substrate 44. compaction control 85, as well as other functions of end effector 26, can be controlled by controller 30 as shown in figure 1.
    [0043] Figure 4 illustrates additional details of an end defector modality 26. Spool holders 32a, 34a, pickup spool 96 and cutting mechanism 88 are mounted on frame 74. Table 74 includes a plate 72 that is mounted sideways on a second plate 70 attached to an arm 68 of the manipulator 27. A pneumatic cylinder 76 attached to plate 70 has an output shaft 78 coupled to plate 72. Pneumatic cylinder 76 moves plate 72 and therefore the frame 74 in the direction shown by arrow 80 towards or away from the substrate 44.
    [0044] The sliding assembly of the plates 70, 72 together with the pneumatic cylinder 76, provides a compaction control 85 that allows the compaction pressure applied by the roller 42 to be adjusted. A strip of resin film 38 taken from the reel holder 32a passes through a guide 82 that directs the strip of resin film 38 to a nip 86 between compaction roller 42 and substrate 44. The resin film strip 38 it can include a lining paper 94 to prevent twisted layers of the resin film 38 on the reel 32 (figure 1) from sticking together. The liner paper 94 is removed from the resin film 38 after passing it through the guide 82, and is wrapped around the pick-up spool 96.
    [0045] The reel holders 32a, 34a are substantially aligned with each other in the direction of travel 75 of the end effector 26 on the substrate 44, so that the resin film strip 38 and the fiber reinforcement strip 40 overlap and are substantially aligned with each other when deposited and consolidated on substrate 44 by compaction roller 42. Strips 38, 40 are taken from coil holder 32a, 34a at substantially the same rate and pass respectively through guides 82, 84 that direct the strips 38, 40 in overlapping relationship for the narrowing 86. The cutting mechanism 88 may comprise a pneumatic cylinder 92 attached to the frame 74 which reciprocates with a cutting blade 90. The cutting blade 90 simultaneously cuts strips 38, 40 in lengths desired.
    [0046] The resin film strip 38 is consolidated by the decompaction roller 42 below the dry fiber strip 40. The adhesion of the resin film strip 38 serves as an adhesive that forms a moderate bond with the substrate 44 and the strip of fiber 40 under which it is installed. In some embodiments, depending on the particular resin system that is employed, it may be necessary or desirable to heat the resin film strip 38 to increase its adhesion as it enters nip 86. This heating process can be performed with the use of any of a variety of techniques and devices, such as, without limitation, an infrared heater, a gas torch or a laser (all not shown). The area weight of the resin film strip 38 can be predefined to control the fraction of the fiber volume of the cured structure 20 (figure 1). Although not shown in Figure 4, the guides 82, 84 can incorporate roller drives that initially take strips 38, 40 from the spool holders 32a, 34a until the strips enter nip 86. Once strips 38, 40 have entered at narrowing 86, the movement of end effector 26 removes strips 38, 40 from spool holders 32a, 34a and the roller drives can be de-energized. Additional details on guides, rollers, filleting and drive mechanisms to control the path and movement of strips 38, 40 on end effector 26 can be found in US Patent No. 4,699,683 and US Patent No. 7,213,629, publication of US patent No. 20070029030A1 published on February 8, 2007 and in US patent application Serial No. 12 / 038,155 filed on February 27, 2008, whose patents and patent applications are incorporated by reference in this document.
    [0047] In the embodiment shown in figure 4, a double-layer strip 98 is seated on the substrate 44, in which the resin film strip 38 is sandwiched between the substrate 22 and the fiber reinforcement strip 40 that covers it. This arrangement allows the laminate of interlayered resin layers 50 and fiber reinforcement pleats 52 to form laminate 48b shown in figure 1. The end effector 26 shown in figure 4 can also be used to stack single layer strips 98 comprising only one strip of resin film 38 or only one fiber reinforcement strip 40 when controlling the drives previously discussed in connection with guides 82, 84, and / or when removing one of the coils 32, 34 (figure 3) from the holders coils 32a, 34a.
    [0048] Figure 6 illustrates an alternating modality of end effector 26, similar to that shown in figure 5, but which is dedicated to fix paths 98 of resin film 38 on substrate 34, which can be a dry fiber preform. As previously mentioned, the substrate 44 can comprise a tool 22, a layer 50 of previously laid resin film (figure 2) or a pleat 52 of a fiber reinforcement. A strip of resin film 38 pulled from a reel holder 32a passes through a guide 82 which directs strip 38 towards the nip 86 between the substrate 22 and a compaction roller 42 that compresses the strip 38 against the substrate. A pickup reel 96 picks up a liner paper 94 which is removed from strip 38 after strip 38 has been consolidated under compaction roller 42. This reduces the chance that roll 42 will starch with resin and allows strip 38 be cut more easily. Figure 7 shows a strip of resin film 38 after it has been deposited and compacted against substrate 44, after the lining paper 94 has been removed.
    [0049] Figure 8 illustrates an additional modality of end effector 26, which can be used to fix multilayer paths 98 in which fiber reinforcement 30 is deposited between substrate 44 and resin film 38, as shown in the figure 9. In this embodiment, the reel holders 32a, 34a are positioned in frame 74 so that the fiber strip 40 is positioned between the resin film strip 38 and the substrate 44 as it enters the nip 86 between the reel roll compaction 42 and substrate 44. The lining paper 94 can remain on the strips of resin film 38 and be removed later, thus reducing the possibility of the resin coming into contact with the staff. After removing the liner paper 94, the exposed layer 50 (figure 1) formed by the deposited resin film strips 38 provides an adherent surface to which the fiber preform or other substrate can adhere. Alternatively, in another embodiment, the liner paper 94 can be removed immediately and rolled onto a catching reel 96.
    [0050] Attention now turns to figure 10, which illustrates yet another modality of end effector 26. In this modality, the coil holders 32a, 34a are located in separate frames 74a, 74b which are mounted on a common support 77 connected to an arm 68 of the manipulator 27. The reel holders 32a, 34a are aligned with each other in the direction of travel 75 and feed respectively the resin film strips 38 and fiber reinforcement strips 40 to the independent compaction rollers 42a, 42b. The cutting mechanisms 86a, 86b are mounted on frames 74a, 74b to independently cut strips 38, 40 to the desired lengths. Separate compaction controls 85a, 85b between frames 74a, 74b and common support 77 allow the compaction force applied by the rollers 42a, 42b to be adjusted independently of each other. In the embodiment shown in figure 10, the fiber strips 40 are deposited before the resin strips 38, however, by reversing the position of the two frames 74a, 74b, the resin strips 38 can be deposited before the fiber strips 40 are deposited.
    [0051] Attention now turns to figure 11, which illustrates the steps of a method for depositing resin film, and optionally for depositing fiber reinforcement together with the deposited resin film. Starting with step 100, the coil 32 of the resin film is loaded in the coil holder 32a in an end effector 26. Depending on the particular resin system to be used, it may be necessary or desirable to cool, or otherwise cool , the coil 32 and / or the coil holder 32a before use. In 102, a strip 38 of the resin film is fed to a guide 82 and in 104, the guide 82 is used to guide the resin film strip 38 to a compaction roller 42. In those applications where the reinforcement strip of fiber 40 is also being deposited, the resin film strip 38 can be guided under or over the reinforcement fiber strip 40. In 106, the resin film strip 38 is cut to the desired length as it is taken from the door - coils 34a.
    [0052] In 108, the lining paper 94 of a strip of resin film38 can optionally be removed and captured on a pickup reel 96 as the strip of resin film 38 is being compacted against substrate 44 by the roll of compaction 42. In 110, compaction roller 42 is used to compact the strips cut in lengths 38 of the resin film onto substrate 44, which, as previously discussed, can comprise tooling 22, a previously laid resin layer 50, or a previously laid fiber reinforcement pleat 52. At 122, the end effector 26 is moved over the substrate 44 in order to fix a strip 38 of the resin film and compact the strip 38 against the substrate 44. Depending on the particular resin system that is employed, it may be necessary to heat the resin film strip 38 just before its compaction against substrate 44 so that film strip 38 has the adhesion necessary to cause it to adhere to substrate 44 during the compaction process.
    [0053] Optional steps 112 to 120 can be performed in order to stack strips 40 of fiber reinforcement as the strips of resin film 38 are being laid on substrate 44. Starting with step 112, the fiber reinforcement coil is loaded in a bobbin holder 34a on end effector 26. At 114, a strip 40 of the fiber reinforcement is fed into a guide 84. The guide 84 directs the fiber reinforcement strip 40 to the compaction roller 42, either above or below the resin film strip 38. At 118, the fiber reinforcement strip 40 is cut to the desired length and is compacted on substrate 44 in step 120.
    [0054] Modalities of the description can be useful in a variety of potential applications, particularly in the transport sector, including, for example, automotive, naval and aerospace applications. Thus, referring now to figures 12 and 13, description modalities can be used in the context of an aircraft service and manufacturing method 124, as shown in figure 12, and an aircraft 126, as shown in figure 13. Applications in aircraft of the described modalities may include, for example, without limitation, reinforced composite members such as, for example, fuselage coverings, wing coverings, control surfaces, hatches, floor panels, door panels, access panels and warps, for name a few. During pre-production, exemplary method 124 may include aircraft 126 specification and plan 128 and material provisioning 130. During production, subassembly and component manufacturing 132 and system integration 134 of aircraft 126 takes place. Thereafter, aircraft 126 can pass for certification and delivery 136 in order to be put into service 138. While serving a customer, aircraft 126 is scheduled for routine maintenance and service 140 (which may also include modification, reconfiguration , renewal, and so on).
    [0055] Each of the 124 method processes can be performed or executed by a system integrator, a third party, and / or an operator (for example, a customer). For the purposes of this description, a system integrator may include, without limitation, any number of aircraft manufacturers and main system subcontractors; a third party may include, without limitation, any number of vendors, subcontractors, and suppliers; and an operator can be an airline, rental company, military entity, service organization, and so on.
    [0056] As shown in figure 13, aircraft 126 produced by exemplary method 124 can include an airplane structure 142 with a plurality of systems 144 and an interior 146. Examples of high-level systems 144 include one or more among a propulsion system 148, an electrical system 150, a hydraulic system 152 and an environmental system 154.Any number of other systems can be included. Although an example of an aircraft is shown, the principles of the description can be applied to other industries, such as the automotive and marine industries.
    [0057] Systems and methods expressed in this document can be used during any number of stages of the production and service method 124. For example, components or subassemblies that correspond to the production process 132 can be manufactured or manufactured in a similar way to the components or subassemblies produced while aircraft 126 is in service. In addition, one or more types of apparatus, methods of method, or a combination of these can be used during the stages of production132 and134, for example, when substantially speeding up assembly or reducing the cost of an aircraft 126. Similarly, one or more types of apparatus , method modalities, or a combination of these can be used while aircraft 126 is in service, for example, and without limitation, for maintenance and service 140.
    [0058] Although the modalities of this description have been described in relation to certain exemplary modalities, it should be understood that the specific modalities are for purposes of illustration and not of limitation, as well as other variations will occur for those skilled in the art.
    权利要求:
    Claims (12)
    [0001]
    1. Method of manufacturing a composite structure (20) for an aircraft, characterized by the fact that it comprises: extracting a strip of resin film (38) from a resin film reel; cutting a strip of resin film (38) to a desired length; extracting a dry fiber reinforcement strip (40) from a dry fiber reinforcement coil; cutting the dry fiber reinforcement strip (40) to a desired length; feeding the cut length of the resin film strip (38) to a first compaction roller (42a); moving the first compaction roller (42a) along a surface of a substrate (44) and thus using the first roller (42a) to compact the cut length of the resin film strip (38) against the substrate (44); feeding the cut length of the dry fiber reinforcement (40) to a second compaction roller (42b); move the second compaction roller (42b) along the surface of the substrate (44) and thus use the second roller (42b) to compact the cut length of the dry fiber reinforcement (40) against the substrate (44) in alignment with the strip of compressed resin film (38); and independently controlling the compaction pressure applied by the first and second rolls (42a, 42b) to the resin film strip (38) and the dry fiber reinforcement strip, respectively.
    [0002]
    2. Method according to claim 1, characterized by the fact that the resin film reel and the dry fiber reinforcement reel are loaded in the respective reel holders (32a, 34a) which are located in separate frames (74a , 74b), in which the separate frames (74a, 74b) are mounted on a common support (77) connected to an arm (68) of a manipulator (27).
    [0003]
    3. Method according to claim 2, characterized by the fact that the reel holders (32a, 34a) are aligned with each other in a direction of travel (75) and respectively feed strips of resin film (38) and fiber reinforcement strips (40) for the first and second compaction rollers (42a, 42b).
    [0004]
    4. Method according to claim 2 or 3, characterized by the fact that the cutting mechanisms (86a, 86b) are mounted on the frames (74a, 74b), to independently cut the strips (38, 40) to the desired lengths .
    [0005]
    Method according to any one of the preceding claims, characterized in that the fiber reinforcing strips (40) are deposited before the resin film strips (38) are deposited.
    [0006]
    Method according to any one of claims 1 to 4, characterized in that the film strips (38) are deposited before the fiber reinforcement strips (40) are deposited.
    [0007]
    7. Apparatus for manufacturing a composite structure (20) for an aircraft, characterized by the fact that it comprises: an end effector (26) adapted to be moved along the surface of a substrate; a supply of resin film at the end effector (26); means for extracting a resin film strip (38) from a resin film reel; means for cutting the resin film strip (38) to a desired length; means for extracting the dry fiber reinforcement strip (40) from a dry fiber reinforcement coil; means for cutting the dry fiber reinforcement strip (40) to a desired length; means for feeding the cut length of the resin film strip (38) to a first compaction roller (42a); means for moving the first compacting roller (42a) along a surface of a substrate (44) and thus using the first roller (42a) to compact the cut length of the resin film strip (38) against the substrate (44 ); means for feeding the cut length of the dry fiber reinforcement (40) to a second compaction roller (42b); means for moving the second compaction roller (42b) along the surface of the substrate (44) and thus using the second roller (42b) to compact the cut length of the dry fiber reinforcement (40) against the substrate (44) in alignment with the compacted resin film strip (38); and separate compaction controls (85a, 85b) to independently control the compaction pressure applied by the first and second rollers (42a, 42b) to the resin film strip (38) and the dry fiber reinforcement strip, respectively.
    [0008]
    8. Apparatus according to claim 7, characterized by the fact that the resin film reel and the dry fiber reinforcement reel are loaded in the respective reel holders (32a, 34a) which are located in separate frames (74a , 74b), in which the separate frames (74a, 74b) are mounted on a common support (77) connected to an arm (68) of a manipulator (27).
    [0009]
    9. Apparatus according to claim 8, characterized by the fact that the reel holders (32a, 34a) are aligned with each other in a direction of travel (75) and respectively feed strips of resin film (38) and fiber reinforcement strips (40) for the first and second compaction rollers (42a, 42b).
    [0010]
    10. Apparatus according to claim 8 or 9, characterized by the fact that the cutting mechanisms (86a, 86b) are mounted on the frames (74a, 74b), to independently cut the strips (38, 40) to the desired lengths .
    [0011]
    Apparatus according to any one of claims 7 to 10, characterized in that the fiber reinforcing strips (40) are deposited before the resin film strips (38) are deposited.
    [0012]
    Apparatus according to any one of claims 7 to 10, characterized in that the film strips (38) are deposited before the fiber reinforcement strips (40) are deposited.
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    同族专利:
    公开号 | 公开日
    US8900391B2|2014-12-02|
    CA2976484C|2020-12-15|
    US9889612B2|2018-02-13|
    EP2540480B1|2017-07-12|
    US11260606B2|2022-03-01|
    KR101900957B1|2018-09-20|
    CA2775329C|2017-08-22|
    US20180162072A1|2018-06-14|
    PT2540480T|2017-10-11|
    CN102837434B|2016-09-07|
    US20150034247A1|2015-02-05|
    US20120325398A1|2012-12-27|
    JP2013006415A|2013-01-10|
    CN102837434A|2012-12-26|
    CA2775329A1|2012-12-26|
    BR102012015808A2|2013-07-09|
    CA2976484A1|2012-12-26|
    EP2540480A1|2013-01-02|
    JP6058297B2|2017-01-11|
    ES2643475T3|2017-11-23|
    KR20130001689A|2013-01-04|
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    法律状态:
    2013-07-09| B03A| Publication of a patent application or of a certificate of addition of invention [chapter 3.1 patent gazette]|
    2018-04-03| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-08-27| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-02-18| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|
    2020-08-18| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2020-12-01| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 26/06/2012, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US13/168,990|US8900391B2|2011-06-26|2011-06-26|Automated resin and fiber deposition for resin infusion|
    US13/168,990|2011-06-26|
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