# US 2024/0201099 A1 · Unconsolidated Composite Material Component Verification via Non-Contact Chemical Sensing

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- Number: US 2024/0201099 A1
- Document ID: US20240201099A1
- Status: Published application
- Kind: A1
- Application number: 18/416,717
- Filed: 2024-01-18
- Published: 2024-06-20
- Earliest claimed: 2022-07-08
- Assignees: The Boeing Company
- Applicants: The Boeing Company
- Inventors: David Williamson Shahan; Ashley Marie Dustin; Tiffany Allison Stewart; Ekaterina Stonkevitch; Yuksel Can Yabansu; Andrew L. Bauer; Gwen Marie Lanphere Gross
- Web page: https://patentgrep.com/patent/US20240201099A1

## CPC

- G01N 21/8851: {Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges (G01N21/8806 and G01N21/93 - G01N21/95692 take precedence; optical measurement of dimensions G01B11/00; optical scanning G02B26/10; image transformation G06T3/00; computerised image enhancement G06T5/00; image processing per se for flaw detection G06T7/0002)}
- G05B 19/41875: {characterised by quality surveillance of production}
- G01N 21/35: using infrared light (G01N21/39 takes precedence)
- B29C 70/50: for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
- B29C 70/54: Component parts, details or accessories; Auxiliary operations {, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing}
- G01N 2021/0137: {with PC or the like}
- G01N 2021/3595: {using FTIR}
- G01N 2021/8411: {Application to online plant, process monitoring}
- G01N 2021/8472: {Investigation of composite materials}
- G01N 2201/1296: using neural networks
- G05B 13/0265: {the criterion being a learning criterion}
- G05B 13/04: involving the use of models or simulators
- G05B 2219/32177: Computer assisted quality surveyance, caq
- G05B 2219/32187: Correlation between controlling parameters for influence on quality parameters
- G05B 2219/32194: Quality prediction
- G01N: INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES (measuring or testing apparatus or processes other than immunoassay, involving enzymes or microorganisms C12M, C12Q)
- G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)

## Abstract

A method for verifying a material chemistry. A Fourier transform infrared scan for a section of an unconsolidated composite material is received in real time during manufacturing of the unconsolidated composite material by a composite material manufacturing system. Verifying whether the material chemistry for the section of the unconsolidated composite material is correct is verified in real time during manufacturing of the unconsolidated composite material by the composite material manufacturing system using the Fourier transform infrared scan and a scan classifier.

## Claims

### Claim 1

A material chemistry verification system comprising:
a computer system;
a Fourier transform infrared spectroscopy system configured to generate Fourier transform infrared scans of absorbed infrared energy for frequencies in an infrared spectrum for unconsolidated composite materials;
a scan classifier configured classify material chemistries in unconsolidated composite materials using the Fourier transform infrared scans of the unconsolidated composite materials; and
an analyzer configured to:
control the Fourier transform infrared spectroscopy system to generate a Fourier transform infrared scan for a section of an unconsolidated composite material in real time during manufacturing of the unconsolidated composite material by a composite material manufacturing system; and
verify whether a material chemistry for the section of the unconsolidated composite material is correct in real time during manufacturing of the unconsolidated composite material by the composite material manufacturing system using the Fourier transform infrared scan and scan classifier.

### Claim 2 (depends on 1)

The material chemistry verification system of claim 1, wherein the analyzer is configured to perform a number of actions in response to determining that the material chemistry is incorrect in the section.

### Claim 3 (depends on 2)

The material chemistry verification system of claim 2, wherein the number of actions is selected from at least one of:
generating an alert;
tracking the section of the unconsolidated composite material;
marking the section of the unconsolidated composite material;
logging a presence of an unverified material chemistry in the section of the unconsolidated composite material; and
halting production of the unconsolidated composite material.

### Claim 4 (depends on 1)

The material chemistry verification system of claim 1, wherein in generating the Fourier transform infrared scan, the Fourier transform infrared system is configured to:
emit infrared energy at the unconsolidated composite material;
detect the infrared energy emitted at the unconsolidated composite material to form time domain data; and
perform the Fourier transform that converts the time domain data into frequency domain data to form the Fourier transform infrared scan of the absorbed infrared energy for the frequencies in the infrared spectrum for the unconsolidated composite material.

### Claim 5 (depends on 1)

The material chemistry verification system of claim 1, wherein the Fourier transform infrared spectroscopy system comprises:
Fourier transform infrared spectroscopy devices at different locations in the composite material manufacturing system, wherein the Fourier transform infrared spectroscopy devices generate the Fourier transform infrared scans for the section of the unconsolidated composite material at the different locations in real time during manufacturing of the unconsolidated composite material by the composite material manufacturing system.

### Claim 6 (depends on 1)

The material chemistry verification system of claim 1, wherein the scan classifier is a classification process that uses standardized Fourier transform infrared scans.

### Claim 7 (depends on 1)

The material chemistry verification system of claim 1, wherein the scan classifier is a machine learning model system trained to classify the material chemistries in the unconsolidated composite materials using the Fourier transform infrared scans of the unconsolidated composite materials.

### Claim 8 (depends on 7)

The material chemistry verification system of claim 7 further comprising:
a machine learning model trainer configured to:
identify sample Fourier transform infrared scans of sample materials;
calculate a mean of the sample Fourier transform infrared scans;
determine correlations of the sample Fourier transform infrared scans to the mean;
remove a selected sample Fourier transform infrared scan from the sample Fourier transform infrared scans having a lowest correlation to the mean in response to a number of sample Fourier transform infrared scans having a correlation that is less than a threshold;
repeat calculating the mean, determining the correlations, and removing the selected sample Fourier transform infrared scan in response to the number of sample Fourier transform infrared scans having the correlation that is less than a threshold; and
train the machine learning model system using the remaining sample Fourier transform infrared scans in response to the remaining sample Fourier transform infrared scans having the correlation greater than the threshold, wherein the remaining sample Fourier transform infrared scans are standardized Fourier transform infrared scans.

### Claim 9 (depends on 7)

The material chemistry verification system of claim 7 further comprising:
a machine learning model trainer configured to:
identify the Fourier transform infrared scans of the absorbed infrared energy in unconsolidated composite material samples having different material chemistries;
generate a training data set using the Fourier transform infrared scans; and
train the machine learning model system using the training data set.

### Claim 10 (depends on 1)

The material chemistry verification system of claim 1, wherein the composite material manufacturing system is a carbon fiber prepreg coating line, a reinforcing fiber resin impregnation line, a resin mix process system, a resin filming line, a prepreg system, and a slitting process system.

### Claim 11 (depends on 1)

The material chemistry verification system of claim 1, wherein the unconsolidated composite material is selected from at least one of a prepreg, an aerospace-grade prepreg, a thermoset prepreg, a thermoplastic prepreg, a woven fabric prepreg, a fiber tow prepreg, a tow prepreg, unidirectional tape prepreg, a resin coated film, non-crimp fabric, or a resin mix.

### Claim 12

A material chemistry verification system comprising:
a computer system;
a scan classifier configured to classify material chemistries in unconsolidated composite materials using Fourier transform infrared scans of the unconsolidated composite materials; and
an analyzer in the computer system, wherein the analyzer is configured to:
receive a Fourier transform infrared scan for a section of an unconsolidated composite material in real time during manufacturing of the unconsolidated composite material by a composite material manufacturing system; and
verify whether a material chemistry for the section of the unconsolidated composite material is correct in real time during manufacturing of the unconsolidated composite material by the composite material manufacturing system using the Fourier transform infrared scan and the scan classifier.

### Claim 13 (depends on 12)

The material chemistry verification system of claim 12, wherein the Fourier transform infrared scan is received from a Fourier transform infrared spectroscopy system.

### Claim 14 (depends on 13)

The material chemistry verification system of claim 13, wherein the analyzer is configured to:
control the Fourier transform infrared spectroscopy system to generate the Fourier transform infrared scan for the section of the unconsolidated composite material in real time during manufacturing of the unconsolidated composite material by the composite material manufacturing system.

### Claim 15 (depends on 14)

The material chemistry verification system of claim 14, wherein in controlling the Fourier transform infrared spectroscopy system, the analyzer is configured to control the Fourier transform infrared spectroscopy system to:
emit infrared energy at the section of the unconsolidated composite material in real time during manufacturing of the unconsolidated composite material being manufactured by the composite material manufacturing system;
detect the infrared energy emitted at the unconsolidated composite material to form time domain data; and
perform a Fourier transform that converts the time domain data into frequency domain data to form the Fourier transform infrared scan of absorbed infrared energy for frequencies in an infrared spectrum for the unconsolidated composite material.

### Claim 16 (depends on 13)

The material chemistry verification system of claim 13, wherein the Fourier transform infrared spectroscopy system comprises:
Fourier transform infrared spectroscopy devices at different locations in the composite material manufacturing system, wherein the Fourier transform infrared spectroscopy devices generate the Fourier transform infrared scans for the section of the unconsolidated composite material at the different locations in real time during manufacturing of the unconsolidated composite material by the composite material manufacturing system.

### Claim 17 (depends on 12)

The material chemistry verification system of claim 12 wherein the scan classifier is a classification process that uses standardized Fourier transform infrared scans.

### Claim 18 (depends on 12)

The material chemistry verification system of claim 12, wherein the scan classifier is a machine learning model system trained to classify the material chemistries in the unconsolidated composite materials using the Fourier transform infrared scans of the unconsolidated composite materials.

### Claim 19 (depends on 18)

The material chemistry verification system of claim 18 further comprising:
a machine learning model trainer configured to:
identify sample Fourier transform infrared scans of sample materials;
calculate a mean of the sample Fourier transform infrared scans;
determine correlations of the sample Fourier transform infrared scans to the mean;
remove a selected sample Fourier transform infrared scan from the sample Fourier transform infrared scans having a lowest correlation to the mean in response to a number of sample Fourier transform infrared scans having a correlation that is less than a threshold;
repeat calculating the mean, determining the correlations, and removing the selected sample Fourier transform infrared scan in response to the number of sample Fourier transform infrared scans having the correlation that is less than a threshold; and
train the machine learning model system using the remaining sample Fourier transform infrared scans in response to the remaining sample Fourier transform infrared scans having the correlation greater than the threshold, wherein the remaining sample Fourier transform infrared scans are standardized Fourier transform infrared scans.

### Claim 20 (depends on 12)

The material chemistry verification system of claim 12, wherein the composite material manufacturing system is a carbon fiber prepreg coating line, a reinforcing fiber resin impregnation line, a resin mix process system, a resin filming line, a prepreg system, and a slitting process system.

### Claim 21 (depends on 12)

The material chemistry verification system of claim 12, wherein the unconsolidated composite material is selected from at least one of a prepreg, an aerospace-grade prepreg, a thermoset prepreg, a thermoplastic prepreg, a woven fabric prepreg, a fiber tow prepreg, a tow prepreg, unidirectional tape prepreg, a resin coated film, non-crimp fabric, or a resin mix.

### Claim 22

A material chemistry verification system comprising:
a computer system;
a scan classifier configured to classify material chemistries in unconsolidated composite materials using electromagnetic scans of the unconsolidated composite materials; and
an analyzer in the computer system, wherein the analyzer is configured to:
receive an electromagnetic scan for a section of an unconsolidated composite material in real time during manufacturing of the unconsolidated composite material by a composite material manufacturing system; and
verify whether a material chemistry for the section of the unconsolidated composite material is correct in real time during manufacturing of the unconsolidated composite material by the composite material manufacturing system using the electromagnetic scan and the scan classifier.

### Claim 23

A method for verifying a material chemistry, the method comprising:
receiving a Fourier transform infrared scan for a section of an unconsolidated composite material in real time during manufacturing of the unconsolidated composite material by a composite material manufacturing system; and
verifying whether the material chemistry for the section of the unconsolidated composite material is correct in real time during manufacturing of the unconsolidated composite material by the composite material manufacturing system using the Fourier transform infrared scan and a scan classifier.

### Claim 24 (depends on 23)

The method of claim 23, wherein the Fourier transform infrared scan is received from a Fourier transform infrared spectroscopy system.

### Claim 25 (depends on 24)

The method of claim 24 further comprising:
controlling the Fourier transform infrared spectroscopy system to generate the Fourier transform infrared scan for the section of the unconsolidated composite material in real time during manufacturing of the unconsolidated composite material by the composite material manufacturing system.

### Claim 26 (depends on 25)

The method of claim 25, wherein controlling the Fourier transform infrared spectroscopy system comprises:
controlling the Fourier transform infrared spectroscopy system to:
emit infrared energy at the section of the unconsolidated composite material in real time during manufacturing of the unconsolidated composite material by the composite material manufacturing system;
detect the infrared energy emitted at the unconsolidated composite material to form time domain data; and
perform a Fourier transform that converts the time domain data into frequency domain data to form the Fourier transform infrared scan of absorbed infrared energy for frequencies in an infrared spectrum for the unconsolidated composite material.

### Claim 27 (depends on 24)

The method of claim 24, wherein the Fourier transform infrared spectroscopy system comprises Fourier transform infrared spectroscopy devices at different locations in the composite material manufacturing system, wherein the Fourier transform infrared spectroscopy devices generate Fourier transform infrared scans for the section of the unconsolidated composite material at the different locations in real time during manufacturing of the unconsolidated composite material by the composite material manufacturing system and wherein the Fourier transform infrared scan is generated from one of the locations.

### Claim 28 (depends on 23)

The method of claim 23 wherein the scan classifier is a classification process that uses standardized Fourier transform infrared scans.

### Claim 29 (depends on 23)

The method of claim 23, wherein the scan classifier is a machine learning model system trained to classify material chemistries in unconsolidated composite materials using Fourier transform infrared scans of the unconsolidated composite materials.

### Claim 30 (depends on 29)

The method of claim 29 further comprising:
identifying sample Fourier transform infrared scans of sample materials;
calculating a mean of the sample Fourier transform infrared scans;
determining correlations of the sample Fourier transform infrared scans to the mean;
removing a selected sample Fourier transform infrared scan from the sample Fourier transform infrared scans having a lowest correlation to the mean in response to a number of sample Fourier transform infrared scans having a correlation that is less than a threshold;
repeating calculating the mean, determining the correlations, and removing the selected sample Fourier transform infrared scan in response to the number of sample Fourier transform infrared scans having the correlation that is less than a threshold; and
training the machine learning model system using the remaining sample Fourier transform infrared scans in response to the remaining sample Fourier transform infrared scans having the correlation greater than the threshold, wherein the remaining sample Fourier transform infrared scans are standardized Fourier transform infrared scans.

### Claim 31 (depends on 29)

The method of claim 29 further comprising:
identifying the Fourier transform infrared scans of absorbed infrared energy in unconsolidated composite material samples having different material chemistries;
generating a training data set using the Fourier transform infrared scans; and
training a machine learning model system using the training data set.

### Claim 32 (depends on 23)

The method of claim 23, wherein the composite material manufacturing system is a carbon fiber prepreg coating line, a reinforcing fiber resin impregnation line, a resin mix process system, a resin filming line, a prepreg system, and a slitting process system.

### Claim 33 (depends on 23)

The method of claim 23, wherein the unconsolidated composite material is selected from at least one of a prepreg, an aerospace-grade prepreg, a thermoset prepreg, a thermoplastic prepreg, a woven fabric prepreg, a fiber tow prepreg, a tow prepreg, unidirectional tape prepreg, a resin coated film, non-crimp fabric, or a resin mix.