Automated fiber placement and in-situ fiber impregnation system and method
AssigneeSpirit AeroSystems, Inc.
InventorMark A. Wadsworth
Life of this patent
Estimating the term…
Abstract
An automated fiber placement (AFP) and in-situ fiber impregnation system includes a feeder, a resin dispenser, and a compaction roller. The feeder feeds a tow of fiber from a fiber supply toward a forming tool. The resin dispenser deposits resin onto the forming tool in front of the compaction roller. The compaction roller moves over the tow along the forming tool so as to press the tow onto the resin such that the compaction roller impregnates the resin into the tow a direction away from the forming tool via compaction forces immediately after the resin is deposited by the resin dispenser.
Claims26
A roller unit for an automated fiber placement system for placing a tow of fibers onto a forming tool, the roller unit comprising:
- a plurality of belt controllers;
- a manipulator configured to move the plurality of belt controllers;
- and
- a centerless belt being positioned on the plurality of belt controllers, the centerless belt being configured to move over the tow of fibers along the forming tool to press the tow of fibers onto the forming tool, the plurality of belt controllers being configured to deform the centerless belt when the manipulator moves the belt controllers toward the forming tool.
An automated fiber placement system for placing a tow of fibers pre-impregnated with resin onto a forming tool, the automated fiber placement system comprising:
- a feeder configured to feed the tow of fibers toward the forming tool;
- and
- a roller unit including a centerless belt, a plurality of belt controllers, and a doctor blade, the centerless belt being configured to move over the tow of fibers along the forming tool to compact the tow of fibers including the resin onto the forming tool.
An automated fiber placement system for placing a tow of fibers pre-impregnated with resin onto a forming tool, the automated fiber placement system comprising:
- a feeder configured to feed the tow of fibers toward the forming tool;
- a roller unit including:
- a centerless belt divided into lateral segments for lateral conformance of the centerless belt to the forming tool, the centerless belt configured to move over the tow of fibers along the forming tool to compact the tow of fibers including the resin onto the forming tool;
- a plurality of belt controllers divided into lateral segments corresponding to the lateral segments of the centerless belt, the plurality of belt controllers being configured to guide the centerless belt;
- a doctor blade configured to remove excess resin from the centerless belt;
- and
- an idler roller configured to transmit compression waves through the centerless belt to the tow of fibers via vibrations;
- and
- a heater configured to heat a section of the centerless belt before the section compresses a portion of the tow of fibers onto the forming tool.
A method of automated fiber placement, the method comprising steps of:
- moving a centerless belt positioned on a plurality of belt controllers toward a forming tool via a manipulator;
- moving the centerless belt over a tow of fibers along the forming tool;
- pressing the tow of fibers onto the forming tool via the centerless belt;
- and
- deforming the centerless belt via the plurality of belt controllers so the tow of fibers conforms to the forming tool.
Dependencies are inferred from the claim text.